About Salt Industry1

8/6/2019 About Salt Industry1

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ACKNOWLEDGEMENT

With a sense of gratitude and respect, I would like to extend my sincere

thanks to the Western India Sea Brine Pvt. Ltd. family for their kind

attention, guidance and advice which has made my training a great pleasant

and excellent experience.

I sincerely thank Mr. Prakash Jiandani, factory in-charge who let me to

fulfill mydesire and dream to work at this prestigious organization. I mindebted to Mr. Biren Mehta, factory manager, who gave his kind advice,

encouragement and support throughout the training tenure.

I am obliged to Mr. Atul Sharma, Quality Manager, for his active

involvement and support.

I express profound thanks to Mr. Ravindra Jain, Purchase Manager, Mr.

Bharat Rathode, Head of Electrical Department, Mr. Patel, Head of

Maintenance Department, Kuashal Soni, Dispatch Officer and Mr.

Mulchand Chuadhry, who had given me the detail information of theirrespective departments.

A PROJECTREPORT ONFUNCTIONS OF

WESTERN INDIASEA BRINEPRIVATE LIMITED

THIS REPORT EXPLAINS INDIAS SALT INDUSTRY, FUNCTIONS OFVARIOUS DEPARTMENTS, PROFILE AND SCOPE OF WISBPL,PROCESS FLOW OF MANUFACTURING OF SALT.

MULCHANDANI BHARTI D25/05/2009


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CONTENT

1. Introduction3

2. Description of Indias Salt Industry.4

2.1 State wise distribution of Salt production in India..4

2.2 Market leaders of Salt Industry5

2.3 Application of Salt in Industry.5

2.4 Regulation

Body...6

2.5 Scope of Salt Industry..6

3. Unit Profile..7

4. Organization Structure..8

4.1 Procurement Management...8

4.2 Maintenance Management.10

4.3 Quality Management..10

4.4 Safety and Cleanliness Management.12

4.5 Packaging Management.13

4.6 Dispatch

Management....14

5. Technical Detail16

6. Scope..17

7. Conclusion.17

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INTRODUCTION

Salt in industry is used for two purposes. Firstly as a food product and secondly as a

raw material. Total capacity of Indian salt industry is 170 lakhs metric tons per year.

From these 120 lakhs mt per year is used for industry purpose and 50 lakhs mt is used

as edible salt.

Western India Sea brine is a salt manufacturing company with an annual production

of 2.5 lakhs tons per year. It was incorporated in 1997 and is situated at salt city

Chopadva, Kutch, Gujarat. The market share of it is 1.47 % and turnover is Rs. 60

crores. It manufactures various salt brands, viz. Annapurna for Hindustan Unilever

Ltd., i-Shakti for Tata Chemicals Ltd., Everyday for RKMK, Sun Gold for Chirai Saltand Dandi for Dandi. The backbone system of WISBPL works on a sophisticated

organizational structure.

The process flow of manufacturing salt includes filtering, washing, drying, sieving,

crushing, iodizing and packaging.

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2. DESCRIPTION OF INDIAS SALT INDUSTRY

The capacity of Indis Salt Industry is 170 lakhs metric tons per year. From these 120

lakhs mt per year is used for industry purpose and 50 lakhs mt is used as edible salt.

From these 50 lakhs mt tons 30% (15 lakhs mt) is refined free flow iodized salt and

70% (35 lakhs mt) is non-refined iodized salt.

INDIAS SALT INDUSTRY

2.1 STATE- WISE DISTRIBUTION OF SALT PRODUCTION

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2.2 MARKET LEADERS OF REFINED FREE FLOW IODIZED SALT

Name Production in Lakhs mt

Tata 7.5

HUL 1.5

ITC 1.5

Others 4.5

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2.3 APPLICATIONS OF SALT IN INDUSTRY

Edible Salt is used as a food product.

Non-edible Salt in following Industries:

Leather Industry for cleaning (In process)

Rayon Industry (In process)

Cold Storage as an anti-melting agent

Fishing Industry as a preservative

In Food processing as a additive

Dye Industry if chloride agent is required

Caustic Soda and Sodium Bicarbonate as a Raw-Material

2.4 REGULATION BODIES

1) Salt Department:

It estimates the salt production in a year

Verification of Raw Salt

Regulation of Distribution

Permission for C and D supply

2) Prevention of Food Adulteration (PFA): It provides following standards for salt

industry.

Iodine: 30 ppm

Water Insoluble: CaSo4, sand, stones, etc.

Moisture: Max. 6% (in WI 0.15%)

Matter Soluble other than NaCl: CaSo4, MgSo4, MgCl2

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NaCl: 96.2%

2.5 SCOPE OF SALT INDUSTRY

Conversion from non-refined to refined salt

Low Sodium Salt

Iron fortified Salt

3. UNIT PROFILE

The WesternIndia Sea Brines Pvt. Ltd. is situated at salt city Chopadva, Kutch,

Gujarat. It was incorporated in 1997. Initially the plant structure was made up of

RCC, but after earthquake occurred in Gujarat in 2002, it was reconstructed and made

earthquake proof. Mr. Jawerilal Nahata is Managing Director of this company. The

main product of this unit is Iodized Free Flow Salt. The annual turnover of WISBPL

is Rs 60 crores. The Plant capacity is about 2,50,000 tons per anum (TPA). The

byproduct is Superfine. In WISBPL, following salt brands are made.

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Brand Name Corresponding Firm

Annapurna Hindustan Unilever

i-Shakti Tata Chemicals Ltd

Dandi Dandi

Everyday RKMK

Sun gold Chirai Salt


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4. ORGANIZATIONAL STRUCTURE

Managing Director

Manager

Procurement Quality Maintenance Electrical Packaging Production HRA

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FFS Plant Time Office Security Office

Dispatch Production Supervisor Store Plant Operator

Systems (SAP)

4.1 PROCUREMENT MANAGEMENT

Following are the three major activities of this department.

1) Planning of raw material and dispatching of final product: Planning of

required raw material is done based on following parameters.

o Weather Conditions

o Rate of raw material in market

Planning of dispatching of final product is done based on the following

parameters.

o Customer Requirement

o Availability of rack and trucks for transportation of finished good

2) Procurement of raw salt from various parties: Parties for raw salt

procurement are decided based on following parameters.

o Growth of Customer

o Payment Policy

o Market Impression

For WISBPL, following are the three parties from where raw material is

procured.

o Chirai Salt Work

o Gayatri Salt Work

o International Salt

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With these parties Memorandum of Understanding (MOU) is prepared, which

has following terms.

o Quantity of lifting final product

o Rate of product material

o Payment (Terms and conditions)

o Specification of quality

3) Factory Planning: Following parameters are planned.

Month wise planning of production each customer

Planning of plant running hours

Planning for man power with contractor

Planning for Raw material, Packaged material, fuel and additives

4.2 MAINTENANCE MANAGEMENT

There are basically three types of maintenance processes.

1) Shut down Maintenance: Under this process, maintenance is done after

breaking down.

2) Periodic Maintenance: Here maintenance is done regularly.

3) Preventive Maintenance: Under this process, maintenance is done before

breaking down.

4.3 QUALITY MANAGEMENT

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Activities of Quality department: In QD, quality of salt at various stages is analyzed

with respect to specified measures, which are mentioned below.

Appearance: White crystalline/free flow

Dynamic Flow Rate (m/sec): Min 160Bulk Density (gm/cc): 1.23 1.26

Non-white particles (No/gm): 30/250

Particle Size: 850 microns (18 mesh) Max 1%

710 microns (20 mesh) Min 84-86%

150 microns (100 mesh) Min 93%

150 microns (100 mesh) Max 7%

Moisture: 0.2%

Sodium Chloride (NaCl): 99%

Calcium (Ca): Max 0.12%

Magnesium (Mg): Max 0.1%Sulphate (So4): Max 0.3%

Water Insoluble (CaSo4, SiO2, etc): Max 0.35%

SiO2 allowed: 0.3%

Potassium Ferro Cynide (as an anti-caking agent): Max 10 ppm

Iodine: 30 ppm

PH: 7

Quality Control Point (QCP): These are the points at which quality of material is

checked.

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We

t

Elutriation

PrimaryTank

Thicken Centrifuge

We

t

Raw Salt

Storage

Elutriation

PrimaryTank

Thicken Centrifuge

Fluid Bed

OversizeBucketElevator

QC

P

Ca: 0.12%Mg: 0.10%

850 u-Max30%

150 u- Max

10% Moisture:

< 4%


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SAMPLING PLAN

Finished Product

Spot sample: One sample shall be drawn out into a transparent pack every hour from

the previous hours packed stock from every production line.

Composite sample: 100 gms sample from each spot sample shall be drawn and

mixed into a tub. The mixture shall be made into a heap. 50 gms sample shall be drawfrom all four corners of the heap and mixed together. This composite sample shall be

used for analysis.

Sample for Attribute Checking: One bag per 100 bags produced (of each SKU)

shall be selected at random, evenly distributed over the lot. From each bag, draw 5

pouches for attribute and weight checking.

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Storag

e

Distribution

Vibro SieveBucketSurge

Hoppe

Produc

tStorag

Form

Filling

Ca: 0.20%Mg: 0.50%4000 u-

About Salt Industry1

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