INDUC-SHRAN

Sections of EHS Safety Guideline for Corporate, divisional

and internal audits are divided into six sections:

1. EHS Organization and Management2. Occupational Health and Hygiene3. Electrical, Mechanical, Buildings, Housekeeping

and safe work practices4. Fire Protection and Life Safety5. Environment6. Accident Reporting, investigation and ControlAll the safety systems and rules are covered in

detail in these sections with clear guideline.

Accidents Reporting Lost Time Accident: If a person does not return to work

immediately. Report is sent to Corporate EHS. Reportable Accident:If a person does not return to work within

48 hr. Report is sent to Factory Inspector Serious Accident: Accident which causes death or serious injury.

Report is to be sent to Factory Inspector, DM, Commissioner for workmen compensation

Property damage: Dangerous Occurrence: Incident Reporting: Incident is an accident resulting neither in

injury or property loss. These are also important for reporting and analysis

Work Permit System Work Permits are required before

starting the work. Different Kind of work permits are:

• Height Work Permit• Electrical Work Permit• Confined work Permit• Excavation work permit• Hot Work Permit• Fragile floor work permit etc.

Imp. Safety systems Fencing and guarding of dangerous

machineries and parts Regular testing of Pressure vessels,

Compressed gas cylinder, Safety relief valves etc.

Make, hand signals and testing of lifting gear tools and tackels.

Certificate of registration and testing of boilers.

LEAF GODOWN

Tobacco Plant-Farmers

PurchasesBy ILTD

Storage

Threshing

Inspection

Transport toITD Factory

Receipt atLeaf Godown

Issues to PMD

InfestationControl

Leaf Godown Flow Line

Air Cured and Flue cured tobacco

GLOBAL GRADING SYSTEM – Lamina

Source Plant Position Quality (Color,Ripeness,) Breath Suffix Form Suffix (Threshing) Crop Year

P O X W / T /04

1 2 3 4 5 6

A stands for Flue cured Only A stands for NLS grade (Northern light soil) A1 stands for high sugar flue cured A2 Stands for low sugar Flue Cured

AY stands for KLS (Karnataka Light soil) i.e from Mysore. B denotes the Stem that is air cured.

GLOBAL GRADING SYSTEM – Stem

Random Check of 10%

10% of CFCs checked at random• Infestation, mould, wet mark, oil mark, physical

damage to the packs, bulge CFCs • Weight• Findings noted down in a register

In case of rain damage, oil marks or other damage in transit, ILTD and Leaf HO are informed and the CFCs are sent to the part pallet zone for priority issue

In case of water marks 100% pack deshelled & checked

Stacking Procedure

Stacking – As per put-away list CFCs are stacked in the respective cells.

Example :-

Q / 28 / 2

Row Position Stack

Unloading Infestation Checking

Infestation monitoring by workman Serrico trap monitored for minimum 2 hrs Count = 0 : Stk will be received at rack go-down Count > 1: Stk will be sent to go-down no 14 for

fumigation

Leaf godown capacity

No. of Cells = 3304 (Considering 4 high only) No. of cells reserved for Part Pallet Zone = 124 Cells reserved to first to move CFC’s = 80 Therefore, Total effective bin = (3304-124-80 = 3100* Max Capacity of each cell = 4 CFC’s @ 200 Kg each = 800 Kg

Capacity = 3100 (0.25x720 + 0.75x800)** = 2.4 Mln Kg Assuming 80% efficiency = 2.4 x 0.8 = 1.98 Mln Kg.** Assuming 25% CFC’s of 180 Kg (as 20% is of stem and 5% are some

special kind of lamina which comes in 180 Kg pack

Infestation

Infestation is one major area of concern in tobacco industry.

Infestation control – As tobacco dust in humid atmosphere is ideal for beetle breeding, housekeeping must be in center of the focus.

Type of Infestation control Preventive Curative

Infestation Control

Monitoring Serrico Trap sticker - Serrico trap is located at various

locations to monitor beetle count in that area.

Preventive Treatment Misting - By natural Pyrethrum mixed with water. Fogging - By natural Pyrethrum mixed with fogging oil.

Curative Treatment Fumigation : Fumigation is done by using Phosphin

(aluminum phosphate) for infested tobacco.One tablet/mtr3 in a leak proof chamber for 10 – 12 days is kept.Then it is kept for normalization in open air. This is done in Godown No:14

Introduction

Purpose of PMD?To Convert leaf tobacco of various grades into

Blended Cut Tobacco,Ready to produce cigarettes consistently to give consistency in smoking.

Two Process Line A Tobacco leaf contains Fleshy & Midribs

• Lamina – Fleshy portion of leaf

• Stem – Midribs of the leaf

Two measure differences between Stem and Lamina are:

• 22% m.c. is required in Lamina for making it soft and pliable for cutting while for stem 40% moisture is req.

• 30 CPI is required for lamina cutting while for stem 140 CPI is required.

Because of the above differences, there are separate Processing lines for both

Lamina LineThere are two major steps in Lamina lineLamina Conditioning Lamina cutting and dryingAfter drying Lamina is mixed with the CRS stored in addback bins for final CT which is again processed through cooler.

LAMINA CONDITIONING

Feeding De-shelling

B.T. DeviceInspectionSlicer

DCC & C Blending Bins

Inspection

LAMINA CUTTING AND DRYING

Discharge from Bins Air Lift Sieve

Complex

CuttersSearch & Fill

GFP Weycon

KLD Dryer Cooling and flavoring

Cut Tobacco Bins

Skip Filling and weighment

CTS

By Pass CuttersCRS from Bins

Equipments in Lamina line : ‘U’ Conveyor Bale tilting devices Slicer DCC&C Lamina bins Shieving complex Metal detector assembly Lamina cutter (KTC) Search & fill Weighing con HT (Lamina expansion sys.) KLD

Lamina FeedingFollowing steps are followed: Issue of leaf as per Pick list Lay down in feeding sequence (U-

conveyor is used) De-shelling the lamina cake using

grab hoist and Bale turner Inspection of leaf Cutting in 3 cuts (4 pieces) in slicer Feeding cut leaf to DCCC

Lamina Feeding… U-Conveyor: CFC, after laying down in

sequence, gets auto feed.

De-shelling:Scissors type grab in combination with hoist with 1 Ton capacity is used. Lifting Drive is 1.5 HP and Traverse drive is 0.25 HP

Bale Turner: BTD has a bands within it to receive the bale and discharge it after turning. it helps to expose all the sides of the bale and thus helping to check all the sides for infestation and for mouldy and musty Tobacco.

Slicer: It cuts the bale into 3 cuts (4 pieces). The total cycle time is between 120 and 138

seconds (presently 127 seconds). It consists of Pusher (moves forward/reverse), Knife (moves up/Down) and discharge bend.

Feed of DCC&C is controlled here. This ensures uniform feed to DCC&C Ensures proper conditioning by reducing the feed

size to DCC&C from single bale to 4 pieces.

Lamina Feeding…

Lamina Conditioning Dickinson Direct Conditioning & Casing Cylinder

is used for conditioning of Lamina, It is used for:• De-lamination of leafs• Increasing moisture from 11% to 22% (For preventing

dust formation and degrading at cutter)• Applying suitable casing

DCC&C is a re-circulating rotary conditioning cylinder fitted with pins along the inside to tumble the leaves to allow even conditioning. The moisture of Lamina is increased by a combination of water sprays and steam. DCC&C has casing application arrangement added.

PrincipleThe addition of moisture in DCC&C happens due toCondensation Cold Tobacco comes in contact with hot humid air Condensation of water takes place on the tobacco This is absorbed by the surface of tobacco Approx. 4 to 5% moisture increases by condensation (@ 1%

m.c. increase on every 10 0C rise in temp of lamina)

Direct Absorption of Water The cells of the lamina open up due to heat Water particles penetrate these opened up cells

DCCC.. Cylinder is made from SS sheet 3 mm thk. SS spikes are fitted internally (additional pins at the

feed end) Exterior is insulated with rock wool mineral fiber and

clad in plastic coated mild steel sheet Cylinder Dia:2.1 Mtr, Length:7.2 Mtr Cylinder RPM 8.5 variable mechanically from 4 to 17 Designed flow rate 7000 Kg at 9% m.c. (Inlet) and

8167 Kg at 22% m.c. (Outlet) Product Temperature 15 0C in, 75 0C out Drive: 11 Kw 1400 RPM PA fan Drive: 11 Kw 100 RPM PA fan capacity : 5000 cfm max.

DCCC… Preheat Mode: Preheat of cylinder is done to

prevent excessive heating. In preheat mode, dry heat is only is applied to the cylinder by re-circulating PA through a steam treated heat exchanger mounted inside feed hood.

Run Mode:Steam spray and atomized water spray starts. Heat exchanger is bypassed and heating of PA is done by direct spray of steam.

Change in mode: When product has not been fed for a time in excess of 2 min., the cylinder control switches to preheat mode automatically

CasingCasing is applied to the conditioned lamina

from the discharge end of DCC&C. The suitable casing is used :

• To increase the sugar levels in the tobacco with low natural sugars (For Air cured tobacco).

• To enhance moisture retention of the lamina.• To reduce harshness and bitterness of the smoke.

Lamina BinsPurpose of Lamina Bins: Bulking of processed Lamina Homogenizing of the moisture, temperature and other various

properties of different grades of leaves Proper mixing of the leaves by bulking it in horizontal layers

and discharging in vertical layers at the time of discharge with the help of doffers.

Working Principle: The conditioned tobacco is fed to the master trolley. This master trolley feeds the lamina bin Half by the forward motion Another half by the reverse motion Minimum bulking time required is 2 hrs.

Air-liftbypass

To cutter

Sand

1” gap rollers

¼” sieve

Sieve Complex

Mixed >1” ¼”-1”

¼”- <1/18” >1/4”

1/18”

¼”

Sieve Complex

Sieve complexClassification sizes –1/4”, 1/18” Objectives

Separating thru-quarters ( ¼”)

The thru-quarters by-pass the cutter and are air-lifted to post-cutter line before Search & Fill

Sand is obtained as underflow of 1/18” sieve

Lamina Cutter(s)

Objective: Cut the lamina to required and uniform size, for

filling into cigarettes

Model: KTC and KTC80E

Make is Hauni

Cuts to 30 cpi (0.84mm) normally

40 cpi (0.63mm) for bingo blends

Lamina is fed through a GFP SRB receives the lamina and it ensures even feed to the

cutter using two sensors – stroke length must be optimal for proper compacting of tobacco

Transport chain conveys compacted lamina in cake form to mouthpiece

As tobacco leaves m/piece it is cut by knifes on rotating cutter drum

Grinder constantly sharpens the knife and oscillates along an axis parallel to the drum

Diamond is continuously truing the grinding wheel

Lamina Cutters…

Search & Fill & Weigh Con

Operating principles : It ensure continuous feed to weigh con even incase of any stoppages in up stream. Thus acts as a buffer for 15 minutes.

Weigh ConOperating principles : It weighs & measures the

moisture contents of in coming tobacco & feeds the data to PLC for downstream operations.

Search & Fill

Hauni Tunnel

Operating Principles : Increases the fill value of lamina by charging free

steam through No. of holes across the VOV. The amount of increase in moisture content here is around 2 to 4 % the temperature of cut lamina increases from ambient to 90 0C.

KLD Dryer Dryer is required to reduce the moisture

of the lamina (which is about 24% at the outlet of the HT). The moisture is required upto 14 %.

Dries up the excess moisture from cut lamina keeping the fill value gained.

K L D - DryerMajor components : Cylinder (D-1.9 mtr, L- 10 m, Inclination

50) Paddles(12 nos). Process air and admixed air flow system. Cylinder drive. Water nozzle at exit.

K L D

Process parameters : Inlet mass flow- 6815 kg/ hr. Outlet mass flow- 5825 kg/ hr. Inlet temperature- 85oc. Outlet temperature- 60 to 65oc. Avg. inlet moisture content- 26%. Avg. outlet moisture content- 15%. Operating steam pressure- 8 bar. Compressed air pressure- 6 bar. R.P.M – Normal 12, starting 7

Stem Line

There are two major steps in stem lineStem Conditioning Stem cutting and dryingAfter drying stem is stored in CRS bins and mixed with the processed lamina for final Tobacco which is again processed through cooler.

STEM CONDITIONING

Feeding Inspection Autofeed

Air LiftSieving

Admoist Stem Bins

STEM CUTTING & DRYING

Discharge from Bins Cutters Search and

Fill

GFP & Weycon

STSSTS

T.C. Dryer Sieve and Tower Classifier CRS Bins

Stem Feeding for conditioning

Issue by Blend operation Unpacking Physical Inspection of Stem Airlift for conveying for conditioning Removal of heavier foreign materials

Stem Conditioning

Dickinson Admoist Stem ConditionerThe machine is used for increasing both moisture and temperature of Stem, whilst achieving complete penetration of conditioning throughout the cross section of length. Stem is conditioned from 11% m.c. to 38 +/- 2% m.c. with temperature range 600 C to 700 C. This makes stem soft and pliable for cutting purpose.

Admoist Consists of:Feed Arrangement, Trough, Chassis, Rotor (rotating paddles with drive), Water sprays, Casing Spray, Conditioning spray, take off

Admoist…Working

Stem is conveyed through the Admoist by the action of a three bladed rotor supported with in a U shaped trough. The Pipe at the center is perforated and supplied with low pressure steam with rotary union. At intervals along the length, atomized water spray are directed at the product from above. Thorough penetration of moisture is achieved by the combined effect of steam percolating from the rotor spray pipe, together with the finely atomized water from above. Good mixing is achieved by means of gentle tumbling action which ensures that fresh faces of all particles are continually being presented to the steam and water sprays.

Trough Length : 4.5 Mtr. Paddle Diameter: 0.9 mtr Angle of inclination : 50

Paddle Rotation : 6.5 RPM Cylinder drive motor : 2.2 KW Stem flow rate : 2000 Kg/hr Moisture : 11% to 40% Steam : Pr: 4 – 10 bar,Cons: 220 Kg/hr max Water : Pr: 3 bar min, Cons: 895 Lt/hr

Admoist…Technical Data

Stem Bins There are 5 bins for conditioned stem. The purpose of bins is to bulk, mix and feed

different grades uniformly to the cutter. Capacity: 2000 Kg at 11% m.c. Stem is taken to a Shuttle or traversing conveyor,

which layers it uniformly inside the bin. 4 doffer (Runs at 80 RPM) in each bin are provided

for thorough mixing and ease of discharge from bins.

Stem Cutting

Machine Used- KORBER Tobacco Cutter:KT 2Transport chains convey tobacco to the mouth piece. The mouth piece holds the stem firmly during cutting process. An adjustable compaction force generated by a pneumatic cylinder to achieve uniform compaction. The Knives on the knife drum (50 inclined) cut the stems. The grinder unit moves to and fro on a sliding mechanism, mounted parallel to the knife drum axis constantly sharpens the 8 knivesThroughput is determined by:a)Knife drum speedb)Mouth piece openingc)Conveyor chain speedVariable is Knife drum speed other drives are speed synchronized.

Steam Cutter…Parameters

Cut Width : 140 CPI Cutting Moisture: 38 +/-2% Cheese Pressure: 50 KN Cheese Height : 100-160 mm

(Constant for particular run) Knife drum speed: (250 to 660)

Steam Treated Stem (STS) STS process is intensive steam treatment method Stem is fed through gas tight Rotary Air Lock Steam is blown to chamber through nozzles It condenses on the stem particle and induces a rise in

temperature to a value approaching the temperature of condensate .

High level of material and heat exchange and the low pressure in free jets leads to sudden vaporization of water present in stem cells and causes expansion

Post Treatment chamber : This consists of a venturi, which causes steam to accelerate. The static pressure of the steam reduces at this point, resulting in further sudden vaporization of water contained in cut stem cells, causes expansion

CRS Drying – TC Dryer Equipment: TC Dryer- LEGG, UK TC stands for tubular construction To reduce moisture of CRS from 40% to desired

level (15% ) PID controllers compare the measured value against

the desired value, if there is a deviation controller sends a signal to PLC to increase or decrease the temperature

Process air is co-axial and is set to provide maximum drying condition.

Cylinder inclination:80, RPM:8 to 10 RPM Throughput rate : 1600 to 2000 Kg/hr Product Temperature: 60 0C to 65 0C

Throughput rate : 1600 to 2000 Kg/hr Moisture Content of outgoing Product : 15-16.5% Product Temperature: 60 0C to 65 0C

CRS Drying…Process Parameters:

Tower Classifier

Principle is winnowing. The lighter particle are picked up by a gentle suction and heavier are dropped down

After classification, the CRS ready for adding back in every respect is air transported to the addback bin.

Addback Bins There are 5 addback bins. These stores CRS Also used for layering of add backs such

as smalls, expanded tobacco etc. Also serves to even out moisture Mixing is done with the set of 3 doffers at

discharge Capacity – 2000 Kg max (each) Bin Discharge speed – Variable to match

lamina operation No min. bulking time restriction

COOLER/FLAVOURING Cylinder

The air is being sucked from the DRF which is connected to the ventilated area at the entry of the cylinder

Ambient air enters the cylinder from the exit ports and absorbs the heat in the tobacco

The vanes in the Cooler helps in the providing all surface area to come in contact with air.

Top flavor are being added in some blends in this cylinder & also mixing CRS & lamina properly.

Cut Tobacco Bins: There are two cut tobacco bins where cut tobacco from flavoring cylinder are being conveyed.

Skip Stacker: Six skip are stacked in one stacker from cut tobacco bins & weighed.

Cut Tobacco Storage : Weighment slip containing the blend, operation number ,date of operation, weight are attached to stacker & store in CTS.

CTS

SECONDARY MANUFACTURING DEPARTMENT

SMD Functions

Receiving Cut Tobacco from CTS and WMS from warehouse

Manufacturing various brands of cigarettes

Packing the cigarettes in CFCs and delivering to Shipping

SMD FLOW LINECut Tobacco

from CTS

Making Machine

Branded Cigarettes

Packing Machine

Cigarette Packets

Outers / CBOs

CFCs

WMS fromWarehouse

Shipping

WMS Waste

Waste Cigarettes

WinnowingsWMS Waste

Waste Cigarettes

WMS Waste area

Reprocessing at PMD

Shaker Feeder

Pneumatic feedTobacco

Brands & Specifications – As per Length of Cig King Size – 84 mm (64 mm Tobacco length and 20 mm filter length)

a) India Kings

b) Wills Classic

c) Gold Flake Kings Longs – 74 mm (Filter = 11 mm)

a) Wills Navy Cut

Regular Size Filters – 69 mm (Filter=11 mm)

a) Gold Flake Filter

b) Gold Flake Premium filter

c) Capstan Filter

d) Bristol Filter

e) Wills Flake Filter

Brands & Specifications …

As per cigarette circumferencea) King Size – 24.75 mm

b) Longs/Junior Size Filters – 24.5 mm

As per pack varietya) Hinge Lid (HL)

b) Round Corner (RC)

c) Pillow Pack (PP)

d) Hinge Lid / Enlarged Pack (HL/EP)

e) Twin Ten (TT)

As per number of cigarettes in a packa) 10 HL (5 on 5)

b) 10 PP (5 on 5)

c) 20RC (7-6-7)

d) 20 TT (Twin Ten)

On the basis of total cigarettes in a Bundlea) 200’s : King Size and Longs (navy cut)

b) 500’s : All regular Size Filter segment

Brands & Specifications …

Production Planning

Monthly Production Plan Logistics Department generates the plan based on HO

marketing plan and STOs from marketing branches.

Three Day Niche Manufacturing Plan: This is based on STOs received and the stock available at

Shipping. This is used by shift managers to plan the production. This Plan is given by Logistics on following days: Wednesday : For Planning of Friday and Saturday Friday : For planning of Sunday, Monday and Tuesday Monday : For Planning of Tuesday, Wednesday and Thursday

Shift Co-ordination

There are a total of 6 Module Resource Managers (MRMs)

3 MRMs comes in shifts- Early, Late and Night, 1 MRM will be in common shift for module nurturing and one will be in early shift for weekly cleaning schedule.

Shift pattern changes every week.

Modules

The entire SMD shop floor has been organized in small groups called “Modules”

Modules are a combination of making machines and packing machines with certain owned resources and certain shared resources.

There are six modules namely – Pragati, Nai Rahein, Vikas, Frontier, Josh and Nav Marg.

Reasons for dividing into modules are:• Easy monitoring and control of each machine• Creates competition among modules which increases efficiency• Creates a sense of ownership in the employees.

Module 1 – Pragati

Making Machine

No MakeCapacity (CPM)

11 Loga 7000

14 Mark8Max

3000

Total Capacity 10000

Packing Machine

No Make Capacity (PPM)

43 GDX2S 300

44 GDX2S 300

45 GDX2S 300

Total Capacity 9000

Module Ownership : Mr. K G Prasad

Cleaning Day: Wednesday

Size Manufactured : 69 mm

Module 2 – Nai Rahein

Making Machine

No Make Capacity (CPM)

9 Mark8Max 3000

25 Mark8Max 3000

3 Mark8Max 3000

Total Capacity 9000

Packing Machine


33 GDX2NV 350

35 GDX2NV 350

Total Capacity 7000

Module Ownership : Mr. A. Paul

Cleaning Day: Tuesday

Size Manufactured : 74 mm (Wills Navy Cut 10PP)

Module 3 – Vikas

Making Machine


4 Mark8Max 3000

5 Mark8Max 3000

6 Mark8Max 3000

Total Capacity 9000

Packing Machine


33 GDX2NV 420

35 GDX2NV 420

Total Capacity (Cig Per Minute)

8400

Module Ownership : Mr. A. Paul

Cleaning Day: Thursday


Module 4 – Frontier

Making Machine


16 Loga 6500

18 Loga 6500


Packing Machine


37 GDX2NV 420

51 Focke 350 300

46 GD X2NV 350


13700

Module Ownership : Mr. Sujeet Saha

Cleaning Day: Saturday

Size Manufactured : 84 mm (All King Size segment)

Module 5 – Josh

Making Machine


17 MK8 max 3000

15 Loga 7000


Packing Machine


39 GDX2S 300

32 GD X300 300

56 Focke 349 300


9000

Module Ownership : Mr. Sumit Johri

Cleaning Day: Friday


Module 6 – Nav Marg

Making Machine


1 MK8 max 3000

2 MK8 max 3000

19 MK8 max 3000

23 MK8 max 3000


Packing Machine


31 GDX300 300 – EP

38 GDX2S 300 – EP

40 GD X2S 300

60 CME 180 TT


12600

Module Ownership : Mr. Narayan

Cleaning Day: Monday

Size Manufactured : 69 mm (TT & EP packs are also packed here)

Making machine types:

M/c make No of m/cs Std Capacity (Cig / Min)

Loga 3D 3 7,000

Loga 2D 1 7,000

MK8 Max 12 3,000

Packing Machine Types

M/c make No of m/cs

Std capacity(pkts / min)

GDX2NV 6 420

GDX2S 7 300

GDX300 1 300

Focke 349 1 300

Focke 350 1 300 (20 Cig per pack)

CME TT 1 180 (20 cig per pack)

WMS Types

WMS is the material found on cigarette packet except tobacco.

Making WMS : Cigarette Paper Printed/Pre printed Cork Tipping Filter Rod Ink Gum

WMS Types…

Packing WMS: Foil Inner Frame Blank Bi-Axially Oriented Poly Propylene (BOPP) Tear off Ribbon (TOR)

Outer WMS: Gay Wrapper, CBO CFC ITC printed tape

Maintenance Budget

Head Office

Projected sale by All Mktg Offices

Target is divided in all units

SaharanPur

GD : 2.50 Rs / M cig

Focke : 2.00 Rs / M cig

Loga : 4.25 Rs / M cig

MK8 : 1.75 Rs / M cig

Total Maintenance budget is calculated by Multiplying Cig target with the per M budget of individual machine

Maintenance Systems

Preventive Maintenance Cleaning of machines three times a day before the start of each shift –

done by machine crew and technician Weekly 4 hours cleaning – Each module is cleaned for 4 hours once

in a week. A different day is fixed for each of the 6 modules. The maintenance team does this job.

One Day Maintenance (ODM) – A maintenance schedule for each machine is prepared for maintenance every 45 days. Maintenance team with specialists does this job.

Break down Maintenance As and when the machine breaks down or when the quality

parameters are not within the tolerance limits, break down maintenance is done.

Different Maintenance Schedule of Makers and Packers:

Maker Weekly Cleaning ODM (after 750 hrs) Quarterly Maint (after

1500 hrs) After 4500 hrs (Earlier

3000 hrs) PPM (after 9000 hrs)

Packer Weekly Cleaning ODM (after 750 hrs) Scheduled Maintenance

of sub assemblies. Deep Maintenance

(After every 3 year)

Short Folder

Long Folder

Tobacco

Hopper

Elevator

Flapper

Magnet

Cleaner

Carded Drums

Picker & Winnower

Suction Chamber

Ledger

Cutter

Air Cell

Ecreteur Discs

ShoeGarniture

Tongue piece

HeaterP.P.A

Printer

Paper

Mk8 Layout

Commercial Department

Department Structure:

Commercial Manager

Asst Commercial

MgrFS-1 FS-2 FS-3

Excise and taxation

Bill Passing, Budget, IVR, Purchase etc.

Budgeting

There are 3 heads under budget: Employee Budget Personal salary and wages Production expenses

Approved by H.O. every year Discussed in Monthly Branch Performance review meetings MOM of BPR meeting are prepared and circulated Outlook : These are the in-between revised figure of budget Conversion Cost : Cost required to convert Raw Material

into finished goods. This cost involves the 3 heads mentioned in first point.

Purchase

All Raw Material is purchased at HO level Other items are purchased at unit level. These are categorized

into : DI (Direct Indent) : Non codified items

• Further divided into Capex and Revenue items SI (Stock Items) : Coded items, being used regularly

Purchase requisition is generated by user department PR series: 50….. for Capex items. 30…. for revenue items Purchase order is signed by two authorities for value >10,000

Rs. (e.g. CM & BE) PO series: 52….DI items, 45….SI items, 51…Capex items

IVR

IVR is known as Inter Business Area Clearance This is used for any kind of transaction within the

same division of ITC or within the different div of ITC companies

SAP is used for clearance within ITD ACCREMON is used for clearances of different

divisions.

HR Department

Department Structure: HR Manager

Asst Manager 1

Asst Manager 2

Asst Manager 3

Welfare Officer

SMD PMD + Canteen

Engg. + Comm.

Welfare activities

Quality Information System

Function of QUIS is to monitor all the quality parameters of Tobacco, Cigarettes and Packets.

MOISTURE TEST

PARTICLE SIZE TEST

FILL VALUE TEST

PMD TESTS

Electric OvenElectronic weighing machineTraysDessicatorTobacco filling tins

Apparatus used

Moisture test is done for both PMD and SMD. In this test the moisture of the tobacco is found out

Moisture Test

• Samples will be collected from PMD/SMD• 20 Containers in one tray & total 5 trays can be loaded once

into oven• Each container will be loaded with 10 gms of tobacco using

weighing machine• Containers are closed with perforated lids to allow escape of

water content due to heat• Oven is pre-heated to come to 1100c• All the five trays are loaded into oven• Oven is put-on for 3.5 Hrs.• Trays are taken out and placed in the dessicator to cool

down for 20 minutes.

Procedure for Moisture Test

9. Dessicator consists of Silica gel at the bottom which absorbs the heat from the surrounding so that tobacco inside container neither gains nor loses moisture

10. Containers are taken out of the dessicator, individually weighed & readings are noted down

11. Loss in weight expressed in terms of % will give us the moisture of tobaccoWt. Of tobacco before heating = Wx in gms

Wt. Of tobacco after heating = Wy in gms

Moisture (in %) = ___

Wx X 100

Wy1 -

Procedure for Moisture Test…

Particle Size Test

Jel Sieve Electronic weighing machine

Apparatus used

This test decides the quality ratio of tobacco. It is basically to find out the degradation level of tobacco which mainly contributes for sensory characteristics of smoke.

1. Collect 50 gms of tobacco sample.2. Put it into top first bin. (should not be overfilled

because more compression will be there and filtration will not take place properly).

3. Close the container firmly & put on the machine to run for 10 min. continuously.

4. The whole container is subjected to eccentric rotation such that the tobacco on the top gets filtered through various meshes depending on their sizes.

5. Containers are taken out & individually measured and weights are noted down.

Procedure for Particle size test

Q.R. (in %) = A + B----------------A + B + C + D

X 100

A – 2.0 mm

B – 1.4 mm

C – 0.85 mm

D - SAND

A = Weight of 2.0 mm Tobacco

B = Weight of 1.4 mm Tobacco

C = Weight of 0.85 mm Tobacco

D = Weight of sand at bottom most

Note:1. QR should not be less than 70 %2. Sand proportion also should not be more than 10 %3. This test does not depends on moisture

6. Quality ratio is calculated as follows:

Particle size Test

Apparatus used

This test is conducted to find-out the Fill value of the tobacco. This mainly depends on the moisture content. This the most important characteristics, which decides the density of filling.

Fill Value Test

Digital Densimeter Electronic Weighing machine

1. Bring the piston to touch the bottom surface of the cylinder in idle condition and set the indicator to ‘0’

2. 20 gms of tobacco is measured & put into the cylinder

3. Piston is made to exact a load of 3 Kg on the tobacco inside cylinder continuously for 30 sec.

4. Reading is noted i.e. the height of tobacco cheese.

5. With relation to height of the tobacco cheese, volume of the cylinder, fill value is calculated at 13.5 % moisture.

Procedure for Fill value test

SMD TESTS

END STABILITY TEST

FIRMNESS TEST

PACK SEALING TEST (PST)

MOISTURE TEST

End Stability Test

End stability tester Electronic Weighing

machine

Apparatus used

This test finds the loose shorts in the cigarettes.

1. Load 50 cigarettes to cage2. Continue above procedure for remaining 3 cages3. Leave 5 mm gap from the wall to allow loose tobacco

collection into the tray on the bottom 4. Start the machine to run continuously for 268 rev. (3 min

with 90 rpm)5. After the machine stops, transfer loose tobacco collected

in the tray to weighing bin 6. Note down the readings and repeat the same for

remaining cages

Procedure for End Stability test

W = Wt of shorts collected

End Stability = (W/50) x 1000 mg/cig

Firmness Test

Auto Hardness Tester

Apparatus used

This test is done to find out firmness of the cigarettes. Conducted for 30 cigs per test in 3 sets (ex. Maker).

1. The circumference of the cig is calculated in QTM and diameter is derived

2. Diameter = mean Circumference / 3.14153. 30 cigs are loaded on to the machine hopper4. Measured dia is entered in the machine (analog

type)5. Machine accepts a batch of 10 cigs & will be pressed

with the load of 2 kg for 30 sec6. Mean contraction dia is displayed and printed out7. Then the firmness is calculated for 13.5% moisture

Procedure for Firmness Test

Pack Sealing Test

PS Tester

Apparatus used

As the moisture content of the tobacco is very important till it reaches the end customer, it is most necessary to ensure proper sealing of the pack such that the tobacco inside neither gains nor loses the moisture. To ensure the same CPST is done.

1. Load 10 cig packs to the machine2. Machine will pick-up one at a time & pierce into

the pack3. Blows the air from the pierced end continuously4. 50mm WG pressure is maintained throughout

the pack5. Amount of air accepted by the pack is the

indication on quality of packing6. Machine gives the printout indicating the

pressure maintained and flow through the pack which is a direct measure of quality of Sealing

Procedure for PST

Outer Pack CigarettesIt is done for visual defects

PQRS is carried out on

Quick PQRS : Done for both maker and packerDetail PQRS : Detailed test done by quality auditors. Done only after packer

Types of PQRS

PQRS

Engineering Stores…

All inventory is kept in Engineering stores, and material is procured and received through Eng Stores.

Inventory Guideline : 0.5 % of Asset Replacement Value

Actual : 5 % (Approx 6.4 Crore) Type of spares:

VB PD DI


VB : These are codified items for which Safety Stock and ROP is defined. These are procured automatically by running MRP.

PD: These are also codified items for which there is no safety stock defined, these are also procured by MRP run, provided purchase requisition is made in advance by user.

DI: These are Direct indent items, these are not codified and procured directly by user, receiving and issue of these items will be done by stores only.

Engineering Stores:

……….. SS1 : SREFCT Vendor SREFCT SSD : SREFCT CES Vendor

SREFCT SCS : SREFCT CES Vendor

CES SREFCT SIM : These are imported items


Returnable Gate Pass: These gate pass are required for those items which are returnable, and are issued by Stores supervisor

There are four copies : White(gate house), Yellow(stores), Green(Vendor), red(Vendor, and received and filed by stores after getting the material back)

Authorization :• For less than 7 days : Authorized managers• For more than 7 days : HOD• For more than 30 days: BM

Boiler House

Boiler is used for generating steam for following application:

• PMD (DCC&C, Admoist, HT, KLD, STS, TC dryer, casing prep, NTM) : This is mainly for tobacco processing.

• Air Washer and VAM• Canteen – For food preparation• Others (F.O. tank, Feed water tank, service

tank etc.)

Boiler House…

There are 4 no. of boilers

*Boiler No. 4 is water tube boiler installed for DG flue gases heat recovery. Capacity = 2.25 Ton

S.No. Boiler No. Working pressure

Tested on Testing due on

1 UP 5535 10.54 24.01.06 18.01.07

2 UP 3503 9.975 19.10.05 10.10.06

3 MYS 1276 10.02 16.02.06 15.02.07

4 UP 5785* 10.5 28.07.05 03.07.06

Boiler House…

Model : WBN-4TPH-PF-44 H/L Make : Nestler Type : 3 Pass, Wet Back Design Fuel Used : Furnace Oil Capacity : 4 Ton each Stack Height : 54.2 Mtr Surface Area : 127 m2

Three pass Wet Back Design Boilers

Three-pass wetback design has a rear water wall,which separates the primary heating surface of the combustion chamber from the rear tube sheet.The water jacket eliminates the need for a refractory wall.The rear water wall eliminates the need for gasketing,which is vulnerable to the temperature generated in the rear of the turnaround area.The fact of the matter is —a wetback design boiler not only overcomes these expensive deficiencies,but it has great overall efficiency and virtually maintenance-free construction.

Boilers.. Fuel Feeding Ckt

1 2 3 8 9P F.O. tank

Cap:50 KL each (5 Nos)

service tank Cap:5 KL each (2 Nos)

Meter

Pump

FilterP

Pumping and Heating. Pr: 20 Kg/cm2, Temp:100-110 0C

Boiler (1,2 and 3)

Boiler… Feed water ckt

Feed Water Tank (cap 15 KL)

DM Plant

Condensate from PMDMetering & Temp

measurement Common Header

Feed Water PumpHead : 107 MtrFlow : 12 m3/hr

Check Valve

Boiler •Magnetic switch to control water level

•Two level indicators are provided for visual

Boiler… Operating Parameters

Oil Temperature : To be maintained at 100-110 0C

Oil Pressure : 20 Kg/cm2 approx. Inlet Water Temperature : 80 0C

(maintained by steam at feed water tank) Air Flow : 15 Kg for 1 Ltr of fuel Oil Consumption : EVR : 13 to 14 (EVR is the steam

generated (in Kg) per Liter of F.O. consumption i.e. Evaporation Ratio

Boilers… Controls and safety

Low Pressure Cut off : It cuts off supply of fuel to one nozzle and reduces the air flow to run boiler at lower output.

High Pressure cut off : It completely shut off the fuel and air to boiler when desired pressure is reached and starts again at the lower limit

Safety Valve : There are two safety valves provided on boiler discharge to blow out the excess steam

Feed Water Level Control : Feed water is controlled with the water level in boiler, help of magnetic switch

Boiler… Efficiency Calculation

Boiler Thermal efficiency can be calculated on the basis of CV

η = Mw (Hs.x–Hw)x100/(Mo x CV)Where:η = Thermal efficiency of boilerMw: Mass of water/steamHs.x: Heat in steamHw: Heat of feed waterMo : Mass of OilCV : Calorific Value of Oil (9600 Kcal/Kc of F.O.)

Boiler… Efficiency Calculation

Boiler efficiency can also be calculated on the basis of losses

η = 100 – Flue gas loss – Hydrogen Loss- radiation loss

= 100 – 0.576 (Tg – Ta)/% of CO2 – (6.5+2)

Where:η = Thermal efficiency of boilerTg= Flue gas temperatureTa=Atmospheric Temperature

Boiler … Maintenance

Preventive Maintenance is followed for Boilers. Two schedule are followed: Monthly : This involves mainly tube cleaning

and regular scheduled maintenance (This is done on every Monday)

Yearly : This is detailed maintenance which is done every year before the inspection of boilers by boiler inspector.

* M/s Thermofab has been allotted the Maintenance contract for boilers

Boilers… Statutory Requirement

Hydraulic Test : Every Boiler must be hydraulically tested every year in presence of Boiler inspector. It is carried out by applying 1¼ times the working pressure of boiler, for the time of 30 min. (testing water temp should be between 20 0C to 50 0C)

Steam Test : Yearly, in presence of inspector, For checking whether safety valves are working at desired pressure to relieve boilers excess steam.

Stack Emission: This must be less than 250 mg/NM3. (This is checked by M/s Envirochem)

Compressors and Boilers – Layout

4

3

2

1

ARDryer

MYS-1276

UP – 3503

UP – 5535

Compressors…

Qty : 4 Vertical Reciprocating compressor Single stage Double Acting Make : Ingersoll Rand Model: 8 x 5 ESV- 1 – NL - 2 Capacity:125 CFM each Motor Rating : 30 KW / 1470 RPM Compressor RPM : 760 RPM

Compressors…

Safety interlocking: There are two safety interlocking provided

for compressor: Low Pressure tripping/interlocking for

lubrication oil. Low pressure tripping/interlocking for cooling

water.Other safety Interlocking required:

Flow Switch for cooling water.High pressure switch for oil.Outlet compressed air temperature monitoring

and interlocking.

Compressors…Statutory Requirement

Following test are required to be performed for compressed air system by competent agency:

Hydraulic Test for Air Vessel : Every Alternate year, by applying 1.5 times the rated pressure of vessel.

Thickness test : For complete pipe line, frequency is every six months.

Air Dryer

Capacity: 400 CFM Designed Pressure : 10.5 Kg/cm2 Actual Pressure : 5-6 Kg/cm2 Make : ITM Projects (Pvt) Ltd Refrigerant Used: Freon (R22) Refrigerant type air dryer : Based on

refrigerant cycle which consists compression, condensation and evaporation of the refrigerant.

Motor Garage

Maintenance of machines is done by motor garage.

Following Machines are available: Fork Lift : Total 11 Nos. (Make: Macneill Eng. Ltd)

• Fork Type: 7• Clamp Type: 3• Wheel rotating attachment : 1

High Reach Truck (Lindey Make)• For Leaf: 3 Nos (2 for issue and 1 for receipt) • For WMS: 3 Nos

BOPT (Battery Operated Pilot Tube)• For Secondary : 6 Nos• For WMS: 1 No.

Tractors: 2 No (Make: Massey Ferguision)

System of PWKC

PWKC is a peti works contract, these are used for works for which any kind of labor/manpower is involved.

There are two kinds of PWKC SI: Service Indent (Only labor is

involved), 53… series WI: Work Indent (Labor and Material

both are involved), 54… series

Requirement of Job

Quotation, first principle costing & negotiation

Raising Purchase Requisition

Preparation of PWKCand attachment of logic note,

Report sheet and CLRA Act check

Signing by BE/PM, CM and BM

Back to EnggHead clerk

for sending tovendor

Service request Form (For starting

work as per PWKC)

Receiving of PWKCAfter completion of

work

PW

KC

Sys

tem

Commands Used for PWKC…

ME51 : For raising PR ME52 : For editing PR ME53 : For over viewing PR ME21 : To raise PWKC against PR ME22 : To edit PWKC ME23 : To over view PWKC ML81 : For Receiving PWKC

P1 P2 P3 P4

P5

P6

P7

P8

P9

DOMESTIC / DRINKING(100 KL)

PROCESS(100 KL)

Sprinkler SumpCap.300 KL.

.

Hydrant SumpCap.328 KL.

Domestic Sump.(200 KL.)

WaterSupply

AutoController

O/HTank

Common Sump. Cap-88 KL

P1-Jocky PumpP2-Hydrant PumpP3-Sprinkler PumpP4-Hydrant EngineP5 & P6-Domestic PumpP7 & P8-Drinking PumpP9-Drain Pump

Tube well No-1.behind TTCTYPE---SubmersibleMake : GrundfossKW/HP----12.5Head-------60 M3/Hrs

Tube well No2 OPP FO TankTYPE---SubmersibleMake : GrundfossKW/HP----12.5Head-------60 M3/Hrs

Tube well No-3 Near UGRTYPE---SubmersibleMake : GrundfossKW/HP----12.5Head-------60 M3/Hrs

Water Distribution

Water Treatment

DM Plant DM water is used mainly for Boilers, it

is used also in small amount in DG water jackets, PMD bins humidification etc.

Softening Plant : Soft water is used for cooling towers,

Compressors cooling, Air Washers

DM Plant

Demineralization, also known as deionization, is the process of removing dissolved minerals from water to make it suitable for industrial uses.

Make ion exchange Capacity : 300 KL per regeneration Daily Monitoring of following parameters:

TDS : <15 pH: 8 to 10 Total hardness : 10 Alkalinity : 5 to 10

DM Plant

Ion Exchange Technology Ion exchange purifies water by filtering it through a tank

containing small beads of synthetic resin. The beads are chemically treated to adsorb either positively charged cations or negatively charged anions, and exchange these ions for hydrogen (H+) or hydroxyl ions (OH-) based on their relative activity compared to the resin. The ion exchange process purifies the water until all available exchange sites are used, at which point the resin is exhausted and must be regenerated by use of chemicals.

HCl : For regeneration of cation resins Caustic Soda Ca(OH)2: For regeneration of anion resins

Softening Plant

A water softener works on the principle of cation or ion exchange in which ions of the hardness minerals are exchanged for sodium or potassium ions, effectively reducing the concentration of hardness minerals to tolerable levels.

Ion exchange method is used for water softening. This unit uses sodium chloride (table salt) to recharge beads made of ion exchange resin that exchange hardness minerals for sodium.

ETP

Aeration TankSedimentation

Tank

Sludge Tank

Discharge Water TankFF

Cl

TankFor gardening

Alum

V-Notch

Storm Water tank

Sewage Water tank

Blower Blower

ETP…

Aeration Tank: • This tank contains Bacteria and air is supplied to the

bacteria inside the tank with the help of blowers• Urea and Di Ammonium Phosphate are used as a nutrition

of bacteria Sedimentation tank:

• Overflow of Aeration tank goes to sedimentation tank• Alum is dosed into sedimentation tank, Alum reacts and

settles down the suspended solids Discharge water and Sludge tank:

• Overflow of sedimentation tank goes to discharge water tank and settled solids goes to sludge tank

• From discharge tank water is pumped through Multigrade sand filters to separate tank

• Water is pumped in another tank and sent for irrigation purpose

ETP Parameters

Discharge : 200 to 250 KL per dayParameter Value Monitoring

Actual Required

pH 7.0 5.5 –9.0 Hourly

TDS 500-700 <2100 Every Shift

TSS 40 <100 Every Shift

TS 600-700 <2200 Every Shift

COD 70-100 <250 Weekly

BOD 15-20 <30 Weekly

MLSS 250 - 400

Air Washers

Air Washer:• Tobacco m.c. is 13.5% which is stored in CTS and

filled in cigarette at SMD. Tobacco is a moisture sensitive product

• It is experimented and practiced that at 25 0C and 65% RH moisture equilibrium is maintained for tobacco

• Air washers are required to maintain the condition of air at CTS and SMD as per requirement

AHU: Air Handling Unit• Temperature is required to maintained in office

areas at certain level in summer for cooling purpose.• AHU’s are installed which cools the air in the

summer in office areas

Air Washer

There are total 4 Air washers for conditioning SMD floor(Two above CTS and two above shipping area). Capacity of each air washer is 127 TR

There are total two Air washers for CTS floor which are located above CTS floor. Capacity of each is 45 TR

There are total 7 AHU (4 for Admin block, 2 for SMD offices and 1 at WMS

Air Washer…

Return Air Filter, Damper Fan and Motor: Draws air from the conditioned place

Exit Air Damper: To take the air out as per desired qty Fresh air filter and damper: Fresh air is sucked inside the

system with supply air fan suction Preheating coil: In winter air passes through preheating

coil, sensible heat is increased Air Distribution plate: To achieve uniform distribution

throughout the spray chamber, for good contact between air and water

Water spray: Water required is sucked from tank and sprayed to with the help of nozzles

Water Eliminator: PVC make bend plates, these changes the direction of air flow and remove the free water held in suspension and also facilitate deposition of the dist on the eliminator plate

Air Washer…

Water Eliminator: PVC make bend plates, these changes the direction of air flow and remove the free water held in suspension and also facilitate deposition of the dist on the eliminator plate

Cooling Coil: Air looses sensible heat when passes through the cooling coil

Reheating coil: (For winter) For increasing the sensible heat of air, it is passed through reheating coil

Supply Air Fan: These fans are drawing the processed air and passes it to the supply air fan room where it goes through the duct to conditioning zone

Supply air damper: Provided to regulate the air quantity which is delivered to conditioned zone

Chillers

Chilled water is required for Air Washer as well as Air Handling Units in summer

Chillers are used to make water chilled

There are two chillers:• Screw Chiller (Refrigeration cycle): 390 TR• VAM (Vapor Absorption Machine) : 600 TR

Power House

There are 5 Generators in Power House Fuel Used : HSD

1 2 3 4 5

Make: CumminsGeneration Capacity: 1000 KVA

Make: MTUCap: 1670 KVA

RUPS

Rotary UPS

Requirement : To handle interruption of Grid power supply.

Time required: 12 seconds Capacity: 1670 KVA Power Bridge stores the Kinetic

Energy by running of Flywheel at 3400 RPM

Rotary UPS…

M/G

DGPower Bridge (Flywheel)

Rectifier

DG No.5 Make:MTU

Clutch

Grid Supply

Supply to critical loads

Breaker

Mechanical energy remains stored in flywheel during grid power supply, which acts as a power source at the time of power failure for the time period required for DG to start and take the load.

Fire Protection systems…

FIRE

Hea

t

Oxygen

Com

bustible Material

Fire can be controlled by eliminating any of the cause mentioned above i.e. Heat, Oxygen or Combustible Material that can be done by Cooling, Smoothing and Starvation respectively

Fire Protection System…

Following Fire Protection systems are used at different location inside factory:

• Fire Extinguisher• Fire Hydrant• Foam Trolley• Water Cum Foam Monitor Trolley• Sprinklers• Fire Hose reel drums (installation process)


Fire Extinguisher:• Water Type : Used for only A type of fire.• Foam Type : Can be used for A and B type

of fire. More suitable for Fuel.• DCP Type : Can be used for B and C type of

fire. • CO2 Type: Used for B and C type of fire.

More suitable for electrical panels and electronic items


Fire Hydrant : Fire hydrant consists of pressurized pipe line and 60 points to operate the same. This system will always be pressurized with the help of pump located at UGR.

Hose reel Drums: These are hose reel with nozzle for accessing the points which are not easily covered with the Hydrant hose and nozzle. These points are connected with the hydrant line.

Foam Trolley : Four foam trolleys are provided at Boiler house, Power House, waste oil storage and flavor room. These can be connected to hydrant points for operation. Capacity is 100 Ltr of foam in each trolley.


Water Cum Foam Monitor Trolley: These trolley does not contain foam. Foam is supplied externally, which is stored in separate containers of 30 Ltr each. These can be used for big fires as per the availability of foam.

Sprinklers : Sprinklers are water suppression as well as detection system as it suppresses the fire and displays the location of fire at gate house.


Fire Detection Systems: Smoke Detectors Heat Detectors Beam Detectors Sprinklers

Alarming System: MCP (Manual Call Points) Public Address system (Strobe hooters are

installed now with flashing system) Danger Siren for evacuation Portable Hand Siren Emergency Phone No. 241


Breathing Apparatus: Consists of Compressed Air Cylinder at 300

bar, Pressure gauge and Lungs demand valve

Its capacity is 30 min, and an alarm is generated when pressure in cylinder falls below 50 bar.

Smoke Hood It covers the face and filters the smoke

mixed with air for breathing. It can operate upto 10 to 15 minutes. This

used once can not be used again.

INDUC-SHRAN

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