chapter 4&5

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CHAPTER IV

PROTOTYPE

4.1 Sketch of Product

Our non alcoholic liquid cough medicine, has a shape of plastic bottle

made by polystyrene and sealed by aluminium foil. The volume of our product is

30 ml. We can drink it directly just shake it for a while, take the seal off, and

drink it. We don’t have to drink water after drinking out product because actually,

our product is already have much water content.

Figure 4.1 Bottle prototype design(source: self-designed)

4.2 Brand, logo, and tagline

Figure 4.2 Logo design(source: self-designed)

Universitas Indonesia

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Our cough medicine will be named by Cough-ZERO. We think that the

name is a unique and easy to remember name. We also think that the name of our

product can increase the opportunity of consumer to buy our product.

We chose the Cough-ZERO name, because we make this cough medicine

with zero alcoholic content. Some of people don’t realize that cough medicine in

the market has alcohol content in there. After we do some questionnaires, finally

we know that alcohol is bad for us in the case of religion aspect, especially for

Moslems people. So, after that, we make a cough medicine product that has no

alcohol content in it. We hope that because of our product, all people can consume

cough medicine easily without concern about the effects of alcohol for the

Muslims people. Our brand is also easy to remembered and pronounced by public,

and also our cough medicine logo can be seen on the picture above.

Tagline is a phrase or catchword that becomes identified or associated with

a product. An interesting and easy-to-be-remembered tagline also has an

important role to get more attention from the consumer.

Our tagline is “No cough, No alcohol”. We chose that tagline because we

think that will be perfect if the cough medicine can cure cough and also has no

alcohol content in that. So, the tagline means that this product can be drunk by all

people and also has a good effects.

4.3 Packaging of the product

Our cough medicine product will be packaged with polystyrene plastic

bottle which equipped with aluminium foil as seal of the medicine. We use plastic

bottle because of the needs from the questionnaires we have done before and the

public chose the simple and handy storage, so we think if we use polystyrene as

the packaging, it will be easy to consume. We use aluminium foil as the seal, so

we can drink it directly from the plastic bottle. We also use cartoon box as

secondary packaging, it is for easy to storage at the sales time.


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Figure 4.3 Secondary packaging design(source: self-designed)

So, we make products based on the type of cough that is needed. There are

3 types of cough, which are dry cough, chesty cough, and also cold flu cough.

Based on that, we make just 2 types of medicine cough with different main active

substance in each of that. We combine the cold flu cough and the chesty cough

because the active substance is not too dangerous.


CHAPTER V

PRODUCT MANUFACTURING

5.1 Market Segmentation

The main target of our consumer is segmented based on two

considerations. The first is the geographical location and the second consideration

is based on the market class segmentation (based on the income). In the first

consideration, we consider our product to be distributed only in Indonesia. The

consideration is based on some reasons. The first is Indonesia has a very high

population. Based on the data from ‘United Nations, Department of Economic and

Social Affairs, Population Division’, as on the year of 2015 the population of

Indonesia is reaching 255,708,785 and according to the same source the

population of the south east asia country in the same year is approximately 633

million people. It means that the population of Indonesia has a share of 40%

population in ASEAN that makes it a very good opportunity to be capitalized.

The other reason is the increasing amount of the Indonesian people

spending to any products related to health. Based on the data from the ‘Business

Monitor International’ the Indonesian’s people spending on health product has

reached the number of 194 trillion rupiah in 2011. The number is projected to

grow in a constant rate of 13.9% each year. The growth rate then becomes the

basis on forecasting the growth of Indonesian people on medicine in couple years

ahead.

Figure 5.1 Amount of health products spending in Indonesia(source: Business Montior International : Indonesia

Pharmaceuticals & Healthcare Report Q3 2012)

The market of our products itself, the OTC (over-the-counter) drug market

is also increasing in Indonesia. According to the research done by BMI, the

research considers Indonesia to be the most attractive market in South East Asia

4 Universitas Indonesia

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(preferable to Singapore, Philippines, Indonesia, Malaysia, Vietnam and Thailand)

for companies looking to sell OTC products. OTC drugs sales in Indonesia

reached IDR24,067 billion (US$2.56 billion) in 2012, more than twice the value

of the Philippines and Thailand.

Although the OTC sales as a share of the total pharmaceutical sales is

expected to decline over the coming decade, as the government becomes

increasingly committed to provide universal healthcare for its population and as

regulations are tightened. Nevertheless, the overall value will continue to increase

at annual growth rates of around 5-6% in local currency terms.

Figure 5.2 OTC medicine market forecst 2008-2022(Source: AESGP, BMI)

The relatively low cost and easy availability of OTCs and a difficult

financial situation still preclude many from visiting doctors, instead driving them

to self-medication. Such factors are encouraging the sale of herbal medicines.

Deficient health insurance in Indonesia is also pushing the consumption of OTCs

as many patients cannot afford to pay for their prescriptions and are forced to rely

on low-cost consumer health products − although the government aims to address


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this issue. Similarly, according to Kalbe Farma's statements from August 2013,

consumers in the country are purchasing healthcare products despite fears over

inflation and economic slowdown. Moreover, the activity of pharmacy chains

supports the development of the OTC market. Companies such as Apotek K-24

and Century have not only made OTC products more accessible and affordable,

but have also increased consumers' knowledge of drugs, and their confidence to

self-medicate. The growing number of new communicable diseases will further

stimulate the OTC market over the coming years, as patients seek to prevent

contracting infection by any means possible. Environmental factors, such as

severe air pollution in urban areas and contamination of water supplies, are

causing deterioration in health across the country, thus also assisting sales of

OTCs as consumers attempt to manage their ailments.

To take a look deeper, the increasing the market of the OTC products is

also affecting the sales of the cough medicine product which is the part of the

OTC markets. The research done by the BMI in 2014 shown that the cough

medicine market sales is also increasing each year. Reaching the sales of $423.9

million in 2010.

Figure 5.3 Sales of cough and cold OTC category in 2004-2010(Source: AESGP, BMI)

From the data above, we could calculate the OTC medicine sales

estimation for the year of 2018 by using the linear regression method. We are

using the 2018 data because we estimate that we need 3 years from now to

develop our plant and product to be ready to enter the market.


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2003 2004 2005 2006 2007 2008 2009 2010 20110

50

100

150

200

250

300

350

400

450

f(x) = 34.4928571428571 x − 68919.3928571429R² = 0.964774689644383

Cough Medicine Sales

Year

Coug

h M

edici

ne S

ales

Figure 5.4 Cough medicine sales(Source: AESGP, BMI)

By using the trendline above ( y=34.493 x−68919¿, we can determine the

sales for cough medicine in 2018:

Sales of 2018=34.493 ×2018−68919

¿ $687.874 mn

5.2 Market Capacity

In determining the market capacity of our products, we define it based

some considerations. First is from the supply chain of cough and cold medicine in

Indonesia. The second one is based on the sales of cough and cold medicine

product

5.2.1. The Demand of Liquid Couch Medicine Syrup

One of the basis to calculate the market capacity of our product is to

calculate the demand of cough and cold medicine product in Indonesia. To

determine the demand of the cough medicine product in Indonesia, we are using

the sales of the cough and cold medicine in 2010 based on the figure 9.1. The total

amount of the cough and cold medicine sales in that year is $423.9 million dollars.

We assumed that the exchange rate between USD-IDR is Rp13,000/US$ we could

calculate the total sales of cough medicine in year in rupiahs


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$ 687,874,000 ×13,000IDRUS $

=Rp 8.9 ntrillion

By using the leading product in the market ‘Vick’s formula 44’ as prices

basis, we divide the total sales of the cough medicine each year with the price of

the ‘Vick’s’ product of Rp15,600 for each pack of 100ml, we could calculate the

production demand of cough medicine each year

Demand= Rp 8.9 trillion20,000/ pack

=445,000,000 pack

From the data above, then we could calculate also the demand of the

cough and cold medicine per day by dividing it with the total days a year of 365.

Daily demand=445,000 , 000 pack365 days

=1.219 .180packsday

According to ‘Business Monitor International’, the share of liquid form of

cough and cold medicine in the cough medicine market is about 60%. So, the total

demand in every year would be :

60 %× 445,000,000=267,000,000

5.2.2. Production Supply

The next step is determining the production supply of liquid medicine in

Indonesia. The amount of supply is determined from the statistic of the total liquid

medicine produced by all of the pharmaceutical company in Indonesia. We can

determine the total supply by combining the total liquid medicine production in

Indonesia from the statistic as below

Table 5.1 Production supply for every cough medicine company

Company Production (bottles)

Darya Varia Group 800,000

Indofarma 11,000

Kalbe Farma 40,000,000

Kimia Farma 10,000,000

Pyridam Farma 1,105,920


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Table 25.1 Production supply for every cough medicine company (cont’d)


Tempo Scan Pasific 7,200,000

Bristol Myers Squlb Indonesia 2,400,000

Bayer Indonesia 49,000,000

Dankos Laboratories 8,000,000

Total Production 118,516,920

(source: WHO)

5.3. Production Capacity

From the supply-demand calculation that is done before, we can calculate

the market opportunity of our liquid cough syrup product.

The opportunity = Demand− Supply

= 267.000 million bottles – 118.516 million bottles

= 148.484 million bottles

Then we can determine the market opportunity of our product by dividing

the opportunity by the demand of the liquid cough medicine syrup

%opportunity=148.484267

× 100 %=55.61 %

From the data above, we assumed that our product, non-alcoholic liquid

cough medicine can cover the 5% of the deficit. The value is quite small because

we consider our product as a new product and has no marketing budget as big as

our competitors. The production capacity will be 16 million bottles per year.

Table 5.2 Production capacity per year for every cough medicine company


Darya Varia Group 800,000

Indofarma 11,000

Kalbe Farma 40,000,000

Kimia Farma 10,000,000

Pyridam Farma 1,105,920


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Tempo Scan

Pasific

7,200,000

Table 5.2 Production capacity per year for every cough medicine company (cont’d)


Bristol Myers Squlb Indonesia 2,400,000

Bayer Indonesia 49,000,000

Dankos Laboratories 8,000,000

Cough Zero 16,000,000

Total Production 134,516,920

(source: annual report each company)

Our market share would be

market share= 16 millions134,516 millions

=11.9 %

5.4 Raw Material

The calculation of production capacity in the previous section leads to the

discussion needs of raw materials to fulfill the daily proses production of Cough

Zero. From the final result of market share, the maximum capacity that needs to

be prepared for our manufacturing unit is 44.000 bottles per day. In cough

medicine syrup manufacture process, there will be four cycles in a day to optimize

the resources that we had. This section will be describes the details of components

needed to produce in one cycle. The needs of raw materials for Cough Zero

process production can be seen from the tables below :

Table 5.3 Calculation for raw materials composition

Basis

Yearly production (L) 480.000

Composition

Ingredients Composition (%) Needs (L)

Dextrometorphan Polistirex 0,0083 39,84

Pseudoephedrin HCl 0,0208 99,84

Chlorpheniramine Maleat 0,0001 0,48

Paracetamol 1,3889 6.666,72


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Pepermint oil 0,0278 133,44

Alcohol 0 0

Table 2.3 Calculation for raw materials composition (cont’d)

Composition

Ingredients Composition (%) Needs (L)

Propylene Glycol 5 24.000

Water 57,4125 275.580

Fructose syrup 0 0

Color additives content 0,1 480

Suqqus Liquiritae 0,4639 2.226,72

Sucrose 35 168.000

Benzoic acid 0,2 960

Sodium benzoate 0,2 960

methyl-paraben, propyl-

paraben, butyl-paraben0,1 480

Sorbitol 0,05 240

Essence 0,025 120

Carboxyl Methyl Cellulose 0 0

(Source : Reproduced from Group Discussion)

5.5 Process Description

Cough medicine syrups are produced by mixing purified water,

sweeteners, active ingredients (API), aromas, flavours and other ingredients

(thickeners, etc.). The ingredients are added by means of metering or dosing

systems like flow meters and load cells to one or more reactors, the order and

quantity of the ingredients to add is specified in the recipe. Usually, preparations

are heated before finishing the addition of components. Solid products are added

by means of solid-liquid blenders or vacuum systems. When the process is

finished, the end product is filtered (if required) and sent to a storage tank. The

product is transferred from the storage tanks to the filling machines by pumps.


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Figure 5.5. Process flow diagram

Process Features :

- High efficiency operation to produce different types of end product.

- The measuring systems ensure the correct dosing of each ingredient.

- Components designed according to the pharmaceutical standards.

- Equipment designed according to GMP biopharmaceutical standards.

- Production lines and tanks are prepared for CIP and sanitation.

- Automatic control allows repeatability in the manufacturing process,

reducing the number

- of errors; greater flexibility of manufacturing parameters; reduction in the

number of plant operators.

- Validation protocols: design (DQ), installation (IQ) and operation (OQ).


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Figure 5.6. Algorithm of process

The cough medicine syrup manufacturing process is a batch process.

Initially, the raw material goes through a Quality Check (QC) and if approved

various Active Pharmaceutical Ingredients (API) and Excipients are dispensed for

processing.

In the tank 1 all the excipients are mixed with the sugar syrup. The

mixture of sugar syrup and excipients is taken to the tank 2 where Active

Pharmaceutical Ingredients (APIs) are mixed. The solution from the tank 2 is

taken to the co-mill and homogenizer where all the raw materials are mixed


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uniformly to form a homogeneous solution. This solution is pumped into the tank

3 where it is stored before filling in the bottles. At this stage, a Quality Check is

carried out to check various quality-related aspects of the raw materials. It the

solution is approved during the quality check, it is taken to the filling section.

In the filling section, the bottles are filled as per the requirement where the

specified quantity is dispensed by the machine. After filling the bottle, the capping

takes place and the bottle is sealed. The sealed bottle, is taken for inspection

where the bottle is checked for quality related aspects like :

- Right amount of liquid filled in the bottle

- Bottle is air tight and sealed properly

- Any cracks in the bottle

- Leakage of liquid from the bottle, etc.

After filling the bottle, the labelling takes place. In labelling section, the

various manufacturing details are printed onto the primary pack like batch

number, date of manufacturing, maximum retail price of the therapeutic, etc. as

required by Food and Drugs Act.

Additionally, secondary packing is done for the oral liquids in cardboard

boxes and in corrugated boxes. The packed oral liquids go through QC for final

inspection.

5.5.1 Quality, Standart and Technology

The plant should adhere to the norms laid out in standards. Additionally, if

the unit is set-up for export of pharmaceutical products then should meet the

norms of US FDA, UK MCA, WHO, etc. as required in the export markets.

It should be noted that as the proposed unit would be involved in contract

manufacturing, the manufacturing process related technology would be provided

by the principal organisation for which the contract manufacturing would be

carried out. The proposed unit would not be involved in the basic formulations

related research in the initial years.

Additionally, the manufacturing technology would not differ from other

regions as the same is not region specific. As far as the cough medicine

manufacturing equipment is concerned, the process equipment is widely available

in the country.


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5.6 Unit Operation

Figure 2.7. Cough medicine syrup unit operation(source: www.silverson.com)

A. Mixer

Figure 5.8 Industrial Cough Syrup Mixer making machine(Source : wuximixers.en.alibaba.com)

The series of MF Stainless Steel detergent mixer/shampoo mixer/lotion

mixer/hand soap mixer are made of stainless steel (SUS304 or SUS316L). All


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joints and inside is mirror finished without any dead angle and cleaned easily. It

consists of inner vessel, jacket and insulation with the configurations of agitator,

CIP hole, Manhole, sight glass, thermometer etc. The interior surface of the vessel

is subjected to mirro polishing 300EMSH (sanitary level), which is in accordance

with sanitary requirements.

Table 5.4. Unit details

Spesification Value

Application Liquid with Suspended Solids

Voltage 110V ~ 480V

Working state Vacuum / Normal Pressure

Mixer Type Agitator

Cooling system Cooling water

Heating medium Water / Oil / Steam

Heating method Electric / Steam

Price US $1,000 - 50,000 / Set

(Source : wuximixers.en.alibaba.com)

Table 5.5. Technical Parameter


Table 5.6. Spesification


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B. Filling Machine

Figure 5.9. Syrup Filling and Capping Machine for Pharmaceutical(Source : wuximixers.en.alibaba.com)

Filling and Capping Machine adapt 316SS pump to fill different type of

liquid , syrup, lotion , shampoo.


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Configuration and performance, features:

1. Low cost filling and capping in one machin

2. Not stable container best choice machine

3. Adopt injection pump to fill high precision, large range of adjusting dosage.

4. The pump system don’t absorb the medicament, good chemical stability, be

5. able to resist high temperature and erosion.

6. Low level liquid receiver, convenient to clean.

7. Filling system has the function of shrinking, no drop leak.

8. Apply to fill various viscosity liquid.

9. Special manipulator and guiding device are equipped on it to ensure the spray

10. cap reliably fitted on the opening of container.

11. Filling nozzle is diving bottom of bottle to fill and moving up slowly, avoid

12. foaming.

13. Magnetic moment capping system, adjust degree of tightness freely.

Main performance Parameter:

1. Name: Filling and Capping Machine

2. Model : NP-MFC

3. Applied bottle range : 20ml - 1000ml

4. Filling Nozzle : 6 and 4

5. Cap Type : Aluminum cap, Plastic cap and Ropp Cap

6. Filling speed : 2400 bottle – 3000 bottle/h

7. Power Source : 220 V,50 HZ

8. Air pressure : 0.6 Map

9. Air Consumption : 0.25m3/min

10. Dimension : 2200 mm*1300 mm*1600 mm

11. Price : US $12,000 - 12,500 / Set

C. Packaging


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For packaging unit, we use manual methods (human) to packages the

cough medicine syrup in bottles to package which contain 4 bottles for each

package. In packaging unit, we split this section to two jobs. First packing jobs,

this jobs have a responbility to packages the cough medicine syrup in bottle to the

packages and the second is sealing jobs, this jobs have responbility to seal the

packages. Each jobs will be did by 5 peoples for each shift.

5.7 Mass and Energy Balance

5.7.1 Mass Balance

The calculation of production capacity in the previous section leads to the

discussion of mass balance of Cough Zero medicine production. From the final

result of market share, the maximum capacity that needs to be prepared for our

manufacturing unit is 11.000 bottles per cycle. In liquid cough medicine

manufacture process, there will be four cycles in a day to optimize the resources

that we had. In this mass balance, will be described details of components needed

to produce in one cycle. The mass balance can be seen from the tables below :

Table 5.7. Calculation for Base Capacity

Basis (mg)

Daily production 396000

IngredientsComposition

(%)

Composition

(mg)

Dextromethorphan

Polistirex

0,0083 32,868

Pseudoephedrin HCL 0,0208 82,368

Chlorpheniramine Maleat 0,0001 0,396

Paracetamol 1,3889 5500,044

Pepermint Oil 0,0278 110,088

Suqqus Liquiritae 0,4639 1837,044

Propylene Glycol 5 19800

27362,81

Table 5.7. Calculation for Base Capacity (cont’d)

Ingredients Compositio Compositio


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n (%) n (mg)

Water 57,4125 227353,5

Sucrose 35 138600

Benzoic Acid 0,2 792

Sodium Benzoate 0,2 792

Paraben 0,1 396

Sorbitol 0,05 198

Essence 0,025 99

368230,5

Total

input/day395593,3

(Source : Reproduced from Group Discussion).

The calculation of mass balance will devided into five parts, which are :

pre mixing, homogenizing, tank storage, filling & capping, and packaging. These

mass balance is made based on the block flow diagram of the process and weight

basis in the begining of market demand.

Table 5.8. Calculation for the mass balance of pre mixing process

Unit Process MaterialInput

(mg)

Ouput

(mg)

MixerPre-

mixing

Active

Compound

Dextromethorphan

Polistirex32,868 32,8023

Pseudoephedrin HCL 82,368 82,2033

Chlorpheniramine

Maleat0,396 0,3952

Paracetamol 5500,044 5489,0439

Pepermint Oil 110,088 109,8678

Suqqus Liquiritae 1837,044 1833,3699

Table 5.8. Calculation for the mass balance of pre mixing process (cont’d)

Unit Process Material Input Ouput


21

(mg) (mg)

Propylene Glycol 19800 19760,4

27362,80

8

27308,0823

8


Table 5.9. Calculation for the mass balance of homogenation process


(mg)

Ouput

(mg)

Homogen

-ator

Homogen-

ation

Addition

Material

Water227353,

5

226898,7

93

Sucrose 138600 138322,8

Benzoic Acid 792 790,416

Sodium

Benzoate792 790,416

Paraben 396 395,208

Sorbitol 198 197,604

Essence 99 98,802

Intermediate

Product

27362,8

08

27308,08

238

395593,

308

394802,1

214


Table 5.10. Calculation for the mass balance of tank storage

Unit Process Materia Input (mg) Ouput (mg)


22

l

Tank Storage Storage Bulk 394802,1214 394012,5171


Table 5.11. Calculation for the mass balance of filing and capping ptocess

Unit ProcessMateria

lInput (mg) Ouput (Bottle)

Fille

rFilling & Capping Bulk 394012,5171 10945


Table 5.12. Calculation for the mass balance of pavkaging process


(mg)Ouput (Box)

Packagin

gPackaging Bottled Product 10945 2736


5.7.2 Energy Balance

To determine the energy balance of the production process, the power

usage in Cough Zero is obtained by summing each equipment power requirement.

The energy is supplied by PLN. The power usage is based on equipments energy

specification and duration of equipment operation. However, the power used is

not fully efficient, there are energy losses in each equipment due to heat loss of

heater to the environment, setting up energy consumption, and mechanical energy

inefficiency. The details is described below.


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Table 5.13. Calculation for the energy balance

No EquipmentElectric Power

(kW)Number of Equipment

Equipment

Capacity

Production Target of

Equipment

Total

Operation

Time

(min)Unit Value Unit

1 Stirer 5,5 1 Lt/Cycle 22.802 Lt 45

2 Pump I 1 1 Lt/hr 22.802 Lt 45

3 Homogenizer 15 1 Lt/Cycle 329.661 Lt 60

4 Pump II 2 1 Lt/hr 329.661 Lt 60

5 Filtration System 0 1 Lt/Cycle 329.661 Lt 45

6 Pump III 2 1 Lt/hr 329.661 Lt 45

7 Heating System 36 1 Lt/batch 329.661 Lt 60

8 Filling 1,5 1 Bottle/hr 10.945 Bottle 120



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Based on literature, the power loss due to table plant energy requirement is

14% of the total power usage for overall process. Therefore, the power which

PLN supplied is 114% of total power requirements each day. The details is

described below.

Table 5.14 Calculation for total power needed

No Equipment(Power supply from

PLN) kWh

(Total power /

day) kWhLoss

1 Stirer 4,7025 4,125 0,5775

2 Pump I 0,855 0,75 0,105

3 Homogenizer 17,1 15 2,1

4 Pump II 2,28 2 0,28

5 Filtration System 0 0 0

6 Pump III 1,71 1,5 0,21

7 Heating System 41,04 36 5,04

8 Filling 3,42 3 0,42


From the table above, we know that the energy requirement to maintain

the manufacture process/ day for Ms.Marble, marble cleanser is 71.1075 kW with

14% energy loss.

5.8 Schedulling

5.8.1 Duration of Manufacture

The production process of cough medicine occurs in batch conditions. In

order to maximize the production of cough medicine, production carried out for

14 hours per day. This is because in order to minimize losses due to the cessation

of work tools. In addition, with this production operations can maximize the

performance of the human resources available. Factory can operate for all year.


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Meanwhile, experienced a period of operation of this plant and maintenance

purpose of the tool factory was supervised once in a month.

The duration of cough medicine production based on the time needed for

mixing, homogenizing, storing, filling, and packanging. Our calculation is based

on mixing in order to make the solution more homogeneous, the mixing time is a

function of Reynolds Number. The process of mixing that occurs is the process of

mixing with liquid as feed.

By using the specification tool that has been obtained, then the

calculations can be done. Here are reviews of specifications of mixing tanks are

used.

Mixer Spesification :

N = rpm of impeleer shaft = 43 rpm

d = impeller diameter = 100cm = 39.4 inch

D1 = tank 1 diameter = 1.2 m = 47.2 inch

D2 = tank 2 diameter = 1.5 m = 59 inch

MIXING

Mixing process in preparation of making marble cough medicine are

divided into two mixing: pre-mixing process and homogenation. Mixing both is

done at the time of insertion of the feed that comes from a mixture of active

compound and additive.

For the first mixing process, the process can take place by the following

equation.

ℜ=10.75N d2 S

μ=10.75

(43) (39.4 )2(0.174026)121.24

=1.03×103

Based on graphic on ‘Chemical Process Equipment, Chapter 10’, we can

determine tmixing time.

t b N ( dD )

2.3

=1240.5

So, the mixing time required is as follows.


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t b=500

N ( dD )

2.3= 1240.5

43( 39.447.2 )

2.3=44.8 minutes

Mixing process in the acid granulation takes time to reach steady state, the time

required for mixing for 44.8 minutes.

The second mixing process in the acid granulation can determine by the

following equation.

ℜ=10.75N d2 S

μ=10.75

(43) (39.4 )2(0.644709)709.53

=1.76 ×102

Based on graphic on ‘Chemical Process Equipment, Chapter 10’, we can

determine tmixing time.

t b N ( dD )

2.3

=1022.7

So, the mixing time required is as follows.

t b=500

N ( dD )

2.3= 1022.7

43( 39.459 )

2.3=60.2 minutes

Mixing process in the acid granulation takes time to reach steady state, the

time required for mixing for 60,2 minutes.

FILTRATING

Based on our pump and filter capability, we have the capability of

filtrating and we set our intermediate products as much as 329.661 mL in 45

minutes

BOTTLING

Based on our tools capability, we have the capability of bottling machines

to bottle the products as much as 180 bottle per minute. We achieved our

production in 10945 as one cycle of the packaging. Thus, the time required is as

follows.

t= 1 minutes180 bottles

×10945 bottles


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t=60.80 minutes

Based on the above calculation, the operating time required to package our

products is 60.8 minutes.

PACKAGING

Based on our human resources capability, we have the capability of

packaging using human resources to package the products as much as 45.6 packs

per minute. We achieved our production in 2736 as one cycle of the packaging.

Thus, the time required is as follows. Based on our setting, the operating time

required to package our products is 1 hour.


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TIMEPROCESSheating up 15 minPre mixing 45 minpreparation 15 minHomogenizing & Filtrating 105 minFilling & Capping 120 minPackaging 60 min

heating up 15 minPre mixing 45 minpreparation 15 minHomogenizing & Filtrating 105 minFilling & Capping 120 min

heating up 15 minPre mixing 45 minpreparation 15 minHomogenizing & Filtrating 105 minFilling & Capping 120 minheating up 15 minPre mixing 45 minpreparation 15 minHomogenizing & Filtrating 105 minFilling & Capping 120 minTOTAL 1260 min

CYCLE 1

CYCLE 2

CYCLE 3

CYCLE 4

13 Hr 14 Hr 15 Hr 16 Hr 17 Hr 18 Hr7 Hr 8 Hr 9 Hr 10 Hr 11 Hr 12 Hr1 Hr 2 Hr 3 Hr 4 Hr 5 Hr 6 Hr

Figure 5.10. Time schedulling(Source : Reproduced from Group Discussion)


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Based on Figure 2.9, Cough Zero production time in 1 cycle lasts for 5

hours but we can start new process cycle after preparing and filling our mixing

tank in 3 hours. Because of that we can make 4 cycles in 14 hours. We also can

know the start time and end time of a process by looking at the beginning and the

end of the boundary the rectangle when drawn vertically can be obtained starting

time and the completion of process. In table 8.1, we can identify the processes that

take place in accordance with the color.

Table 5.15. Total Time for Each Cycle

Cycle 1 2 3 4

Start

(minute)0 195 375 555

Finish

(minute)300 480 660 660

Hour/Day 5 4.75 4.75 4.75


Based on table 2.15, it can be seen that for a day to do the cough medicine

production for 4 cycles. The finish time at fourth cycle is 660 minutes per day or

14 hours per day. If we add an unexpected events and supervising, we can

maintain our production everyday. So, we can conclude that our estimation is still

can be accepted. The variable that can be changed in this method is the filling and

packages machine.

5.9 Utilities and Plant Maintenance

Aspects of sanitation and hygiene in the plant, especially in the production

unit is a thing that should not be ruled by us . Especially for companies that

produce medicine, as well as for the convenience of employees sanitation and

hygiene will greatly affect the product. Sanitation is planned to control the

environment, raw materials, production, equipment, and workers in order to

prevent mixing of the ingredients that are not in want into the product .

5.9.1 Plant Sanitary

In our cough medicine syrup plant, sanitation and hygiene should be

highly considered because it is directly and indirectly affect the quality of the


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products. Building construction has either to protect employees, machinery , and

industrial equipment in it.The outdoor courtyard and the exterior of the building

or plant should be neat, well-maintained, and free of garbage. Maintenance always

done and that is responsible for the general section. Place of the loading and

unloading of goods, parking lots , and roads for vehicles should always be clean .

Drainage must be well maintained and ensured water flow so well that

there is no stagnant water. Trash or waste water must be sealed so as not to invite

pests and microbes. The dumpster must be well maintained and regularly

transported garbage, it has been entrusted to the janitors who do the cleaning

every day. Besides the lighting must be adequate and easy to clean. For easy

cleaning , the buildup of material at least 25 cm from the wall.

To obtain a work environment that is safe and comfortable, the building

must be equipped with sanitary facilities are made based planning meets the

requirements of engineering and hygiene. Sanitation facilities are provided by the

company, namely water supply facilities, disposal and others.

Production floor must also be designed in such a way to be able to support

its production process. Production using ceramic flooring in all areas of the plant.

The purpose is other than the use of ceramic tile is water-resistant material made

from a ceramic material would easily cleaned considering the condition of the

production process. When there are spills it will be easy to clean spills, in addition

to improving the hygiene of the floor should always be clean.

Additionally spaces in the plant should be divided into spaces that do not

require high hygienic, semi high hygiene hygienic to require workers to wear

masks, gloves, etc. to maintain hygiene.

5.9.2 Equipment Sanitation

Sanitary equipment becomes an important aspect in the industry. This is

because the equipment that we use actually direct contact with food that will be

processed. Therefore we have to apply some cleaning methods in the industry,

especially equipment, consisting of:


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a. Foam or soap

Cleaning the HSA is used to clean the outer layers of the equipment. This

cleaning chemicals increase touch time with a chemical solution with mechanical

pressure and low temperature.

b. High Pressure

Increasing the mechanical pressure to help remove dirt. This cleaning method

is sometimes added detergent and increase the temperature to increase cleaning

efficiency.

c. Clean Out of Place ( COP )

Cleaning is done to the engine parts that can be separated. Cleaning is done in

containers containing chemicals are heated.

d. Clean in Place ( CIP )

Clean up for the inner surface of the tank and piping. Chemical solution put

into the tank circuit to clean the inside. Time, temperature and pressure

chemically altered as needed to achieve maximum cleaning for our equipment

such as mixer, blancher etc.

Basically, the CIP is a dry process without the need to remove the insulation

hydrodynamic (dismantling), where in the cleaning process is done with the

cleaning fluid to circulate in all channels through which the product . The cleaning

fluid can contain detergents where mechanics will lift the existing crust . CIP

process is divided into 2 types:

Single Use

The cleaning process with the use of disposable (one cycle) and sanitizer

detergent solution , and to further direct disposal (discharge). For the efficiency of

the cleaning process required flow turbulence at very high flow rates , the

consequences will be using a lot of water and effluent that great anyway . The

advantage of this process is expensive and requires a small place process .


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Figure 5.11. Diagrams Work Cleaning In Place(Source: www.poubler.ibm.com)

Reuse Systems

Cleaning process that uses a cleaning fluid and would be used again at

the beginning of the cycle (subsequent) as much as possible. This process is more

expensive and requires more space to position the CIP equipment.

This method is applied to our synthetic meat plant because although

initially more expensive to buy the tools, but the process will happen

continuously, just need to control . In contrast to single use systems that are much

cheaper but the tools we have to buy on a regular basis and periodically monitor

anyway.

5.9.3 Electricity and Water Needs

a. Electricity

The power usage in Cough Zero production process is obtained by

summing each equipment power requirement. The energy is supplied by PLN.

The power usage is based on equipments energy specification and duration of

equipment operation. The energy balances is made for rough estimation of our

plant for each cycle, excluding electricity needs.

For instance, in cleaning process, it requires water pump to force the raw

material especially to make it clean with blanching.. However the power used is

not fully efficient, there are energy losses in each equipment due to heat loss of


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heater to the environment, setting up energy consumption, and mechanical energy

inefficiency but in this section we assuming that the efficiency of unit operation is

100%.

After we sum the power capacity in Energy Balance Section, our plant will

need 71 kW/cycle of electrical energy, so in a day we consume electricity power

about 284 kW.

b. Water

We can see that in production process there is water that forced into

cleaning-bleaching for mixing section and forcooling system, we need to stock

300 L of water per day then carry out the waste water to the environtment because

the content of waste water from cleaning the isn’t dangerous for environtment or

to be recycle for cooling system. Water that we used come from PAM PDAM.

5.10 Plant Layout

The factory will be located in Rancaekek with ground size 200 hectare.

The price of the ground is Rp 3.000.000 / m2.

Figure 5.12 Plan Location(Source: www.googlemaps.com)

The selection of plant location is based on several factors. Such as:

The location is an Industrial Area which the land are ready to built and

the access to build it is easy.


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Easy to Access from main road. Located near a toll gate.

Close to highway access, airports or harbors.

Close to public facilities such as hospitals, banks, suppliers, and

equipment technician.

Far from citizens housing

Wide Roads facilitate entry to this area, It is 5 km from the Cileunyi toll gate

and within distance to the container terminal of Gedebage which is essential for

transporting goods. Availabily of manpower as it is close to center of excellence

like Institute of Technology Bandung (ITB) and University of Padjadjaran

Bandung (UNPAD). This industrial estate is fully supported by PLN and PT

Telkom for the infrastructures. We can dispose of industrial waste into Citarik

river, so we do not need any place and special treatment for our industrial waste.

Figure 5.13 Plan Layout(Source: Group Discussion)


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