A REPORT ON INDUSTRIAL TRAINING AT HLL LIFECARE LIMITED PEROORKADA, TVM

SUBMITTED BY:-RAKESH.N,NITHIN.V.MDEPT. OF MECHANICAL ENGINEERING,MOHANDAS COLLEGE OF ENGINEERING AND TECHNOLOGY, ANAD, THIRUVANANTHAPURAM.TRAINING PERIOD: 04-01-2013 to 06-01-2013

ACKNOWLEDGEMENT

It is always a pleasure to acknowledge with gratitude the help and guidance received from various persons in the successful completion of our training and report. First of all we would like to express our sincere gratitude to our guide. Mr. Mahesh Kumar P R, Manager (mech), HLL Lifecare Limited, Peroorkada factory, Trivandrum for his valuable comments, support and guidance. We also thank all the employees of HLL Lifecare Limited, who spared their valuable time in making us understand the working and functions of each section.

We thank our college principal and our department head for enabling this training for us. Last but not the least we place our heartfelt thanks to GOD Almighty, for the successful completion of our training.

COMPANY PROFILE

HLL Lifecare Limiteds journey started with its incorporation as a corporate entity under the Ministry of Health and Family Welfare of Govt. of India on March 1, 1966. HLL was set up in the natural rubber rich state of Kerala, for the production of male contraceptive condoms for the National Family planning programme. The company commenced its commercial operations on April 5, 1969. HLL, from being condom manufacturers diversified into contraceptive manufacturers and later into hospital product manufacturing including surgical sutures, surgical gloves, hydrocephalus shunts, tissue expander and blood bags. As a commitment to social cause HLL has set up non profit organization, HINDUSTAN LATEX FAMILY PLANNING PROMOTION TRUST (HLFPPT), whose current activities include, implementing sexual and reproductive health projects, HIV/AIDS target interventions, and IEC projects funded by national and international development agencies.Among the seven manufacturing units of HLL Lifecare Limited, the Peroorkada unit is the single largest unit in the world producing male contraceptive condoms with a total capacity of more than 1 billion condoms per annum.CERTIFICATES OF PEROORKADA FACTORY

TYPES OF MALE CONTRACEPTIVE CONDOMS PRODUCED AT HLL PEROORKADASIZE WISEA TYPE: Lay flat width :( 49+/-2) mm Length: min170 mmB TYPE: Lay flat width :( 53+/-2) mm Length: min 180 mmTEXTURE WISE: a) PLAIN TYPE b.) DOTTED TYPE c.) RIBBED TYPE

COLOUR WISE: a.) PINK b.) GREENc.) VIOLET d.) PEACH e.) BLUE etc. FLAVOUR WISE: a.) CHOCOLATE b.) BANANA c.) VANILLA d.) ORANGE, STRAWBERRY, COFFEE, etcLUBRICANT WISE:a.) SIILICONE OIL b.) PEG + BENZOCAINE GELSECTION 1: PRIMARY PRODUCTION

Plant AM1, M2, M3, M4Plant BMA, MB, MC, MDPlant CM5, M6Plant DME, MF, MGThe primary production division consists of four units; plant A, B, C, D which are completely mechanized, consisting of Japanese OKAMOTO Technology machines and German RITCHER Technology machines (rrt machines). The first plant- Plant A was installed on April 5 1969 under the technical collaboration of M/s OKAMOTO RIKEN GOMO Co Ltd. Altogether, there are 13 moulding machines- 5 rrt machines and 8 Okamoto machines. The mouldig machines are organized into various plants as per the following ram:

The moulding machines- MC, MD, ME, MF and MG are rrt machines, and the rest of the moulding machines are Okamoto machines.

The primary production department operation consists of:i. COMPOUNDING OF RAW LATEX ii. MOULDINGiii. VULCANIZING/ POWDER FINISHINGiv. ETP (EFFLUENT TREATMRENT PLANT)

GENERAL PROCESS LINE DIAGRAM

Condoms sent to HPQCQuenching barrel.Vulcanizing machine.DehydratorStripping of condoms.Second dipping in the latex tankLeaching the dipped condoms using 1% NH3 solution.Heating the dipped condomsFirst dip in the latex tankCooling the compounded latex to 180C.Compounding the latex at 550C

Edge rolling and leachingHeating

PROCESS DESCRIPTION: 1.) COMPOUNDINGCompounding is done to make latex suitable for moulding operations and for making the final product conforming to requirements of the end user. This is achieved by the addition of fixed quantity of liquid compounding chemicals (like NH3) followed by compounding chemicals (like ZnO) dispersion, to raw latex in mixer. The dispersion is prepared by attritor mill. The compound is then heated (pre vulcanized) by introducing steam to the jacket of mixers. After attaining the required degree of cure (13 to 14hrs at 55C), the heating is arrested by introducing chilled water to the jacket. The compound can also be subjected to room ageing without heating; and then cooling to achieve the required degree of cure (18C). The latex properties will be regulated before supplying to the moulding process by keeping it for 3-4 days maturing.2.) MOULDINGCompounded latex is moulded and dried in an automated process. A conveyor chain fitted with glass moulds (called as former) rotates and dips the glass moulds into the latex tank. The latex tank is continuously agitated by agitators. The layer of latex which gets formed on the glass moulds is dried in a chamber where hot air generated from steam is circulated in Okamoto machines. In Richter machines, heating is done electrically. This constitutes the first dip (regarding rrt machines). Then they are dipped for a second time in the latex tank. Then they are subjected to leaching by passing them through a tank of 1% ammonia solution. In the case of Okamoto machines, the moulds are subjected only to a single dip. Then the edge of the condom is rolled from mould by beading brushes. Stripping of the condoms is achieved by impinging silica slurry jet. The condom with silica slurry flows to dehydrator by gravity. The mould passes through water jet, soap solution, and finally washed with hot water jet. The condoms are then dried and sent for vulcanizing.3.) VULCANIZING Vulcanization operations are done in automatic vulcanizing machines. Condoms are separated from slurry using dehydrator, and are conveyed pneumatically to vulcanizing machine. After vulcanizing, they are quenched inside a quenching barrel. Vulcanized condoms are collected every 45 minutes.

VULCANIZATION MACHINEDEHYDRATORRIGHT BARRELLEFT BARRELCONDOMS WITH SILICA SLURRY FROM MOULDINGQUENCHING BARRELCONDOMS TO HALF PRODUCT QUALITY CHECK

4.) EFFLUENT TREATMENT PLANT:-The factory has its own Effluent treatment plant (ETP). Its installed to handle up to 1000 KL effluent / day. There are four types of liquid waste coming from the factory. They are latex water, waste water, slurry water and canteen effluent. They are at first fed into the sedimentation chambers. Heavy particles settle down and the liquid above is pumped using motor driven pumps into mixing chamber-1. The pH of the water now is in the range of 8-9. It is now increased to about 12 adding Lime through a tap to the mixing chamber at a fairly constant rate. For enabling coagulation, FeCl3 is added to it in a similar way. Then they enter mixing chamber-2 for thorough mixing. Then they are directed to settling tank. Here all the heavy particles settle down. Then they are passed through pressure sand filters 1 and 2 for trapping lighter particles and are subjected to aeration. Then the water is chlorinated using Hypochlorous acid and is passed through carbon filters to remove any stray particles. All flowing process of the ETP (except for the pumps of sedimentation tanks) is achieved by gravity only, thereby saving electricity. The treated water is used for gardening and for sanitation in the factorySECTION 2: ELECTRONIC TESTING DEPARTMENT (ETD) The condoms from the primary production department, goes into the primary production quality controlling section or HPQC, after which they are send to the ETD for sorting the good and bad condoms electronically. ETD consists of seven indigenous machines, each with 10 units, making a total of 70 testing units. Each unit comprises of a HVT (High Voltage Pin Hole Tester), chain conveyor on which two mould lines are mounted, rubber flaps, solenoid switches, relay and proximity switches, condom edge rollers, compressed air lines, air nozzles etc.This department employs four workers per machine in each shift and the target per employee is to check 14600 pieces. The machines were made indigenously loaning the German Doka machine technology. The moulds used are made of steel, coated with chromium. The employees are trained to feed the condoms onto the moulds so that theres no trapped air between the mould and condom.HVT uses the dielectric property of condom to determine whether it is good or bad. Its principle of working is by measuring the current passed through the condom to metallic mandrel or mould, due to high voltage present in the conduction brushes( rubber flaps coated with carbon), which comes in contact with entire condom wall during the testing time. Usually the voltage applied is 1200. If the current is less, the PLC reads it as good condom and if its more, bad condom. Also the PLC can identify an empty mould. The counters provided, helps to register or count the number of good and bad condoms tested. The proximity switches and relays activate the air solenoids which, uses compressed air to separate good and bad condoms into two barrels. Red barrel is filled with bad ones while green is filled with good ones. The HVT is designed to test upto31 gauge pin holes in a condom.

SECTION 3: QUALITY ASSURANCE

QUALITY OBJECTIVE The quality assurance department will set objectives and overall targets based on corporate objectives and overall objectives. The quality objective will be measurable and consistent with the quality policy and will be recorded. The QA mainly deals with:a.) HALF PRODUCT TESTINGb.) FINISHED PRODUCT TESTING. PROCESS FLOW CHARTS 1. HALF PRODUCT TESTING PROCESS

Lots from all lines of moulding machine

Provide lot identity, batch number and lot number

Visual inspection,Dimension testingWater leak testingBurst volume/ pressure testing

Collect samples for testing

PASSQuality is assured

Warning to production if defect is detected and the whole batch is destroyed if the observed no: of failures is more than the number indicated in the sampling plan.

FAIL

2. FINISHED PRODUCT TESTING PROCESS

Colour fastness testCollect samples as per sampling plan based on product standardBV/BP test before and after ageingPackage seal integrity, conditions and markingsFinished products in packingTendering/ external inspectionDESPATCH IF PASSDESTROY IF FAILWater leak testLubricant qty testFinished product testing as per product standard/ customer specificationDimensions testTransfer to finished product depot

MATERIALS AND EQUIMENTS USED:1.) Computerized Inflation Tester 2.) Water leakage tester 3.) Ageing ovens 4.) Packing seal integrity tester 5.) Electronic Weighing Balance 6.) Thickness gauge 7.) Ultrasonic cleaner 8.) Scale on mandrel 9.) Width scale 10.) Tensile tester 11.) Electrolytic hole tester

Handling and storing of condoms in its various stages of production is also done in this section. Good products are stored in black or blue bags and bad lot in red bag

SECTION 4: PACKING

PACKING PROCESS

It can be divided into two:- a.) Primary packing or Strip Packing b.) Secondary Packing Naked condoms from QA are received batch wise and differed batch coding will be generated in the packaging stage according to QA batch. Silicone oils, foils, pouches, wallets, cartons, boxes etc after passing the incoming inspection made at Material Testing department are received from the stores department. Naked condoms are issued to packing machines for strip packing in foils as per the packing scheme.Required quantity of silicone oil is dosed in the strips as a part of the machine operation. Quantity of silicone oils dosed is as per the customer requirement; for example PEG + Benzocaine gel, having higher viscosity than Silicone oil is used for extra time condoms. After completion of packaging of a batch (about 5 lakh pieces), its informed to QA department for inspection.Two main types of packaging are done here; a.) Square pack - 55x56mm & 55x57mmb.) Squeeze pack - 30x70mm The square packing is done in SQUARE MACHINES: SINGLE LINE (ROTARY JAW) - SS SINGLE LINE (STATIC JAW) - ST THREE LINES (ROTARY JAW) -BRTThe squeeze packing is done in SQUEEZE MACHINES: SINGLE LINE (WITH AUTOFEEDER) - SR SINGLE LINE (WITHOUT AUTOFEEDER) - SRThe strip packing is done in aluminum foils. For branded condoms, PET foil is used. The foil consists of paper, adhesives and sealant (cerlin in PET foils). For square packs, in SS and ST machines, the foil width is 55mm and in SR, 30mm. For squeeze packs, the foil width is 70mm. The printing of manufacturing date, batch number, expiry date etc are done in this section itself, with the help of ink jet printers and work rolling machines. There are 2 single line printers and a triple line printer. Each machine is provided with a pump and nozzle set for dosing the required amount of lubricant into the un-lubricated condom. Temperature controlled sensors are also provided to control the jaw temperature. The temperature of upper jaw and lower jaw are maintained as per specifications.Secondary packing involves the packing of the strips into pouches, wallets, boxes and cartons, according to marketing specification with the help of over wrapping machines. After completion of packaging of a batch, its informed to the QA department for FPQA.

SECTION 5: COMMERCIALThis section comprises of three sections namely:

1.) PURCHASE DEPARTMENT2.) SALES DEPARTMENT 3.) STORES DEPARTMENT PURCHASE DEPARTMENT:The objective of this department is to ensure that materials and services are available to have uninterrupted Production and Packing as per plan. The objectives of purchase dept. shall be fixed yearly as per the procedure mentioned in the Quality Manual.On receiving an indent from MPC (material planning and control) department or other departments, the purchase departments checks if its a consumable item, capital goods or work contract. For consumable items, capital goods / work contracts