training report edited
TRANSCRIPT
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1. INTRODUCTION
Hindustan Latex (HLL) commenced its journey to serve the Nation in the area of
Health Care, on March 1, 1966, with its incorporation as a corporate entity under
the Ministry of Health and Family Welfare of the Government of India. HLL was
set up in the natural rubber rich state of Kerala, for the production of male
contraceptive sheaths for the National Family Planning Programme.
The company commenced its commercial operations on April 5, 1969 at
Peroorkada in Trivandrum. The Plant was established in technical collaboration
with M/s Okamoto Industries Inc. Japan. Two most modern Plants were added,one at Thiruvananthapuram and the other at Belgaum in 1985.
The production facility at Peroorkada has emerged as one of the largest single
manufacturing Plants in the world for the production of Condoms, with a capacity
to produce over 1 Billion Condoms a year. With the addition of this capacity,
HLL today has an annual production capacity of 1.316 billion condoms.
HLL is today a multi-product, multi-unit organization addressing various public
health challenges facing humanity
The manufacturing unit at Peroorkada was set up by HLL in 1969 with the
technical collaboration using Japanese technology. The plant which has an
annual production of 1066 million pieces condoms undergone continuous
modernization over the years. The facility is equipped with modern production,
inspection and quality control machines and equipments in international quality
norms. Condoms manufactured by this facility have CE Mark and can meet a
range of international quality norms by WHO 2003, ISO 4074:2002, SANS ISO
4074, ASTM D 3492, GOST- 4645-81 etc.
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2. PRODUCTION PROCESSES
Transformation of tested raw latex to condom taking place in primary production
consists of three major processes.
i) Compounding
ii) Moulding
iii) Vulcanizing
2.1 Compounding
Production starts with compounding. The required characteristics of latex is
obtained during compounding. This is achieved by the addition of fixed
quantity of compounding chemicals in dispersion to raw latex in large
mixer tanks. The dispersion is prepared by using ball mill/sand
grinder/pearl mill/attritor mill. The compound is then heated (pre-vulcanized)
by introducing steam to the jacket of mixers. After the predetermined time
,the heating is arrested by introducing chilled water to the jacket. The
compound latex from the mixer tank is then transferred to supply tank and is
mixed with required amount of 1% ammonia water solution in order to
control the properties like TS (total solid) content, viscosity etc. Along with
this colour pigments are added, depending on the type of condom required.
Then it is kept for a predetermined time for ageing before supplying for
moulding. The whole compounding time takes 11.5 hours to complete.
2.2 Compounding Chemicals And Their Functions
Stabilisers used are Ammonia Solution, Casein solution, potassium salt of
fatty acids etc. are added to prevent, or retard decay or spoilage of latex
under the conditions of use or storage.
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Vulcanising agent used is Sulphur.
Chemical that permits the acceleration of Vulcanisation reaction.
Zinc oxide is used as the vulcanizing activator
Compounding chemicals that is used to prevent deterioration of the
properties of the film caused by oxidation or by natural ageing
Surface-active substance used to facilitate the suspension of solid
compounding materials in a liquid medium and to stabilize the dispersion
thereby produced.
Pigments are added to the compounded latex at the supply tank stage to
impart colour to the condoms.
2.3 Moulding of Condoms
Primary Production includes:
Two types of moulding machines are available
Eight machines: M1, M2, M3, M4 (PLANT-A)
MA, MB (PLANT-B)
M5, M6 (PLANT-C)
The machines are named in the order in which they were assembled. The
machines with the nomenclature consisting of alphabets, i.e, MA,MB,MC,MD are
those which are designed by the original manufacturers (Okamoto & Ritcher) and
are imported while those with the nomenclature with numbers, i.e,
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M1,M2,M3,M4,M5 &M6 were indigenously fabricated and commissioned by our
production department.
1) German Technology (M/s Ritcher Hi-Tech)
Two machines: MC, MD (PLANT-B)
2) Japanese Technology (M/s. OKAMOTO RIKEN GOMU CO)
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SOAP
WASHING
STRIPPING
2.4 Japanese Technology Moulding Operation:
MOULDING PROCESS
EDGE
ROLLING
DRYING LEACHING
ANTI-
STICKING
DRYING
FIRST
DIPPING
COMPOUNDING
MOULD
DRYING &
COOLING
HOT
WATER
RINSING
BRUSHING
SECOND
DIPPING
DRYING
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2.5 Vulcanisation of Condoms
Uncured natural rubber is sticky, can easily deform when warm, and is
brittle when cold. In this state it cannot be used to make articles with a good
level of elasticity. The reason for inelastic deformation of unvulcanized rubber
can be found in its chemical nature: rubber is made of long polymer chains.
These polymer chains can move independently relative to each other, which
results in a change of shape. By the process of vulcanization, crosslinks are
formed between the polymer chains (Vulcanisation consists of creating a
sulphur crosslink, i.e., a bridge is being formed by one or more sulphur atoms
between adjacent polymer chains) so the chains can no longer move
independently. As a result, when stress is applied the vulcanized rubber will
deform, but upon release of the stress, the rubber article will go back to its
original shape.Vulcanising Induces extensive changes in the physical properties
of natural rubber and is brought by reacting the rubber with sulphur
2.6 De-hydration Operation
Post-Stripping, the condoms are dehydrated in a wire mesh barrel.
The silica slurry is dried off from the stripped condoms by the dehydrator and
leaves the dry powder on the condom to serve as a dusty material during
further processing.
The condoms are dried using hot air so that the products can pneumatically be
carried to the vulcanising machine barrels without sticking anywhere in the
carry-hose.
After the moulding operation the unvulcanized condoms move to vulcanization
stage.
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3. ELECTRONIC TESTING DEPARTMENT (INSPECTION)
FUNCTION
The function of Electronic Testing Department is to test and roll up the condomsin Electronic Pinhole Testing Machine (EPT). The ETD is class 100000. ETD
receives condoms manufactured by HLL as well as from other sources, passed
by HPQC for testing in EPT machines. Testing is done after a minimum
maturation time of 3 days of the passed lots from HPQC.
The Condoms are covered on the mandrels fixed to a conveyor chain. Chain
speed is 902 per minute. These condoms pass through a conductive rubber
flap, which is part of the high voltage-testing unit. High voltage is applied to thecondom through the rubber flap. The moulds are rotated at a speed of 2-4 times
across the high voltage tester. The HV tester applies 900-1650 V DC. The
detecting unit identifies the condom as good or bad. A rolling brush rolls up the
tested condoms. The rolled condoms are pneumatically stripped off into the
Good and Bad collection trays.
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4. PACKAGING SECTION
4.1 Primary packaging
The input materials using in this process are foil, silicon oil, and naked condoms.1. Strip packing This is the most important process in packing operation,
which is doing in strip packing machine. There are mainly two types of
machine are using based on type of jaws for sealing and they are
(a) rotary seal jaw machine & (b) flat seal jaw type machine. The most
important parameters monitored in these machines are sealing
temperature, machine speed, pressure and the position of condoms in the
slot of machine. There are 103 machine are using in our plant for packing
in which 55 machines are of single rectangular, 15 are single square
machines, 27 are static square machines and 6 are BRT machines.
Comparison of these different machines are shown in table
Machines
Characteristics
SS SR ST BRT
Sealing
temperature
160+/-5oC 185+/-5
oC 135+/-5
oC 100+/-5
oC
Machine
speed
60 strips/min 85 strips/min 60 strips/min 40 strips/min
Output in min 60 strips 85 strips 60 strips 120 strips
Line of
operation
Single Single Single Triple
Feeding of
condoms in
slots
Manually Manually Manually Automatic
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After setting up the machine parameters, condoms will be picked from the crate
and is placed over clean machine bed. As the conveyor moves condoms are
placed on conveyor plates. As the foils moves through the heated press rollers,
the condoms also get inside the layer of foils and since there are recess in the
press rollers, the condoms are safely positioned inside the pocket formed by the
recess and gets sealed all around and carries out in continuous strip. As the
condoms moves through the slots of machine and it carried towards the silicon
nozzle area, where oil is supplied to the strips with the help of a pump. The
quantity of silicon oil applied in to the strips is depends up on the type of
schemes and is shown in the table
After the oil pumps in to the top of condoms in the strips, sealing will take place
on the four side of the foil and then cut it in to different series as per the
requirements of the customers.
Secondary Packing
The materials as well as machines required for secondary packing operations are
wallet, carton, box, leaflet, catch cover, shrink wrapping machine, hoping
machine, HDPE sheet, weighing machine, wallet coding machine and strip
packed condoms.
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5. ENGINEERING DEPARTMENT
There are four sections under engineering department:
MECHANICAL
UTILITY
ELECTRICAL
INSTRUMENTATION
MECHANICAL SECTION
This section plays a key role as a service section to keep the plant and
machineries in satisfactory condition.Types of maintenance:
Broadly maintenance is divided into two categories:
i) Preventive maintenance
ii) Breakdown maintenance
Preventive maintenance
Activities carried out to prevent failure or detect failure before it develops into a
failure. Preventive maintenance involves lubrication, planned overhauls, regular
cleaning and adjustments.
Breakdown maintenance
Activities carried out to correct the failure or break down after the occurrence of
breakdown/ fault. Breakdown analysis is also done.
Production department calls for the maintenance department to rectify the defect.
This economical for non-critical equipments whose downtime and repair cost are
less.
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6. UTILITY
Utility section is one of the supporting sections providing the facilities required for
the production processes. It maintains generation and distribution of all utilities
associated with production process.
The major functions are,
To generate and supply steam in desired quantity
To supply sufficient quantity of process water and chilled water to various
sections
To generate and supply compressed air to various sections what ever
required.
To maintain diesel engine of DG set in good condition
To maintain all mechanical weighing balances in good condition
To maintain all AHUs in good condition
To maintain Forklifts in good condition.
Utility Equipments
6.1 Boilers
Presently there are two boilers- Kesselpack and, of 8 TPH each. Both are
furnace oil fired, horizontal, packaged, 3 pass, fire tube boiler. Kesselpack is
used continuously and the efficiency is 80-81%. Thermax is used whenever the
requirement exceeds 8 TPH, and the efficiency is about 76%. The number oftubes in Thermax boiler is 188 and of Kesselpack boiler is 242.
Boiler operation:
Both the boilers are furnace oil fuelled. The furnace oil is transferred from the
main tank to an over head tank by means of a gear pump. Then it is pumped on
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to the boiler by another gear pump. The furnace oil is heated to about 120OC
using a heat exchanger heated by steam. For cold start electric heater is also
provided. The furnace oil is then atomised using primary air from a centrifugal
blower and introduced into the chamber. The secondary air is supplied for
combustion. Time, temperature and turbulence should be maintained to burn the
furnace oil effectively. For cold starting of the boilers diesel is used initially and
ignited using a spark.
THREE PASS FIRE TUBE BOILER
(90000 LTS) (2000 LTS)
FURNANCE
OILPRIMARY
STORAGE
SECONDARY
STORAGE BOILER
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SPECIFICATIONS
Feed water:
pH 7.5 - 9.5
Hardness
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There are three compressors of Chicago Pneumatic make. Two are of 75 HP and
1 of 60 HP. The compressors are Horizontal, Two Cylinder, and Balanced-
Opposed Models. The two cylinders are connected with an intercooler cooled by
cooling towers. The compressors provide oil free air. An air drier is also provided.
Operational parameters
Air pressure (1st
stage ) 1 to 2.5 kg /sq. cm
Air pressure (2nd stage ) 3.5 to 6 kg /sq. cm
6.3 Water Supply
There are two main water tanks of 650 KL and 1450 KL. An over head tank of 60
KL is also present. A softening unit for process water is also present. The water
supply is from Thiruvananthapuram Municipal Corporation.
6.4 DG Set
There are currently 5 DG sets of 1000KVA, 500 KVA, 2 Nos. 320 KVA and 1Nos. of 200 KVA. The 1000 KVA generator set uses a 16 cylinder Diesel Engine
KTA 3067G.
K V Engine
T Turbo charged
A After cooler
G - Generator
Displacement 3067 cu inches
Speed 1500 RPM
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6.5 Forklifts
Fork lifts are used to load/unload and transport goods within the factory
premises. There are 2 forklifts. Both are of Godrej make of one is 3 tonne and
other is 5 tonne, diesel powered. Maintenance of these forklifts is given as AMC
to Godrej.
6.6 Power supply:
11 KV HT supply from KSEB is fed through a high tension VCB (Vaccum circuit
breaker) panel. Its then stepped down to 11KV/440V by distribution transformer.
Its then connected to a main voltage panel through 1250A ACB (air circuit
breaker) as an incomer. Bus couplers are provided in the main panel so that the
system does not get affected in case if the transformers are out of service. The
main vaccum circuit breaker (KSEB supply and generator supply) is provided
with an interlocking system. The distribution system consists of mainly 3 nos. of
630 KVA, 11KV/433V step down transformers.
The total connected load of the system is 1450 KVA and the contract demand is
950 KVA. The readings of the various meters such as TOD (time of the day)
meter, HT ammeter, HT voltmeter, LT ammeter and LT voltmeter are recorded in
the daily log sheet at 1 hour interval basis.
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6.7 Electrical Utilities:
11KVA HT Feeder.
3 nos of 630 KVA 11KVA/433V step down Transformer.
HT Panel, Main Panel Board, Sub Switch Boards(SSBs)
Energy Meters which indicates the amount of Electrical energy consumed.
DG sets1000 KVA 1 no; 500 KVA 1no; 200KVA 1nos,320 KVA 2 nos
ACBs (Air Circuit Breakers), OCBs (Oil Circuit Breakers),VCBs(Vaccum
Circuit Breakers) that helps to protect the equipments connected to it.
3 phase Capacitor Bank that helps to improve the power factor .
AVR (Automatic Voltage Regulators) to sustain the voltage fluctuations.
Industrial UPS (Uninterruptible Power Supply) Equipments also helps to
avoid production loss maintain the voltage to the desired level incase if the
voltage fails
7. INSTRUMENTATION
Activities
Repairing and maintenance of process control -equipments.
Calibration of test and measuring equipments as iso -standards.
Preventive / proactive maintenance.
Scheduled maintenance. Break down maintenance - by shift personnel.
Technology up gradation / modification works.
Maintenance of internal telephone communications.
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8. SAFETY DEPARTMENT
Device pre accident strategies and conduct safety audit & inspection.
Introduce work permit system, detailed accident analysis, fire fighting operation
etc. To prepare procedure for emergency preparedness & response method.
Ensure implementation of the procedure by concerned departments. Identify and
evaluate environmental aspects and fix environmental objectives and targets.
To monitor the concentration of ammonia, dust and noise:
To provide guidance for identification of proper personnel protective
equipments by concerned departments. Measurements will be made on a
quarterly basis
To maintain safe height of materials.
9. PURCHASE DEPARTMENT
The aim of the department is to procure right quality of material in the right
quantity at the right time from the right supplier for the right price and thus to
ensure that materials and services are made available to have uninterrupted
Production and Packing as per plan. Procurement of raw materials, packing
materials, equipments, spare parts and services to maintain continuity in
respect of supply of materials to support production schedule and the
companies operation are done here. The department also deals with
developing good and reliable vendors and ensuring healthy buyer-vendor
relationships. Also the evaluation of vendors based on their ability to supply
products in accordance with the organizations requirements is done by this
department.
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10. STORES DEPARTMENT
Objectives
To receive material goods and equipments and check them for
identification.
To keep the traceability of all materials received in Stores in each level.
Issue of material to various sections as per their requirements.
Control of inventory.
Proper storage, preservation and handling of finished goods.
Optimum usage of cubic space.
To initiate purchasing cycle in the appropriate time so that materials
required are never out of stock.
11. QA An Introduction:
The primary function of the QA department is to ensure the quality of product at
all stages of production, so that overall rejection of the final product could be kept
at a minimum. Thereby we ensure that our product meets the internationallyrecognized standards of quality. ISO 4074 (standard for production of natural
latex male contraceptive condoms) is the basic standard for condom production
at Peroorkada Factory. Condoms are Class 2-B medical device. Generally we
follow two standards for the testing of condoms; they are Schedule-R of the
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Drugs and Cosmetics Act & WHO 2003. Sampling plan is derived from ISO
2859-1. The other major functions of the QA department is given below:
Defining and documenting quality system procedures
Establishing quality management systems as per the guidelines of ISO
9001-2000
Contract reviews regarding the requirements of the customer and our own
capabilities.
Keeping the identification and trace ability of the product.
Application of the SQC (statistical quality control) techniques.
Overseeing / Conduction of the receiving inspection, in process inspection
and final product inspection on sample basis.
Conducting monthly GMP audits in all departments
Tendering of batches for Govt. supply
Keeping the test status for the product at every stage of manufacturing.
Thorough review and disposition of non-conforming products.
Maintenance of reserve samples by QA department for the life of the
product.
Offering external batches for inspection.
Participating in inter-lab trials
Collecting customer feedback
Corrective and preventive actions.
Half Product Testing
In this phase the batch number and lot identity is given. From the lot samples are
selected and samples are subjected to visual inspection, dimensional & leakage
checking.
Dimensional Check includes:
Average Weight
Length
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Width
The visual inspections makes sure that defects like wrinkles, bad edge roll,
scratches, twisted condoms, discolouration, sticking, bad print, weak spots, bump
cut, non vulcanized etc. If such defects are present they are rejected and these
defects are shown on screen so that they are met with immediately.
QA Tests Conducted
The QA tests are conducted on samples from the following two phases:
Before Packing
After Packing
30 samples from a lot of electronically tested condoms are taken for before
packing testing. 24 out of these are tested for water leakage. If 2 or more
samples fail, the lot is rejected. Remaining six samples are set for burst test.
Width Burst Volume (Liters)
49 mm 15.82 16
53 mm 18.50 18
In the after packing testing section certain number of samples are subjected toburst test and certain number are subjected to water leakage test.
Numbers of samples to be selected are determined by an empirical formula:
N = (n+1) where n is the total quantity
In burst test the lot is rejected if 10 or more fails within minimum pressure of
1 KPa.
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In the water leakage test lot is rejected if 2 or more fails.
The next test is after ageing test. Samples are placed in ovens at 70C for 3 days
for condoms having expiry date of 3 years and 7 days for condoms having expiry
date of 5 years.
Then the condoms are subjected to lubrication quantity test and package seal
test.