An OJT Report On 3 Month Internship at Surya Nepal

I

TRIBHUVAN UNIVERSITY

INSTITUTE OF ENGINEERING

THAPATHALI CAMPUS

An OJT Report On Three Month Internship At Surya Nepal Pvt. Ltd.

By

Bikram Dahal

067-BIE-10

AN OJT REPORT

SUBMITTED TO THE DEPARTMENT OF INDUSTRAIL ENGINEERING

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE

DEGREE OF BACHELOR IN INDUSTRIAL ENGINEERING

DEPARTMENT OF INDUSTRIAL ENGINEERING

KATHMANDU, NEPAL

SEPTEMBER 18, 2014

An OJT Report on Three Month Internship at Surya Nepal Pvt. Ltd.

II

COPYRIGHT

The author has agreed that the library, Department of Industrial Engineering,

Thapathali Campus, Institute of Engineering may make this report freely available for

inspection. Moreover, the author has agreed that permission for extensive copying of

this project report for scholarly purpose may be granted by the professor(s) who

supervised the project work recorded herein or, in their absence, by the Head of the

Department wherein the project report was done. It is understood that the

recognition will be given to the author of this report and to the Department of

Industrial Engineering, Thapathali Campus, Institute of Engineering in any use of the

material of this project report. Copying or publication or the other use of this report

for financial gain without approval of the Department of Industrial Engineering,

Thapathali Campus, Institute of Engineering and author’s written permission is

prohibited. Request for permission to copy or to make any other use of the material

in this report in whole or in part should be addressed to:

Head

Department of Industrial Engineering

Thapathali Campus, Institute of Engineering

Thapathali, Kathmandu

Nepal


III

TRIBHUVAN UNIVERSITY

INSTITUTE OF ENGINEERING

THAPATHALI CAMPUS

DEPARTMENT OF INDUSTRIAL ENGINEERING

The undersigned certify that they have read, and recommended to the Institute of

Engineering. For acceptance, a OJT report entitled “An OJT Report On Three Month

Internship At Surya Nepal Pvt. Ltd." submitted by Bikram Dahal in partial fulfillment of

the requirements for the degree of Bachelor in Industrial Engineering.

__________________________________________________

External Examiner,…..…………………………………..

…………….………………………….

……….…………………………......

__________________________________________________

Internal Examiner,……….…………………………………

…………….………………………….

……….…………………………......

__________________________________________________

Er. Sailendra Khanal Head of Department

Department of Industrial Engineering

Date: September 18, 2014


IV

DECLARATION

I hereby declare that I carried out OJT reported in this report in Surya Nepal Pvt. Ltd.,

Simara, Bara under the supervision of Mr. Ayush Raj Aryal, I/C PMD. I solemnly declare

that to the best of our knowledge, no part of this report has been submitted here or

elsewhere in a previous application for award of a degree. All sources of knowledge

used have been duly acknowledged.

………………………………………..

Bikram Dahal


V

Letter of Completion


VI

EXECUTIVE SUMMARY

Success of industries dependent on questioning the underlying premises associated with

basic issues and problems in the areas of quality, productivity, timeliness, flexibility,

responsiveness to customers, optimization, research, data analysis for pattern, and cost

minimization rather than focusing only on tools and techniques.

Analysis of data help to identify problems and find pattern in problem, so that a model

can be develop to solve that problem. Data collection and analysis also helps to create

benchmark for future reference.

Solving engineering issues and manufacturing problem is one of the most important

task of engineer. Finding the cause and implementing best possible suggestion so as to

increase quality and quantity is primary goal of engineering.

Challenging economic conditions and tough competition make production errors and

waste unacceptable. Therefore it is necessary maximize output without violating some

constraint. Optimization of layout on production floor and inter-operational change

time is important, so as to maximum utilization of resources and reduce ideal time along

with improvement in quality.

As an industrial engineering student project related to research and data analysis,

problem solving and optimization were carried out during my OJT and successful

completed. Under research and data analysis projects, filling value of Surya was

increased by 3 percent, Admoist protocol was passed and Cp and Cpk of CRS dryer was

calculated. Under problem solving, spillage at CTS area was reduce by 5-8 kg/ day,

uniform feed was maintained at CRS cutter, and two design were made. Under

optimization project, blend change time was optimized.


VII

ACKNOWLEDGMENT

Foremost, I would like to thank The Department of Industrial Engineering (DoIE), IOE,

Thapathali Campus for including such opportunities in the BIE syllabus. Especially, I am

indebted to Er. Sudan Neupane, DHOD (DOIE) whose continuous effort always guided

me.

I express my gratefulness to Surya Nepal Pvt. Ltd, Simara, Bara for giving me suchgreat

opportunity of doing on job training.

I would like to express my deep gratitude towards Suresh Kaji Shrestha, Factory

Engineer, Surya Nepal, Simara, for selecting me for the training at SNPL.

I would like to express an earnest thankfulness to my project guide Mr. Ayush Raj

Aryal, I/C PMD, for his guidance throughout the project. Similarly appreciation to Mr.

Sarabjit Rana, Production Manager, and Mr. Dinesh K.C., SMD IC, will always be a due

for his valuable instruction and guidance.

I would also like to extend my thank you to Mr. Sarbin Shrestha, Welfare Officer, for

his suggestions and help in all possible ways during internship period.

Last but not least, I would also like to thank all the operators, staffs of PMD and QUAS,

for their cooperative and helpfulness attitude during my training.


VIII

TABLE OF CONTENTS

Copyright ............................................................................................................................... II

Approval Page ……………………………….………………………………………………………………..……III

Declaration .................................................................................................................IV

Letter Of Completion ..................................................................................................V

Executive Summary ....................................................................................................VI

Acknowledgment ....................................................................................................VII

Table Of Contents ....................................................................................................VIII

List Of Figures .............................................................................................................. X

List Of Tables .............................................................................................................. XI

Abbreviation.............................................................................................................. XII

CHAPTER 1. INTRODUCTION .............................................................................................. 1

1.1 Company profile ..................................................................................................... 1

Introduction ................................................................................................... 1

Portfolio of Business ...................................................................................... 1

SNPL Logo ....................................................................................................... 2

1.2 Vision and Values ................................................................................................... 3

1.3 Policies and Philosophy .......................................................................................... 5

Environmental Policies ................................................................................... 5

1.2.2 Energy Policy .................................................................................................. 5

1.2.3 EHS Policies .................................................................................................... 6

1.2.4 Quality Policy ................................................................................................. 7

1.2.5 Social Accountability Policy ............................................................................ 7

1.4 Major Department in SNPL .................................................................................... 8

Primary Manufacturing Department ............................................................. 8

Secondary Manufacturing Department ......................................................... 9

QUAS ............................................................................................................ 10

Slitting Complex ........................................................................................... 12

Filter manufacturing department ................................................................ 12

1.5 Products of SNPL .................................................................................................. 13

CHAPTER 2. PROJECT AREA INTRODUCTION ................................................................... 14

2.1 PMD ...................................................................................................................... 14

Lamina processing is describe as below ...................................................... 14

CRS Processing line is described as below ................................................... 18


IX

CHAPTER 3. PROJECTS ..................................................................................................... 21

3.1 Research and Data Analysis ................................................................................. 21

Admoist Protocol Test .................................................................................. 21

Increase the filling value of Surya Tobacco .................................................. 28

Cp & Cpk of CRS dryer .................................................................................... 40

3.2 Problem solving .................................................................................................... 44

Maintenance of Feed gap at CRS cutter CFP ............................................... 44

Wastage reduction at product bin ............................................................... 47

Design of pan for HT sampling and stand for Serrico trap ........................... 50

3.3 Optimization ........................................................................................................ 51

Optimization of blend change time of CRS line ........................................... 51

CHAPTER 4. CONCLUSION ................................................................................................ 54

REFERENCES ............................................................................................................ 55

GLOSSARY ............................................................................................................................ 59

Appendix 1 .......................................................................................................................... 67

Appendix 2 .......................................................................................................................... 68

Appendix 3 .......................................................................................................................... 69

Appendix 4 .......................................................................................................................... 70

Appendix 5 .......................................................................................................................... 71

Appendix 6 .......................................................................................................................... 72

Appendix 7 .......................................................................................................................... 73

Appendix 8 .......................................................................................................................... 74

Appendix 9 .......................................................................................................................... 75

Appendix 10 ........................................................................................................................ 76

Appendix 11 ........................................................................................................................ 77


X

LIST OF FIGURES

Fig 1.1.1: Logo of SNPL .............................................................................................. 2

Fig 1.4.1: Flow diagram of PMD Process ................................................................... 8

Fig 1.4.2: Flow diagram of SMD Process ................................................................... 9

Fig 1.4.3: flowing diagram of slitting process .......................................................... 12

Fig 1.4.4: Flow diagram of filter making .................................................................. 12

Fig 2.1.1 Lamina processing flow Diagram .............................................................. 17

Fig 2.1.2: Stem processing flow diagram ................................................................. 20

Fig 3.1.1: Fishbone diagram of factor causing M.C variation after ex-CRS Cutter .. 24

Fig 3.1.2: S.D chart of moisture variation after Ex-cutter (Appendix 1) .................. 25

Fig 3.1.3: Mean Moisture after Ex-cutter (appendix 1)........................................... 25

Fig 3.1.4: Coefficient of Variation of weighcon Weight (Appendix 1) .................... 26

Fig 3.1.5: CPI of cutter before and after (appendix-4) ............................................ 35

Fig 3.1.6 Wax Thickness Before and after (appendix-4).......................................... 35

Fig 3.1.7: Percent expansion from Ex-cutter to Ex- Dryer (appendix-2 and 3) ....... 36

Fig 3.1.8: FV of CRS after cutter before and after (appendix-2) ............................. 36

Fig 3.1.9: FV of cut tobacco before and after implementation (appendix-5) ......... 37

Fig 3.1.10: FV distribution after and before after implementation (appendix-5) ... 37

Fig 3.1.11: Cp and Cpk of old and new boiler. (Appendix-6) ................................... 42

Fig 3.1.12: SD of stem pressure at HT of boilers (Appendix-6) ............................... 42

Fig 3.2.1: bin to cutter layout of CRS line ................................................................ 45

Fig 3.2.2: Angle of bulk Belt (left) smoothing of Belt (right) ................................... 47

Fig 3.2.3: Feeder and CRS bin layout of four bin ..................................................... 48

Fig 3.2.4: design of cover for spillage ...................................................................... 48

Fig 3.2.5: Spillage before and after instillation of cover ......................................... 49

Fig 3.2.6: Pan design (left), stand (right) ................................................................. 50

Fig 3.3.1: Admoist inter-operational time (Appendix-10) ....................................... 52

Fig 3.3.2: CRS dryer inter-operational time (Appendix-10) ..................................... 52


XI

LIST OF TABLES

Table 3.1.1: Temperature after Ex-admoist before ................................................ 27

Table 3.1.2: Temperature after Ex-admoist after ................................................... 27

Table 3.1.3: Filling value jump (appendix 2and 3) .................................................. 35


XII

ABBREVIATION

SNPL: Surya Nepal Private Limited

PMD: Primary Manufacturing Department

SMD: Secondary Manufacturing Department

EHS: Environment Health and Safety

QUAS: Quality Assurance

CRS: Cut Roll Stem

FV: Filling Value

HT: Heating Tunnel

CTS: Cut Tobacco Storage

MC: Moisture Content

DRF: Dust removal Filter

VOV: Vibrating over vibrating

SD: Standard Deviation

Cp: Process capability

Cpk: Process Capability Index

mm3/gm Cubic millimeter per gram

cc/gm cubic centimeter per gram

kg/hr kilogram per hour

1

CHAPTER 1. INTRODUCTION

1.1 Company profile

Introduction

Surya Nepal Private Limited (SNPL) is an Indo-Nepal-UK joint venture, which started

operations in Nepal in 1986. Surya Nepal Private Limited is one of the largest private

sector enterprises in Nepal and a subsidiary of Indian Tobacco Company (ITC) Limited,

India. The balance shares are held by 17 Nepalese individuals & Corporate

shareholders and British American Tobacco (Investment) Limited, UK.

SNPL’s commitment to its corporate vision “enduring value for all stakeholders” has

been uncompromising through the years and is reflected in every product, process

and service provided by the company.

The company has been recipient of prestigious FNCCI National Excellence Award for

being the best managed corporation in Nepal and honored as most systematic

company. The company is also the recipient of various national safety and

environmental awards like British safety council award, National Safety Award and is

certified with Quality Management System Standard ISO( International Standard

organization) 9001:2001, Environmental Management System Standard ISO

14001:2004, Occupational Health and Safety Management System Standard ISO

18001:1999, Social Accountability ISO 8000:20001.

Portfolio of Business

SNPL’s business includes manufacture of Cigarettes, Safety Matches and Agarbatti in

Nepal with a total turnover of over US $175 million .

SNPL has more than 90% of Nepal’s cigarette market and is the single largest

contributor to the national exchequer of 3.5% of country’s revenue. And top

manufacturing company in tax paying. Total Number of Permanent employees

working in Tobacco division of Simara factory of SNPL consists of 47 managerial and

353 non-managerial staff. It also employee many workers on contract basis.


2

SNPL Logo

SNPL logo stands for company ethos and the beliefs

it hold true as a company. It reflects company’s

passion for quality and excellence and compelling

vision to create enduring value for all its

stakeholders.

The mountain stands for SNPL deep roots in Nepal,

and connotes a sense of solidity and permanence,

symbolic of its position as the nation's foremost professionally managed company.

The rising sun stands for leadership as well as company passion for excellence. It

encapsulates the pioneering spirit that inspires company to create and innovate

products that adhere to the highest international standards as well as create enduring

value for its stakeholders. The sun also represents the optimism that it feels for the

future, and its deep conviction that, by generating employment, earning foreign

exchange and through various CSR efforts, help create a better, brighter tomorrow for

everyone.

Fig 1.1.1: Logo of SNPL


3

1.2 Vision and Values

To be an internationally benchmarked multi-business corporation in Nepal, delighting

domestic consumers with a proud “Made in Nepal”. To be a partner in nation-building

and creating enduring values for all stakeholders.

Core Values

a. Nation Orientation

Company is aware of its responsibility to generate economic value for the nation. In

pursuit of its goals, company will make no compromise in complying with applicable

laws and regulations at all levels.

b. Trusteeship

As professional managers, employees are conscious that SNPL has been given

to us in “trust” by all its stakeholders. It will actualize stakeholder value and

interest on a long-term sustainable basis.

Highest standard of Corporate Governance – Absolute Integrity.

c. Excellence

SNPL do what is right, do it well and win. It will go the extra mile and seek superiority

in all that we undertake.

d. Customer Focus

SNPL is always customer-focused and will always strive to surpass customer

expectations in terms of value, product quality and satisfaction.

e. Respect for People

We are result-focused, setting high performance standards for themselves as

individuals and teams.

SNPL will always respect and value people and uphold human dignity.

SNPL acknowledge that every individual brings a different perspective and

capability to the team and that a strong team is driven by the variety of

perspectives within it.


4

f. Innovation

SNPL will constantly pursue newer and better processes, products, services and

management practices.

g. Corporate Governance

Corporate Governance is a systemic process by which companies are directed and

controlled to enhance their wealth-generating capacities. The governance process

should ensure that companies are managed within the applicable statutory

parameters in a manner that meets stakeholders’ aspirations and societal

expectations.

The operations of Surya Nepal Private Limited are governed by its Corporate

Governance Policy.

SNPL believes that any meaningful policy on corporate governance must provide

empowerment to the executive management of the company, and simultaneously

create a mechanism of checks and balances which ensures that the decision-making

powers vested in the executive management are not only not misused, but are used

with care and responsibility.


5

1.3 Policies and Philosophy

Environmental Policies

The company is committed to preserve environment by taking the following proactive

measures in its activities.

Company with all applicable national environmental legislations, regulations

and EHS guidelines and will endeavor to go beyond compliance over a period

of time.

Practice pollution prevention techniques in its operations

Conserve natural resources like Energy, water by optimizing the usage.

Continuously strive to reduce waste generation and lay emphasis on reuse

and recycle of wastes.

Monitor and reduce dust level and emission in ambient air, hence strive to

offer clean and green environment to its employees, communities and

contractors.

Achieve continual improvement through regular review of Environmental

Management Systems.

Promote environmental awareness amongst employees, suppliers, and

contractors through training and communication.

Set an example of leadership of leadership in the field of Environment

Management System through adoption of Globally Acknowledged

Environment Management System.

1.2.2 Energy Policy

Surya Nepal is committed to continuously improve our energy performance in all our

activities, products and services so as to make it environmentally sustainable for

future generations.

To meet the above, they will strive for:

Energy efficient goal power distribution, fuel consumption and steam

generation.


6

Nurturing energy efficient designs and technologies for all future acquisitions,

wherever practicable.

Enhancing utilization of energy resource, updating hardware, operational

practices and employs cleaner and efficient technology as appropriate.

Recognizing efforts of our employees and their family members in energy

conservation initiatives.

Yardsticks, which drives us to monitor and improve energy performance

through periodic reviews and skill up gradation of our employees.

Trains employees to make SNPL, the pace setter in the area of energy

conservation.

Benchmark continuously our performance against the best in the world.

1.2.3 EHS Policies

To contribute to sustainable development through the establishment and

implementation of environment standard that is scientifically tested and

meets the requirement of relevant laws, regulations and code of practice.

To take account of environment, occupational health and safety in planning

and decision-making.

To provide appropriate training and disseminate information to enable all

employees to accept individual responsibility for environment, health and

safety, implement best practice and work in partnership to create a cultural

of continuous improvement.

To install a sense of duty in every employee toward personal safety as well as

that of other who may be affected by the employees’ action.

To provide and maintain facilities, equipment, operation and working

conditions which are safe for employees, visitors and contractors at the

company’s premises.

To ensure safe handling, storage, use and disposal of all substances and

materials that is classified as hazardous to health and environment.

To reduce waste, conserve energy and promote recycling of materials

wherever possible.


7

To institute and implement a system of regular EHS audit in order to assure

compliance with laid down policy, benchmarked standards and requirement

of laws, regulations and applicable codes of practice.

To proactively share information with business partner towards inculcating

world-class EHS standard across the valve chain of which SNPL is a part.

1.2.4 Quality Policy

We are committed to satisfy our customer quality product, processed and

manufactured by harnessing the potential of all people in a safe and hygienic

environment at competitive cost, and delivered on schedule. It will be our continuous

endeavor to strive for bringing in continual improvement in our quality attributes for

the benefit of customer

1.2.5 Social Accountability Policy

We are committed to implement social accountability standard in our operations

through adoption of the following:

Comply with national and other internationally acknowledged law/SA

requirements with due respect to the principle of other instruments.

Conduct operations with due regard for environments and provide a safe and

hygienic work place for each employee.

Continue sustainable development through improving social performance by

enhancing the scope of corporate social responsibility.

Respect employees and considers as valuable assets.

Communicate the policies to all employees and interested parties.

Continuously keep abreast and follow the least change that may benefits

society at large for enduring sustenance.


8

1.4 Major Department in SNPL

Primary Manufacturing Department

PMD process lamina and stem and make them suitable for making cigarette. PMD has

two line of process each for lamina and stem. Both lamina and CRS goes through

similar processing. They are conditioned (stem in ad-moist and lamina in DCCC) than

bulked in bin for 2 hours minimum. Then they are cut and passed through H.T for

expansion by steam. After that they are dried in dryer and CRS is stored in silo. Stem

is mixed with lamina after dryer in a ratio of 20:80 and flavored. Final cut tobacco are

stored in CTS bin. As per demand in SMD cut-tobacco are supplied by pneumatic

conveyer at 14+0.5 moisture.

Fig 1.4.1: Flow diagram of PMD Process

Reweight

Cutting

Conditioning

Expansion in H.T

Mixing

Drying

Mixing &

Flavoring

Storage in CTS

Supplied to SMD


9

Secondary Manufacturing Department

Final cut tobacco stored in CTS bin, are supplied by feeding and then the pneumatic

conveyer at 14+0.5 moisture to the SMD as per demand of making machines. The

making machine produce the cigarette rod of required specification and the assembler

unit of making machine assemble filter to the cigarette rod (besides the plain

cigarette). The cigarette from the making machine is transported to packing machine

via trolley and is fed to packing machine in order to produce the packets of required

specification in packer unit. The wrapper unit of packing machine adhere excise stamp

and wrap the Biaxially oriented poly propylene over the packets and seal them after

proper folding. The over wrapper machine wrap Biaxially oriented poly propylene over

the bundle of 10 or 20 packets as per the specification. The outers are then fed to

boxing room to pack the outers in the corrugated fiber cartoon boxes as per the

specification. The finished goods ready for shipment are then temporarily stored in

shipping room.

Fig 1.4.2: Flow diagram of SMD Process

CTS bin

Pneumatic conveyor

Feeding conveyor

Making machine

Wrapping machine

Packing Machine

Overwrapping machine

Central conveyor

Boxing room

Shipping room


10

QUAS

QUAS daily checks different parameters of PMD and SMD. Like moisture content and

filling value at different processing stage of tobacco along with quality ratio. Loose

end, moisture at catcher and packer, packet sealing, weight etc. of final Cigarette.

Following instrument are used for quality testing.

1. Loose end tester

2. TQM 5

Used to measure loose end of cigrattes.

Cigarettes are rotated 270 times and

gm of tobacco lost from cigarette is

calcuted.

Used to measure pressure drop and

circumference of Cigarettes.

3. STC jel- sieves

4. Humidity Cabinet

Use to calculate quality ratio of tobacco. HC maintain desired environment i.e. RH

and temperature for require amount of time.

5. Lab Gauge

6. Desnimeter


11

Displays instantaneous moisture,

nicotine, sugar and temperature

Use to measure height of compressed

tobacco.

7. Auto Hardness Tester

8. Moisture Oven

Use to test Firmness of cigarette. Fix

weight is applied for certain period of

time and deformation of cigarettes rod

is measured.

Use to evaporate moisture of tobacco.

Sample are kept at 1100C for 3 hours.

9. Water cooled Desiccator

10. Packet Seal tester

Use to absorb any moisture remaining

after Moisture oven.

Use to test sealing of packet. Certain

amount of air is supplied for 5

seconds, inside the packet and

amount of leakage is measured.

Addition to this smoke panel test cigarette after each batch of production. IPQRS is carried

out.


12

Slitting Complex

The rejected cigarette from SMD after sorting goes to slitting complex. After sitting

only tobacco is added back in PMD after lamina dryer as smalls.

Filter manufacturing department

Filter rod used in filter cigarette are manufacture in this section. Filter rod are made

from the fiber called acetate to. Two machines makes different size filter for king size

85mm and regular size 70mm cigarette

Fig 1.4.4: Flow diagram of filter making

Cigarette Feed

Sieving

Slitter

Sieve

Smalls

Sand Paper/filters

Added back to PMD after Lamina Dryer

Fig 1.4.3: flowing diagram of slitting process

Raw material

Blooming

Application of plasticizer

Wrapping in PWT

Garnishing and Cutting

Collecting

After quality inspection displaced to SMD


13

1.5 Products of SNPL

Surya Nepal Pvt. Ltd, Simara, business is all about manufacturing and marketing of

cigarettes.

Major cigarette brand of Surya Nepal are:

Bijuli

Chautari

Pilot

Khukuri

Shikhar

Surya

Surya 24 Carat


14

CHAPTER 2. PROJECT AREA INTRODUCTION

2.1 PMD

PMD receives dries leaves (lamina) and stem from leaf Department at MC of 9-11.

There is separate processing unit for stem and lamina one each. Final cut tobacco is

stored in bin and delivered to SMD at 14.5+ 0.5 MC.

Lamina processing is describe as below

a. Receiving of leaf

After leaf are issue for processing they are reweighted and send to bale turning device.

b. Bale Tipping Device (BTD)

Bale of 150 kg and 200kg of leaf are fed to the BTD through roller conveyer. Upper

side of bale of bale is open manually and bale is fed to BTD. BTD rotates bale at 1800.

And other side of bale is open manually. After that bale are passed to slicer through

belt conveyer.

c. Slicer

The bale slicer divides dry compressed tobacco bales into the form suitable to

conveyed and fed directly to DCCC. Slicer cut bales into 3pieces i.e. 2 cut for 150kg and

4 pieces i.e. 3 cut for 200kg.

d. DCCC ( Direct casing and conditioning cylinder)

Conditioning is achieved by 2 mechanism occurring simultaneously within the DCCC

process. Conditioning by condensation and direct moisture addition from water

sprays. Condensation process is controlled by regulating the dry bulb temperature of

air flow. Air flow is co-current with product flow. An automatic temperature controller

compares the temperature set point with actual value and output.

Water and Casing are sprayed in atomizes form to prevent spot formation.

Atomization is done by steam.

e. Lamina Bin

Conditioned lamina are arranged in layer across the length of bin. At least two grade

of each grade of tobacco is made in bin. Minimum of two hours of bulking is done.


15

Reason for bulking

Homogenous mixture of grades in a blend.

Uniform moisture content of blend before lamina cutting.

f. Airlift

Conditioned tobacco from bins is discharged into VOV (vibrating over vibrating) which

transfers it to the air leg of the airlift.

Reasons for Airlifting

to separate foreign material stone metal present in the leaf before feeding to cutter.

g. Sieve Complex

It is use to separate small lamina particles (through< ¼”). These small particles are

separated to reduce dust formation in cutter as it is already small and need not to be

cut. The particles coming through ¼ sieve is added back to lamina after cutter.

h. Lamina cutter

Cutter consists of two sections, a packer/feeder and a cutter. Transport chains convey

tobacco to the mouth piece. The mouth piece is forced down to tobacco by constant

force. This force is called cheese pressure. As the tobacco leaves the mouthpiece, it is

cut by the rotating knife drum. A grinding device, which moves as long the axis to and

fro parallel to the knife drum constantly sharpens the knifes. Cutting width can be

adjusted by changing the speed of the transport chain.

Lamina is cut at 30 CPI and 18KN cheese pressure.

i. Weigh conveyer

Weighcon measures and set the flow rate of tobacco passing through it. It is essentially

a band conveyer with load sensor. Before weighcon a Gravity feed pipe is provided.

With a variable speed machine, the band speed is automatically regulated through

control loop so that the actual flow rate along the band coincide with the present

desired flow rate.

j. Lamina Drying

The purpose of lamina drying is to expanded the lamina and reduce incoming moisture

to desired moisture level.


16

It consists of two unit.

i. Heating tunnel

HT is used to for expansion of tobacco particles by application of free steam. Steam at

a pressure is released through small holes creating a high velocity. Cut tobacco is made

to float on thus loosening the product. The final temperature of product leaving steam

is about 95oc.

ii. Dryer

It is used to dry cut expanded lamina uniformly preserving gain in expansion.

Process

The high temperature and high moisture cut tobacco comes in contact with high

volume and heated process air at a particular set temperature. Flash drying by

evaporation takes place initially there by preserving the pre-expanded cut tobacco.

Subsequently, the steam jacketed paddles and steam heated paddle blades transfer

the heat to the cut tobacco thereby driving water particles lamina. The process air get

gets more water for evaporation and evaporates, there by cooling the product. The

shell rotates repeating the process to desired label.

Feedback

The deviation of output mc from desired level is measured and cylinder wall

temperature changed by changing steam pressure.

k. Mixing and flavoring

CRS from bin is added to lamina after dryer at the ratio of 20:80. Than product is fed

to flavoring cylinder. Flavor are aromatic materials added to final tobacco. A weighcon

before the flavoring cylinder gives the input tobacco flow and flavor is sprayed

accordingly as per blend setting. Atomized flavor are sprayed while rotating the

cylinder.

l. CT bins

Purpose of CT bins is to achieve a homogenous mix of lamina with CRS/ Add backs and

keeps Inventory for SMD. Humidity is maintained at CT bin at 65+5 with Jet spray

nozzle.


17

Lamina Line

Fig 2.1.1 Lamina processing flow Diagram

Leaf Receive

Reweight

Airlift

Sieving

Blending /Bulking

Bale Opening

Slicer

Conditioning & Casing

Sieving

Mixing & Flavoring

Cutting

Drying

Heating Tunnel

Storage (CTS)

Sieving Complex

Dust

Dust/Sand

Dust/Sand

Smalls Cut Stem

PMD

DRF

Thro

ugh

5/1

6”


18

CRS Processing line is described as below

a. Stem feed:

Stem CFC is fed to the twin band conveyor where top side is opened and inspected.

The open cfc then goes to stem tipper where it is lifted and tipped towards the hopper

at an angle of 1600 .Hopper can hold up to 6-7 CFC of stem and it feeds to the discharge

VOV, sieve VOV, fast moving band, airlift, GFP, metering band and finally to admoist.

b. Admoist:

In Admoist moisture is addition and absorption. This process is facilitated by

Condensation, Water addition, tumbling effect.

Conditioning process:

GFP and weighcon is used to give uniform supply to admoist. The stem entering

through the feed end is hit by steam sprays from the central large pipe. The steam

spray adds moisture by condensation and also increases product temperature. The

atomized water sprayed from the top enables water particle deposition on the

tumbling stems. Since the stems are being continuously tumbled in steam and water,

absorption takes place mainly due to capillary action from the ends.

c. Stem bins:

After conditioning the stem is stored in stem bins to bulk condition stems i.e. uniform

moisture across the layer.

d. Stem cutting:

Cutting principle is similar to lamina cutting where inlet MC is 38±2% and cutting speed

is increased to 160 CPI for stem.

e. Heating tunnel

The cut stem now move towards the HT where it comes contact with high pressure

steam for expansion which is important to increase the FV.

f. CRS drier

The purpose of drier is to dry cut and expanded tobacco to required moisture

preserving FV again. CRS dryer is similar to Lamina Dryer.


19

g. Classifier

Tower classifier is used to separate improperly cut stem (heavies) from good CRS.

After drying, the CRS is fed to classifier through a VOV. A VOV delivers an evenly

distributed carpet of CRS from the dryer to the winnower. The action of winnower is

to gently throw the incoming CRS to thin air which is moving upwards to the top in

direction of suction. The heavy particles that falls down are called heavies and these

heavier particles are further separated in a mesh where smaller heavies are rejected

and held over mesh is reprocessed. The CRS is transferred from classifier to CRS bin

through air lock/VOV.

h. CRS bin

The purpose to store expanded cut stem after drying and classification ready for add

back to main blend.

i. Mixing and Flavoring

CRS from bin are added to lamina after dryer and flavored along with lamina and

stored in CTS bin.


20

Stem Line

Fig 2.1.2: Stem processing flow diagram

Bale Opening

Airlift

Sieving

Bulking (Silo)

Conditioning

Cutting

Heating Tunnel

Drying

Sieving

Classifier

Storage (CRS bin)

Dust

Dust/sand

Winnowing

Heavies

PMD

DRF

Mixing & Flavoring Storage (CTS bin)

Cut Lamina


21

CHAPTER 3. PROJECTS

Following are the projects I carried out during my internship period.

1. Research and data Analysis

a) Admoist protocol Test

b) Increase the filling value of surya

c) Cp & Cpk of CRS dryer

2. Problem solving

a) Maintain the feed gap in CRS cutter

b) Decrease the Spillage at product bin area

c) Design of Pan for Sampling at HT and stand for Serrico Trap

3. Optimization

a) Optimization blend change time

3.1 Research and Data Analysis

Admoist Protocol Test

a. Scope

Admoist at SNPL is newly purchased. For any newly purchased machine protocol has

to be tested, in order to verify that machine has been installed correctly and machine

is operating at proper setting as per manufacture clam. Protocol of admoist was

Tested before but few point of protocol failed i.e. S.D of M.C<0.5, Mean Moisture is

within range of 38±2. I was assigned to find out the causes of protocol fail and take

more data after adjustment had been made.

Filling value is always measured in mm3/gm.

Moisture content in % throughout the report


22

b. Introduction

Before stem are cut its moisture content have to be increase from 11±2 to 38±2 as

stem at low moisture are brittle, the process of increase moisture is done by

conditioning. Conditioning is the process of spraying steam or water in dry stem or

lamina to expand them to their original form. Conditioning can be done by two

method hot and cold. In hot condition steam is sprayed over stem in closed chamber

at fixed temperature and pressure and for certain time (as per the standard protocol

of company). And in cold conditioning water is used instead of steam. This help stem

to gain moisture which they lost during drying. Conditioning helps in smooth cutting

and better expansion of CRS on heating tunnel. For cold conditioning stem has to be

bulked for 12 hours and for hot conditioning 2 hours. Bulking is the process of keeping

stem/lamina in a container so that moisture content is uniformly distributed among

them. The machine used for stem conditioning in SNPL is known as admoist.

Admoist raise both moisture and temperature of product, whilst achieving complete

penetration of conditioning throughout the cross section of individual particles.

Admoist can be used for addition of casing or other additives which is combined with

the conditioning process or for heating stems prior to rolling.

c. Principle

Product is conveyed through the Admoist by the action of multi-bladed rotor,

supported within a U shaped trough. The center of the rotor is a perforated tube,

supplied with low pressure steam via a rotary union. At intervals along the length,

atomized water sprays are directed at the product above. Through penetration of

moisture is achieved by the combination effect of steam percolating from the rotor

spray pipe, together with the finely atomized sprays from above. Through mixing is

achieved by means of gentle tumbling action, which ensures that faces of all particles

are continually being presented to the steam and water sprays.


23

d. Specification

Flow rate (inlet): 1500kg/hr.

Flow rate (outlet): 2175kg/hr.

M.C. (in): 10-12.5%

(out): 38%

Paddle diameter: 0.9 m

Trough Length: 4.5 m

Angle of inclination: 50

Paddle Rotation: 5.13 rpm

Rotation: Clockwise in direction of product flow

e. Objective

To collect data to Test required protocol

To analysis the previous data and find out the possible cause of protocol

failure.

To finding the solution for causes.

f. Methodology

Data of 30 Operation was analyzed. 10 Samples of each operation was taken after CRS-

cutter and its moisture content was tested. Additional 10 operation was tracked after

making necessary adjustment. Addition to this CV of mass flow was analyzed using

data log of weighcon.

Data collected were analyzed using scatter diagram. In order to pass the protocol out

of 30 operation, S.D of at least 29 operation should be within specification limit of <

0.5, moisture mean should be within 38±2 and S.D of input weight variation < 0.5%.

g. Finding

From observation and analysis of data collection following fish-bone diagram was

constructed to find the possible cause moisture variation.

Most important factor in determining MC after Ex-cutter was found to be amount of

steam consumed and uniform flow of raw material.

24

Moisture Content

variation in cutter

above 0.5

Raw material

Machine

Method Mother Nature

Man

Length

Size distribution

Intrinsic Property

Moisture Content

Type

(cold or hot)

Bulking time

Temperature

Power failure

Humidity

Sampling

Method

Measuring Instrument Least count Amount of

Material

Supplied

Calibration Uniformity of filling

Uniformity of water, raw

material and steam flow

Fig 3.1.1: Fishbone diagram of factor causing M.C variation after ex-CRS Cutter


25

h. Result

Fig 3.1.2: S.D chart of moisture variation after Ex-cutter (Appendix 1)

Fig 3.1.3: Mean Moisture after Ex-cutter (appendix 1)

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0 5 10 15 20 25 30 35

S.D

Operation

S.D Chart of Moisture

35.50

36.00

36.50

37.00

37.50

38.00

38.50

39.00

39.50

40.00

0 5 10 15 20 25 30 35

M.C

%

Operations

Moisture Mean


26

Fig 3.1.4: Coefficient of Variation of weighcon Weight (Appendix 1)

i. Discussion

Only one operation SD of moisture content was found to greater than 0.5, all mean

value was found to lie between 38±2. The process Cp was found out to be 2.2 and Cpk

0.98. Which proves that system is capable. Low value of Cpk is was observed due to

shifting of mean value toward lower limit. The main reason for that was observed to

be “MC after Ex-cutter is very high, so it losses it moisture rapidly. Due to this if sample

where kept for longer time in QUAS before taking weigh in tin than there moisture is

found out to be low”.

In some cases flow of HVM Stem were found to be non-uniform. Cause of this non-

uniformity was larger and variable thickness of stem in this grade. Longer steam

occupies larger volume but has less mass so even when weighcon speed is 100 % and

there is product in GFP, criteria for mass is not met.

No future action were required as S.D < 0.5 and mean value between 38±2.

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

0 5 10 15 20 25 30 35

Coefficient of variation of weighcon Weight


27

j. Further observation made during internship

Due to low FV of CRS from regular interval in QUAS daily report after 17 aswin.

Temperature of product at 1 meter distance from outlet of admoist was checked. It

was found that temperature was higher than desired temperature.

S.N Temperature 1(0C) Temperature 2 (0C) Temperature 3(0C)

1 76 77 78

2 78 78 77

3 77 76 77

Table 3.1.1: Temperature after Ex-admoist before

I Cause

Failure of Pressure reducing valve to maintain set pressure of 0.3-0.4 bar. Line

pressure was changing as per main line pressure variation.

II Solution

Main line pressure was decrease to 5bar from maximum pressure by boiler i.e. 7-8

bar.

III Result

Temperature 3 samples of 3 operation was tracked result are as flow

S.N Temperature 1 (0C) Temperature 2 (0C) Temperature 3(0C)

1 71 69 70

2 69 71 71

3 70 71 70

Table 3.1.2: Temperature after Ex-admoist after

k. Recommendation

The temperature after ad-moist should be check in regular interval of time i.e. 1week.

Moisture deviation after cutter should be checked daily. (MC and its SD is checked by

QUAS daily and recently after implementation of PPQRS temperature is also checked

daily)


28

Increase the filling value of Surya Tobacco

a. Scope

This project mainly focus on way to improve the filling value of Surya blend. Filling

value of tobacco depends on various individual process used in processing, aside from

its own intrinsic property. Various process like cutting, expansion, storage effect the

filling value of blend. I was assigned to this project to find out effect each process have

on FV so that further action can be taken for improvement of process.

b. Introduction

Filling power is define as the ability of a unit weight of the material to occupy space.

Filling power is intrinsic property of material. It is measured in mm3/gm or cc/gm.

Firmness is define as a cigarette rods resistance to compression. Each Manufacture

established an internal standard of firmness of his cigarette brand. One of studies

conducted by (Wong and Wilson, 1976) concluded that the relationship between

cigarette firmness, in term of weight savings, and tobacco filling power was highly

significant (r=0.83). Other researcher also support this facts. To illustrate: The effect

of Filling value and cost , Assuming a finished blend cost of Rs.600 per kg, a 4 percent

increase in bland filling power will save manufacturer approximately RS 1.02 crore per

billion of cigarettes sold. Considering average weight of cigarette of 850mgms per

cigarette. (Semfield, 1973)

Filling power of tobacco has great economic important in tobacco industries as well as

affects every parameter of final cigarettes produce like losses end, firmness, density,

burning rate etc. Filling power of tobacco varies with varieties of tobacco leaf and even

within different part of same leaf. Steps in primary manufacturing of cigarettes and

effect on tobacco filling power of both stem and lamina (filling power are measured

after sample are kept in humidity cabinet and maintained around 14 percent)


29

a. Conditioning Increase in filling value due to expansion

b. Cutting Increase FV due increase in gap between two tobacco

pieces

c. Heating Tunnel Increase in FV due expansion by steam

d. Drying Decrease in FV due to contraction of cell and breakage

e. Mixing Change in filling value as per percent of mixture

The loss or gain of moisture or other volatiles, the physical state of the tobacco, and

the addition of casing materials and humectants all affect tobacco filling power during

handling. Changes in filling power due to moisture gain or loss are reversible whereas

the other changes are not. Thus, a cigarette left in a high humidity room will soften

considerably due to absorption of moisture but will regain its firmness if moved to a

lower humidity area. As tobacco loses moisture, it also becomes more fragile; i.e., it

tends to break more easily. This property is known as fragility. Unfortunately, fragility

is generally directly related to filling power; i.e., the higher the filling power the greater

the fragility. Because of the sensitivity of filling power to changes in moisture content,

its measurement must be performed under carefully controlled conditions of relative

humidity and temperature. Even under the most carefully controlled humidity

conditions, however, moisture correction factors may have to be applied to correct

for small and inadvertent changes in relative humidity.


30

c. Methodology

For the baseline data, five operation were tracked. Sample of CRS from Ex-cutter, Ex-

H.T, Ex-bin and Lamina. Ex-Cutter, Ex-H.T, Ex-Dryer sample were kept in humidity

Cabinet for 2day and 1day respectively and their filling value was calculated using

densimeter and MC. Densimeter consist of graduated cylinder of radius(R) with a

closely fitting plunger and weight. The procedure for measuring height is a known

weight i.e. 20 ±0.05 gm. weight is place in cylinder and plunger is inserted into cylinder

gradually weight of 3 kg is applied. After 30 sec height (H) of plunger is measure from

based of cylinder .

Volume occupied by sample= πR2H.

Filling value = volume* moisture correction factor.

These data were analyzed to find the pattern, in order to find the main cause of low

filling value. Different research paper from BAT, American Tobacco, Phillip Morris,

imperial Tobacco etc. Were studied to find way to increase filling value. After making

necessary change again data of addition 10 operation were tracked.

Total of 15 operation were tracked and about 500 samples were taken. Additional data

were taken from daily report of QUAS.

Scatter plot and bar graph where used to compare between two data.


31

d. Finding( Research )

Virginia tobacco have high sugar content. Higher sugar content increase the

equilibrium moisture content. Hence they have lower filling value. (Taylor,

1976)

Filling value is very sensitive to moisture change. Some research argue that

1% change in moisture will cause 10% change in FV.(Akehurts, 1968) other

have conclude that that 1% change in moisture will cause 4% change in FV.

(Semfield, 1973) correction factor used at Surya Nepal show that 1% change

in moisture causes 6.5-7.5% change in FV.

Filling power is the function of fragility. So more filling value does not always

mean more economic importance. More suitable factor is filling power index.

For example, assume that the fragility of tobacco "A" is 0.06 and that its filling

power is 4.0c.c. /gm. Assume that tobacco "B" has a fragility of 0.01 and a

filling power of 3.9 c.c. /gm. In this case a fragility of 006 would mean a 6

percent 10ss during handling and processing and 0.01 would mean a 1

percent loss. The "economic filling power index" of "A" would be 4.01 1.06 or

3.78 c.c. /gm. The economic filling power index of "B" would be 3.9/1.01 or

3.86 c.c. /gm. Thus "A" would be less desirable although its filling power is

greater - assuming, of course, that the price for both is the same. (Semfield,

TJI, 354, 4/80)

Type of dryer has vast impact in filling value. Counter flow dryer are better

than co-flow. Their in fv is bewteen 0 to 3.6%. Hot air with cool tobacco is bad

as they may cause tobacco to dry at inlet zone and cause tobacco praticle to

attach with each other. (Gibb, 1962), (Pedersen , 1990).

Regarding fiber length different researcher have different point of view

(Wochnowski, 1989) said fiber length effect up to 11% in filling value.

Some researchers concluded that 32 is best CPI for lamina. (Semfield, TJI, 509,

6/80). Other concluded that 24 cut are best. Lower cut is supported by the

fact that as width increase apparent density decrease and practically fragility

decrease increasing filling value. Lanore(1945) has emphasized this influence,


32

estimating that an increase in the width of the cut equal to 0.1 mm would

allow the optimum weight to be lowered by 1.6%. More recently, Kamachi, &

co. (1965), Flesselles(1966), have confirmed this observation but evaluate this

effect at a level between 1.3 and 3%. Sharpness of blade play important role

in filling value. Since the apparent density decreases by about 8% when the

cutting angle decreases by 10 degrees. For a given cutter, it is therefore of

importance to watch the quality of the sharpness, and thus to maintain a

sufficient rate of advance in the mill. A well sharpened blade makes possible

a cleaner cut and hence a better particle size distribution. And higher

temperature cause deformation on strands. So low cutting temperature is

preferred. (Pietrucci, 1974)

FV of tobacco on average reduce by 1% for each 1 oC increase in temperature.

Best CRS HT steam pressure is 5bar. (Wochnowski, 1988).

Longer stem expand more than shorter stem due to pressure drop.

Reconstituted tobacco can be made from dust, residues, stem and added back

to lamina. As reconstituted tobacco have higher filling value than dust. (De

Grandpre, 1887)

Temperature 85 0F at 21.5 % MC of tobacco is best environment for cutting

(Drake, 1975), if temperature is increase 90-95 there is 0.6-1.2g/cc loss in

filling value. Or else MC of 22-22.5% at 110 0F to 115 0F is best for cutting.

(Philip Morris, 1984)

Factors effecting filling values

Type of Leaf

Admoist temperature

Bulking time

Conditioning type

Temperature of cutting

Cheese pressure of cutting

CPI of cutting

Angle of cutting

Sharpness of cutting

Moisture at cutting

Steam pressure at H.T

Steam ratio at H.T

Moisture before drying

Type of dryer

Flavoring and casing

Moisture at measurement

Temperature at

measurement


34

e. Finding ( Data collection and analysis )

F.V after Ex-cutter was below average below only 4.2 cc/gm.

Expansion from cutter to H.T of both lamina and CRS was with in speciation

limit

CPI of Cutter was below average i.e. 139 and non-uniform

Steam pressure of CRS H.T could be increase

Cheese pressure was set it 18 KN, Cheese pressure could be decrease for

Surya

f. Implementation

Calibration of Cutter was carried out. CPI of cutter increase from 130 to 166

and cutting was more uniform.

Steam pressure of CRS H.T was increased from 4 to 5 bar.

Cheese pressure of lamina cutter was reduce for NG to 15KN.

As far as possible NG was cold conditioned.

Temperature of damper of Lamina dryer was decrease.


35

g. Result

Filling value jump between process were as show below

Table 3.1.3: Filling value jump (appendix 2and 3)

CPI of cutter before and after maintinance

Fig 3.1.5: CPI of cutter before and after (appendix-4)

Product Process from to Jump Percentage

CRS Cutter to H.T 22.28%

cutter to Bin 13.46%

Lamina Cutter to H.T 15.10%

cutter to Dryer 8.10%

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0 10 20 30 40 50

Wax Thickness(Before) (mm)

139

166

0

20

40

60

80

100

120

140

160

180

Before After

Cu

t p

er in

ch

0

0.05

0.1

0.15

0.2

0.25

0 10 20 30 40 50

Wax thickness(After)(mm)

Fig 3.1.6 Wax Thickness Before and after (appendix-4)


36

Expansion Percentage from Cutter to Dryer

Fig 3.1.7: Percent expansion from Ex-cutter to Ex- Dryer (appendix-2 and 3)

FV before and after calibration of cutter

Fig 3.1.8: FV of CRS after cutter before and after (appendix-2)

13.62%

8.11%

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

16.00%

Ex-cutter to Ex-bin Ex-cutter to Ex-Dryer

CRS Lamina

Percentage Jump

42.03

44.07

41.00

41.50

42.00

42.50

43.00

43.50

44.00

44.50

Before After

Filli

ng

Val

ue

(mm

3/g

m)

F.V after Ex-cutter


37

Filling Value of final Cut- Tobacco (average of 40 Days before and after

Implementation of findings from QUAS Daily Report)

Fig 3.1.9: FV of cut tobacco before and after implementation (appendix-5)

Fig 3.1.10: FV distribution after and before after implementation (appendix-5)

47.78

49.15

47.00

47.50

48.00

48.50

49.00

49.50

Before After

Filli

ng

Val

ue

mm

3 /gm

Filling Value Cut Tobacco

0

1

2

3

4

5

6

7

8

9

10

11

46 47 48 49 50

freq

uen

cy

Filling Value

Before

0

1

2

3

4

5

6

7

8

9

10

47 48 49 50 51

freq

uen

cy

Filling Value

After


38

h. Discussion

Clean cut and uniformity of cut is very important for filling value. After calibrating

cutter cuts were more uniform and CPI was near the SOP. Due to which filling value

increased by 4%.

Increase in stem pressure cause increase better expansion of CRS due to higher ratio

of stem and vapor.

Cheese pressure at cutter compress the tobacco for cutting. But this compression can

result in decrease in FV as more high pressure may cause leaf to lose their elasticity.

Due to this lamina will not expand properly at HT. Chesses pressure is set high for

domestic blend which have high filling value, but for surya even 15KN cheese pressure

is enough. At ITC 14 KN is used.

Higher temperature at dryer can cause case hardening of CRS which are added back

after lamina dryer due to thermal sock. Temperature of Lamina Dryer outlet was

decrease with from 650C to 610C.


39

i. Recommendation

As sharpness of bland and angle of cutting has drastic effect on filling. Cutter

cutting should be checked daily.

Cheese pressure should be reduce to 15 KN for NG during each operation.

Steam pressure should be check for uniformity random during operation.

j. Further scopes

Optimization of steam to tobacco ratio.

Experiment with CPI of both lamina and cutter.

Experiment with flow rate, amount and temperature of air at dryer


40

Cp & Cpk of CRS dryer

a. Scope

In order to find out if system is capable of producing product in give specification limit,

it capability should be checked. This is done by calculating process capability (Cp) and

process capability index (Cpk). I was assigned to calculate Cp and Cpk of CRS dryer.

b. Introduction

The ability of a production process to meet or exceed preset specifications is known

as process capability. Specification often called tolerances, are preset ranges of

acceptable quality characteristics, such as output moisture for dryer. For a product to

be considered acceptable, its characteristics must fall within this preset range.

Otherwise, the product is not acceptable. Product specifications, or tolerance limits,

are usually established by design engineers or product design specialists. In cause of

drier it is output moisture should be within the tolerance limit of set value + 1.

Cp is valuable in measuring process capability. However, it has one shortcoming: it

assumes that process variability is centered on the specification range. Unfortunately,

this is not always the case. So Cpk is used to measure when mean has deviated from

central position.

c. Objective

Collected data of all input parameter at CRS dryer.

Calculate Cp and Cpk of CRS dryer.

Find the cause of lower value of Cp and Cp. if value are low.


41

d. Methodology

Moisture of input and output tobacco were taken in interval of each 100kg passes

through weighcon after tail in. Total 10 data of each operation was tracked. Standard

deviation of these data were calculated and follow formula where use to calculated

Cp and Cpk.

𝐶𝑝 = (𝑈𝑆𝐿 − 𝐿𝑆𝐿

6𝜎)

𝐶𝑝𝑘 = min(𝜇 − 𝐿𝑆𝐿

3𝜎−𝑈𝑆𝐿 − 𝜇

3𝜎)

Where

𝜇 = the mean of the process

𝜎 = the standard deviation of the process

USL= upper specification limit

LSL= lower specification limit

Cp = 1: A value of Cp equal to 1 means that the process variability just meets

specifications. We would then say that the process is minimally capable.

Cp < 1: A value of Cp below 1 means that the process variability is outside the range of

specification. This means that the process is not capable of producing within

specification and the process must be improved.

Cp >1: A value of Cp above 1 means that the process variability is tighter than

specifications and the process exceeds minimal capability.

Cpk = 1: A value of Cpk equal to 1 means that the process is just capable meets

specifications.

Cpk < 1: A value of Cpk below 1 means that the process is not capable to meet

specifications.

Cpk >1: A value of Cpk above 1 means that the process is more than capable to meet

specifications.


42

e. Result and discussion

It was found that Cpk value was greater than 1 when new boiler was in operation. But

during old boiler operation steam pressure to dryer and HT was largely variable so SD

of output moisture was also high due to which Cpk value was below 1.

Fig 3.1.11: Cp and Cpk of old and new boiler. (Appendix-6)

Fig 3.1.12: SD of stem pressure at HT of boilers (Appendix-6)

0

0.5

1

1.5

2

2.5

3

3.5

1 2 3 4 5 6 7 8 9 10

Old Boiler | | New boiler

Cp and Cpk of CRS dryer

Cpk

Cp

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 1 2 3 4 5 6 7 8 9 10

Old Boiler | | New Boiler

SD chart of Steam pressure at HT


43

After interviewing with boiler operator it was found that old boiler was used only few

days in month so no action were taken.

It was concluded that CRS Dryer was capable of producing in given specification limit.

No action were required.


44

3.2 Problem solving

Maintenance of Feed gap at CRS cutter CFP

a. Scope

In order to maintain constant flow of product at CRS cutter, product level at GFP

should always be visible. But some of time, product at GFP of CRS cutter is empty. This

causes non-uniform flow of stem to cutter which may result in uneven cutting and

increase winnowing stems. I was assigned to this project to find causes and solution.

b. Introduction

GFP maintains the level of product within reasonable limit for continuity flow of

product. GFP consists of 3 senor photo sensor.

First sensor: if product falls this limit belt below it stop it so product level can be

increased.

Second sensor: after second sensor detect the product, than belt conveyer below GFP

starts. And if product level fall below this sensor conveyer above GFP starts.

Third sensor: when product reaches this sensor it sends a signal to stop product flow

to GFP.

Only second and third sensor are present in GFP at CRS cutter. Speed of belt conveyer

can be control using Variable frequency drive.

c. Finding

There is start time difference between VOV (2) and bin belt Conveyer (1) i.e. of

5 Sec. This cause big gap up to 3meter between stems at VOV as demand can

vary from 1sec to 4sec too. During this time VOV (2) is started and product will

move forward but stem from bin conveyer will not fall causing gap.

There is start time difference between VOV (4) and belt conveyer (3) i.e. 1 sec

this also helps to increasing gap between stem at feeder.

Speed of belt conveyer(6) below feeder is high, so even if steam are filled

above second sensor and there is demand GFP is emptied in 1sec before even

stem from VOV(4) can supplied to GFP.


45

Fig 3.2.1: bin to cutter layout of CRS line

d. Implementation

Start time between bin belt conveyer and VOV was decreased to 1sec by

replacing delay switch.

Belt conveyer (6) speed was changed between 8 between 20 to find optimized

speed for all grade of stem. By hit and trial, it was found that best speed for

VSN5/VSN5MY was 12.5±0.5, and for HVM was 15±0.5. Higher speed for HVM

was due to larger size HVM stem which occupy less height when compressed.

e. Result

There is no any gaps between stem in conveyers during whole operation.

Product at feeder is visible 98% of total time of operation. It couldn’t be made

to 100% as motor starts at 40 and take a 1.5 seconds to sync to set speed. So

if product level is just above second senor when motor starts feeder is emptied

due to high speed of belt conveyer.


46

Proposed solution

Increase tube size to 1.5m.

Increase diameter of tube.

f. Further action required

Speed of belt conveyer should be changed after change in grade of stem supplied.


47

Wastage reduction at product bin

a. Scope

Due to misalignment between belts, installation faults or dislocation of parts there is

lot of spillage of cut tobacco at product bin. Spillage causes increase need of man-

power, increase foreign particle mix with cut tobacco as spillage tobacco is mixed back

by sweeping the floor, blockage of conveyer, increase dust level at CTS area.

b. Introduction

Conveyer are used to transport cut tobacco from bin to feeder of respective blend.

Each bin has vibrating conveyer and at least one belt conveyer to supplied CT to

feeder. CT at feeder of bin 3 and 4 are supplied by three belt conveyer, after vibrating

conveyer. But all tobacco from belt conveyers are not transferred from conveyer a to

b. Tobacco starts accumulating at belt of c and causes jam of whole system.

c. Finding

Problem 1

When tobacco is transported by belt conveyer a to b due to misalignment of belt and

roller. Some tobacco is not transferred from a to b but carried by belt, this carried CT

is spilled at floor.

Problem 2

Belt conveyer c of is dislocated. The surface have bulk at angle of 100. And due to

misalignment of belt from central position, left end of belts surface is smoothen due

to friction between roller and belt. Because of these two reason tobacco slowly start

accumulating at bottom left side of belt and cause jam of whole feeder system over

period of time. Which causes lot of spillage. And also lower part of belt doesn’t have

chute so tobacco are spilled.

Fig 3.2.2: Angle of bulk Belt (left) smoothing of Belt (right)


48

Fig 3.2.3: Feeder and CRS bin layout of four bin

d. Solution

Problem 1 a cover was design as below and attached at top of belt conveyer, so

that spillage tobacco will fall in cover and then to belt conveyer (b). Detail design is at

(appendix-7).

Fig 3.2.4: design of cover for spillage

Problem 2 Chute was installed at bottom of conveyer c and belt surface was made

flat.


49

e. Result

Problem 1: Spillage was reduce to zero Kg per day.

Fig 3.2.5: Spillage before and after instillation of cover

Problem 2: Jam problem was reduce at conveyer from average of once per day to 1-2

times a week.


50

Design of pan for HT sampling and stand for Serrico trap

a. Scope

For PPQRS, sample from HT has to be taken. As temperature of product at HT is very

high i.e. 900C even gloves is not enough to collect sample. So I was assigned to design

a pan to facilities for sampling.

In order to hanging serrico trap at different point in factory, stand was required.

b. Solution

Pan and stand as following was designed. Detail of design is at appendix 8 and 9

respectively.

Fig 3.2.6: Pan design (left), stand (right)


51

3.3 Optimization

Optimization of blend change time of CRS line

a. Scope

Operations have time gap between each other. This time gap has to optimize such

that no mixing occur and minimum time is lost in idle of machines. Standard for this

time gap is already assigned experimentally before. I was assigned to observe if

ongoing time gap is optimized or not and make necessary changes in time gaps.

b. Introduction

When operation has to be changed like Surya blend has to operate after khukuri blend

there has to be certain time gap between these operations so that these two blend

doesn’t mix up. This time has to be short as far as possible.

When cutter finish cutting, it takes certain time for that CRS to reach HT and come out

of dryer. So when cutter finishes cutting last blend at has to be stop for some time,

this time is known as blend change time. When operation starts, it also takes some

time to reach HT during this time pervious operations dryer should be emptied.

c. Methodology

8 operation were tracked from bale opening to CRS bin. Time for each stage of process

where calculated. After making necessary adjustment additional 4 operation were

tracked to verify the implementation.

d. Finding

Total time emptying CRS dryer was taking longer time than SOP. It was observed that

tail out time was not enough, extra 4 minutes were required to empty dryer.

e. Action taken and Result

No action was required at admoist as average cycle of admoist was only 40 minute

and there was always surpass time.

Speed of tail out was changed from 16 rpm to 18 rpm which cause Inlet to outlet time

at CRS dryer decrease from 690sec to 630sec.

Standard procedure for blend change was made as follow:


52

Fig 3.3.1: Admoist inter-operational time (Appendix-10)

Fig 3.3.2: CRS dryer inter-operational time (Appendix-10)


53

Inter operational time

For admoist 480 seconds. Bin change time after operation is started is 120

seconds.

For CRS dryer 7:30 minute. Bin change time after start of cutter is 180 seconds.

(Inter-operational time for CRS dryer is taken after GFP is empty. As time

required for tobacco to reach GFP from cutter at end of operation can vary from

40 sec to 240seconds)

For CRS dryer intern-operational can be made to 6 minutes as without

mixing two blend as dryer inlet to outlet time for inlet tobacco at start of

operation is 6mins. Bin change time after start of cutter in this case is

330seconds.

f. Further scope

Standard tail out time of CRS dryer is 8 minutes but real tail out time observed was

10:30 minute. This time can be decrease by increase speed of air during tail-out or

increase ahead start of tail out after 15seconds of tobacco inlet at end of operation,

this time is 45 seconds now.


54

CHAPTER 4. CONCLUSION

During these Three month of OJT, I got an opportunity to learn about real industrial

working experience and apply theoretical knowledge gained during my study to real-

life problem at industries.

Project on research and data analysis made me familiar with basic of data collection

along with way to find a pattern and data. Research on filling value provide

opportunity to analysis complex process by breaking down into them into multiple

individual steps. So that we can find out which single process is causing the problem.

Problem solving project made me familiar with common problem faced by company.

These project help me to understand basic cause of any problem and to find it best

solution out of lot of alternatives.

Optimization project made me familiar with bottleneck and cause of time lost during

processes. And think creatively by breaking down complex process, so that each

process can be optimized for overall increase in productivity.

During my project period through my and combine effort of PMD team, filling value of

surya was increased by 3%, admoist protocol was passed, three design were presented

to PMD team as solution of different problem, some process were redesign like CRS

bin to CRS cutter belt speed and time, standard inter-operational time for CRS line was

prepared.


55

REFERENCES

1. Wong, J.S and Wilson, T .L., 1976, "A Study of Variation in Tobacco Filling Power

and Cigarette Firmness”. Amatil Report No. T-89.

2. Dr. M. Semfield, 1973, “Cigarette Manufacture Technology, Tobacco filling

power: part 1”, Cigarettes Manufacturing Technology, 46.

3. S. M. Taylor, 1976, “Some Relations between Chemical and Physical Properties

of Tobacco”, Imperial Tobacco R & D, 173rd symposium of the acs, 217-232.

4. B.M. Akehurts, 1968, “Tobacco”, 462.

5. Dr. M. Semfield, “Effects of making machine and process variables on filling

power of tobacco Blends: part 1”, Tobacco Journal International, 354, 4/80

6. R.M. Gibb, 1962, “An investigation into differences in filling power bewtween

factories”, Filling power of tobacco, reserch confernce.

7. P.M Pedersen , 1990,”A study of Tobacco filling power”, Filling power of

tobacco, reserch confernce, 15.

8. Waldemar, Wochnowski F. K., 1989, “Mathematical Model to Optimize

Cigarette Quality for Changes in Filling Power and the Control System on the

Maker”, Korber AG

9. Dr. M. semfield, “The Relationship of the Physical Properties of the Cigarette

to Blend Filling Power”, Tobacco Journal International, 509, 6/80.

10. Flesselles J., 1966, “Influence of the cut width of cut tobacco on certain

physical characteristics of a cigarette” Ann. SEITA, DEE, sect.1, 4.,

11. Kamachi. T, Kawabata M., and Yoshitan, H., 1965, “Studies on bulkiness and

filling capacity.” Sci.Pap.Cent.Res. Inst., 107

12. Pietrucci A., 1974), “Filling capacity of tobacco from an industrial point of

view”, Ann. de Tabac, Paris SEITA, Sect I, ll,)


56

13. Wochnowski, 1988, “Cause of fluctuations in tobacco filling power and their

influence in the quality of cigarettes”, Korber AG Hamburg, Coresta

14. De Grandpre Y. 1887, “A Review of Firmness and Tobacco Properties”, Imperial

tobacco limited R & D

15. Philip Morris, August 1984, Aspects of tobacco processing.

16. Standard operating procedure of SNPL

17. www.tobaccodocuments.com

18. www.legacy.library.ucsf.edu

19 www.snpl.com

http://www.tobaccodocuments.com/

http://www.legacy.library.ucsf.edu/

http://www.snpl.com/


59

GLOSSARY

BALE: 1. A 50- to 75-pound case of unfermented tobacco,

EXTRUDED TOBACCO.

2. The rectangular packaging of leaf on the farm,

BURLEY farm bale.

3. A 1000-pound rectangular case of cellulose

acetate filter tow.

BRIGHT See FLUE-CURED TOBACCO. See also VIRGINIA

TOBACCO.

BULKING Storage of tobacco (leaf or steam or cut tobacco) in bin

for period of time. It helps in uniform distribution of moisture.

BURLEY An AIR-CURED tobacco. Burley tobacco is grown in

rich limestone soils. It is light brown to reddish brown in color

and has a somewhat greater FILLING POWER than

FLUE-CURED tobacco. Burley is light in body, with a

low sugar content and high alkaloid content. Burley

smoke is more basic (higher pH) than that of FLUECURED

CASE HARDENING Hardening and shrinking of particles caused by drying

from the surface faster than moisture migration from

the interior.

CASING Tobacco additives applied to improve moisture

retention and smoking ability; the process of applying

these additives to tobacco. A mixture of

HYGROSCOPIC AGENTS and/or plasticizing agents


60

and volatile or nonvolatile flavoring agents applied to

tobacco to condition it for processing (to reduce

breakage, facilitate cutting, etc.). Some commonly

known flavoring agents are: cocoa, chocolate,

ginger, cinnamon, vanilla, molasses, rum, brandy,

maple syrup, oils, honey, and sugar. See also: TOP FLAVORINGS.

CIGARETTE FIRMNESS A cigarette rods resistance to compression; the force

required to deform cigarettes a preselected amount;

the deformation of a cigarette after a predetermined

time at a given pressure; sometimes referred to as

CIGARETTE HARDNESS.

CURING The drying process for newly harvested tobacco. AIR

CURING is performed in widely ventilated barns under

natural atmospheric conditions (from which the name

comes) with little or no artificial heat; it takes 3-12

weeks. Light air-cured tobacco is very thin to medium

in body, light tan shaded toward red to reddish brown

in color, and mild in flavor. Burley is light air-cured.

Dark air-cured is medium to heavy in body, light to

medium brown in color. FLUE CURING is performed in

small, tightly constructed barns with artificial heat

beginning at 90 °F and ending round 170 °F; it takes

5-7 days. The name comes from the metal flues used


61

in the heating apparatus. Flue cured tobacco is yellow

to reddish-orange in color, thin to medium in body, and

mild in flavor. FIRE CURING is performed in ventilated

barns with open fires (from which the name comes)

allowing the smoke to come in contact with the

tobacco; it is alternated with air curing. Fire-cured

tobacco is light to dark brown in color, medium to

heavy in body, and strong in flavor. SUN CURING is

performed on racks in the sunshine (from which the

name comes) for set daily periods over 4 weeks,

depending on the weather. Sun-cured tobacco looks

similar to air-cured. Also: bulk curing, homogenized

leaf curing, cross-flow curing.

DENSIMETER Densimeter consist of graduated cylinder of radius(R)

with a closely fitting plunger and weight. The procedure

for measuring height is a known weight i.e. 20 ±0.05 gm.

weight is place in cylinder and plunger is inserted into

cylinder gradually weight of 3 kg is applied.

After 30 sec height (H) of plunger is measure from based of

cylinder.

Volume occupied by sample= πR2H.

Filling value = volume* moisture correction factor.

DUST REMOVAL FILTER Separate tobacco dust from air. Dust are collected from

PMD and SMD using suction fan and send to DRF


62

ELASTICITY 1. The tendency for a cigarette to increase

ventilation rate at higher puffing pressure drop

2. The ability of a leaf to be stretched without

breaking. Leaf with elasticity has good drinking

quality and high FILLING POWER.

END STABILITY Also known as LOOSE SHORTS; Resistance

of a cigarette to lose tobacco. Determined

by quantitating the amount of tobacco which will fall

from the end of a cigarette during a standardized

agitation period reported as mg/cig fallout.

EXPANDED TOBACCO See EXPANSION

EXPANSION A chemical and/or physical procedure that increases

the volume of the cells of tobacco, thus increasing

shred dimensions and the FILLING POWER of the

shreds; performed on cured, cased or uncased filler.

Generally the tobacco is saturated with an inert gas in

a high-pressure vessel called an IMPREGNATOR.

Expansion of the tobacco then takes place in an

expansion tower through the introduction of high temperature

air. See also: PUFFED TOBACCO,

FILLING POWER The ability of tobacco to form a firm cigarette rod at a

given moisture content. A high filling power indicates

that a lower weight of tobacco is required to produce a


63

cigarette rod than is required with a tobacco of lower

filling power. CYLINDER VOLUME is used

interchangeably with filling power; a high cylinder

volume indicates a high filling power. Filling power is

mistakenly referred to as SPECIFIC VOLUME.

FIRMNESS A measure of the resistance of radial deformation of a

cigarette, expressed in counts. Ability of a cigarette to

resist compression.

FLUE-CURED TOBACCO Commonly called BRIGHT or VIRGINIA tobacco.

Flue-cured tobacco is lemon or orange yellow

in color. Flue-cured tobacco possesses a sweet

aroma and slightly acidic taste. It is high in sugar

content and low to average in nitrogenous materials,

acids and nicotine. It blends well with BURLEY and

MARYLAND tobaccos because its sugar content

smooth and neutralizes the smoke.

GRAVITY FEED PIPE GFP consists of a transparent tube with a set

of 3 photo sensors and maintain the level of

product within the GFP within reasonable limit

for continuity flow of product.

HUMECTANT Substance having an affinity for water, with stabilizing

action on the water content of a material; keeps within

a narrow range the moisture content caused by


64

humidity fluctuations; used in treating tobacco. See

also HYGROSCOPIC AGENT.

HUMIDITY CABINET Equipment use to maintain the set temperature

And humidity of sample kept inside it

HYGROSCOPIC AGENT HUMECTANT; ingredient added to tobacco to help it

retain moisture and plasticity. The first such agent was

glycerin, dating from the 1890’s.

MOISTURE CONTENT Percent of water content in total wet weight

of tobacco. Moisture Content is measured by

weighting 10±0.005 gram of sample in tin box

and then keeping tin box in oven for 3hours,

followed by half an hour in silica jell compartment.

Finally net weight of sample was taken.

Moisture content= 10- Net weight of tin after keeping in oven

and silica jell.

PRESSURE DROP The change in pressure in a mass of flowing fluid as it

flows through a resisting element (such as a filter or

tobacco column). See RESISTANCE TO DRAW

PUFFED TOBACCO Expanded tobacco; tobacco whose particle size has

been increased by a combination of heat, high

pressure differential processing, and a puffing agent; a

means of expanding tobacco. See also EXPANSION.

QUALITY Of tobacco as a raw material, there are two


65

considerations: it must be pleasant to smoke and to

look at, and it must possess characteristics favoring

high manufacturing capacity. Tobacco quality is

composed of three major components:

1. PHYSICAL CRITERIA: stalk position, ripeness

and maturity, uniformity, foreign matter, strip yield

and size, filling power.

2. CHEMICAL CRITERIA: nicotine, sugar, petroleum

ether extracts, mineral components, alkalinity of

water-soluble ash, total nitrogen, protein nitrogen,

a-amino nitrogen, starch, nonvolatile acids, total

volatile bases.

3. SMOKE FLAVOR CRITERIA: strength, aroma,

mildness, and sharpness of smoking taste and

odor.

Also: Bruckner Quality Index, Pyriki Quality Index,

Shmuk Quality Index, Trifu Number.

RECONSTITUTED TOBACCO Tobacco dust, stems, by-products, etc. that are finely

ground, that may be mixed with a cohesive agent, and

that are rolled or cast into a flat sheet of uniform

thickness and quality. The sheet may be cut into any

size shreds.

TOP FLAVORINGS Volatile aromatic flavors applied to cut tobacco after


66

final drying, usually applied in the flavoring cylinder. See also

CASING.

VIBRATING CONVEYER: Consists of a tray & a chassis which are connected to

Pair of fiber glass springs & a drive unit which causes the springs

To oscillate backward & forward, this produces

forward motion of the product at tray.

VIRGINIA TOBACCO A general reference to FLUE-CURED tobacco grown

anywhere in the world. BRIGHT tobacco.

SOURCES:

Dictionary of Tobacco Terminology, M. Z. DeBardeleben (1987) Philip Morris document ID:

2054432502/2628; Glossary/Acronyms List, C.S. Lincoln (1987); Brown & Williamson

document, pages 620411092-620411135;

Proceedings of the Smoking Behavior – Marketing Conference 84709-840712 (1984), B&W

document ID588065; RJR document ID 511331024-1028 dated 1993.


67

Appendix 1

Blend

SD of M.C After CRS Cutter

Average of M.C After CRS Cutter

BJ1/11 0.15 37.66

BJ1/13 0.55 36.60

BJF2/3 0.32 38.35

CT10/12 0.36 36.30

CT10/13 0.20 36.40

CT10/15 0.24 36.16

CT10/16 0.29 37.67

NG 5/27 0.34 38.48

NG5/19 0.49 36.82

NG5/21 0.34 36.65

NG5/22 0.25 36.26

NG5/23 0.32 37.16

NG5/25 0.44 37.88

NG5/27 0.23 37.44

NG5/29 0.32 36.10

NKT3/26 0.19 36.33

NKT3/27 0.39 36.24

NKT3/28 0.28 37.50

NKT3/29 0.46 38.79

NKT3/30 0.31 38.33

NKT3/37 0.31 38.26

NKT3/41 0.25 37.07

PLT6/15 0.14 38.07

PLT6/17 0.33 36.84

PLT6/22 0.26 36.56

PLT6/26 0.34 36.49

PLT6/30 0.21 37.11

PLT6/34 0.33 36.08

PLT6/35 0.21 36.98

PLT6/39 0.20 36.91

S.N Blend CV of Weighcon Weight

1 NKT106 0.38%

2 NG71 0.48%

3 NG72 0.41%

4 CT39 0.46%

5 NKT107 0.43%

6 CT40 0.41%

7 NKT108 0.44%

8 NKT109 0.40%

9 NG73 0.47%

10 NKT111 0.40%

11 NKT112 0.38%

12 NKT120 0.37%

13 NKT121 0.46%

14 NKT123 0.43%

15 NKT124 0.45%

16 NKT125 0.47%

17 NKT126 0.40%

18 BJ56 0.48%

19 NCD30 0.42%

20 NKT127 0.41%

21 NKT128 0.40%

22 NKT129 0.40%

23 BJ54 4.78%

24 NKT1/130 0.41%

25 BJO5/05 0.49%

26 BJO5/06 0.43%

27 NKT3/131 0.42%

28 NKT3/132 0.43%

29 BJ1/58 0.44%

30 BJ60 0.36%

Mean Moisture Content and SD of

CRS Ex-cutter

CV of weighcon weight


68

Appendix 2

CRS

Operation number

Average M.C after

H.C(approx.) Ex- cutter

Ex- HT

Ex-Drier

Bin(initial)

Bin(final)

Bin(A.H.C)

Cutter to h.t

cutter to Bin

NG 5/36 14.00 40.59 50.82 45.67 25.22% 12.52%

NG 5/38 14.00 41.58 52.34 47.03 25.87% 13.09%

NG 5/39 14-15 41.68 49.87 47.85 19.64% 14.80%

NG 5/41 20.00 44.27 52.57 48.42 47.25 49.60 18.73% 12.03%

NG 5/43 16.00 46.40 56.86 50.18 50.43 22.54% 8.68%

NG 5/44 16.00 43.28 53.55 47.46 50.74 23.74% 17.24%

NG 5/45 15-16 44.86 55.96 50.43 51.46 52.30 24.74% 16.57%

NG 5/46 14.00 47.73 51.78

NG 5/48 14.00 42.44 51.63 45.30 45.78 47.63 21.64% 12.22%

NG 5/49 14-15 43.04 53.44 45.89 46.33 48.92 24.15% 13.66%

NG 5/51 15.00 43.07 52.99 49.66 48.71 49.10 23.03% 14.00%

NG 5/53 15.00 44.72 53.88 47.74 47.41 48.56 50.74 20.49% 13.46%

NG 5/55 14.00 42.48 50.28 47.52 47.77 48.49 18.35% 14.13%

NG 5/56 16.00 44.30 51.74 47.22 48.16 48.49 16.79% 9.44%

NG 5/57 16-17 45.47 56.37 50.24 50.73 54.42 23.98% 19.68%

NG 5/58 14-15 44.17 54.45 50.43 50.90 51.00 23.26% 15.47%

NG 5/59 49.05

NG 5/60 49.40

FV of CRS at different processing stages

Filling value are always measured in mm3/gm

Moisture content in %


69

Appendix 3

lamina

Operation Number

Average M.C after H.C(approx.)

Ex- cutter Ex- HT

Ex-Drier

Ex- Drier(B.H.C) flav

Cutter to h.t

Cutter to Dryer

NG 5/41 12.00 46.10 51.14 47.14 46.74

NG 5/43 12.00 45.98 53.50 50.73 16.36% 10.34%

NG 5/44 12.00 46.47 54.92 51.41 46.21 18.20% 10.63%

NG 5/45 12.00 47.33 54.11 51.77 48.37 14.34% 9.39%

NG 5/46 12.00 48.23 56.75 52.08 49.06 17.67% 7.97%

NG 5/48 12.00 48.26 53.69 50.34 46.33 47.64 11.25% 4.30%

NG 5/49 13.00 49.37 44.95 46.96

NG 5/51 13-12 48.82 52.99 51.17 46.74 46.69 8.55% 4.81%

NG 5/53 13-14-12 46.06 53.17 51.20 47.24 49.77 15.43% 11.15%

NG 5/55 12.00 46.94 56.00 51.28 49.70 49.43 19.31% 9.24%

NG 5/56 14-13-f(10) 47.16 51.95 48.87 48.27 47.76 10.17% 3.63%

NG 5/57 14-13-15 46.46 55.01 50.88 47.23 48.48 18.41% 9.50%

NG 5/59 13-12 48.97 55.43 53.00 48.96 50.71 13.20% 8.25%

NG 5/60 12.00 48.71 55.15 52.37 48.38 51.52 13.22% 7.52%

FV of CRS at different processing stages


70

Appendix 4

Before Calibration After Calibration

Observation-1 Observation-2 Observation-3

Mean 0.1918 0.1995 0.1527

Standard Error 0.0077 0.0096 0.0036

Median 0.18 0.2 0.15

Mode 0.15 0.15 0.15

Standard Deviation 0.0542 0.0715 0.0244

Sample Variance 0.0029 0.0051 0.0006

Kurtosis 0.3507 -0.9841 0.6843

Skewness 0.9693 0.3286 1.1127

Range 0.21 0.25 0.1

Minimum 0.12 0.09 0.12

Maximum 0.33 0.34 0.22

Sum 9.4 10.97 6.87

Count 49 55 45

Largest(1) 0.33 0.34 0.22

Smallest(1) 0.12 0.09 0.12

Confidence Level (95.0%) 0.0156 0.0193 0.0073

Data summary of Wax thickness after and before Calibration


71

Appendix 5

Blend Filling Value Blend

Filling Value Blend

Filling Value

NG 5/78 49.55 NG 5/45 47.91 NG 5/11 46.01

NG 5/77 48.53 NG 5/44 49.99 NG 5/9 45.59

NG 5/76 47.98 NG 5/43 49.14 NG 5/8 46.37

NG 5/75 49.91 NG 5/42 45.89 NG 5/7 45.03

NG 5/72 48.53 NG 5/40 47.13 NG 5/6 48.05

NG 5/71 49.78 NG 5/39 48.26 NG 5/5 48.3

NG 5/70 49.25 NG 5/38 48.27 NG 5/4 48.16

NG 5/68 48.61 NG 5/37 48.26 NG 5/3 45.56

NG 5/66 50.43 NG 5/36 47.87 NG 5/2 49.03

NG 5/65 49.26 NG 5/33 47.36 NG 5/1 47.03

NG 5/64 47.86 NG 5/32 47.94

NG 5/63 48.31 NG 5/30 47.77

NG 5/62 50.31 NG 5/29 48.64

NG 5/61 49.57 NG 5/28 48.23

NG 5/60 49.5 NG 5/27 48.73

NG 5/59 49.67 NG 5/26 48.26

NG 5/58 50.15 NG 5/25 47.84

NG 5/57 51.47 NG 5/24 48.54

NG 5/56 48.67 NG 5/23 49.17

NG 5/55 49.27 NG 5/22 46.8

NG 5/54 46.45 NG 5/20 51.74

NG 5/53 48.18 NG 5/19 49

NG 5/52 49.26 NG 5/18 47.66

NG 5/51 49.39 NG 5/17 48.32

NG 5/50 49.7 NG 5/16 47.67

NG 5/49 49.68 NG 5/15 48.4

NG 5/48 49.32 NG 5/14 47.55

NG 5/47 49.33 NG 5/13 47.95

NG 5/46 48.18 NG 5/12 47.63

Filling Value of Surya from blend 1 to 78 (Source: QUAS Surya Nepal)


72

Appendix 6

Blend

M.C. inlet M.C outlet

Steam Pressure H.T (bar)

set MC

outlet

Dryer Inlet (bar)

Dryer Outlet (bar)

Cpk Cp Mean S.D Mean S.D Mean S.D Mean S.D Mean S.D

Older Boiler PLT75 39.3 0.3 15.4 0.3 4.1 0.6 15 5.5 0.7 3.8 0.1 0.7 1.1

BJ41 39.5 0.2 16.1 0.5 3.7 0.6 16 5.2 0.7 2.7 0.2 0.7 0.7

PLT78 39.0 0.4 15.6 0.3 4.4 0.2 16 6.0 0.2 4.8 0.7 0.6 1.0

PLT80 41.0 0.2 16.3 0.3 4.5 0.1 16 6.1 0.2 6.7 1.0 0.9 1.2

PLT81 40.0 0.2 16.3 0.3 4.1 0.3 16 5.5 0.4 6.5 0.5 0.9 1.3

New Boiler PLT83 39.8 0.3 15.5 0.2 5.0 0.0 15.5 7.5 0.2 6.6 0.1 2.0 2.1

PLT85 38.7 0.3 15.6 0.1 5.0 0.0 15.5 5.6 0.4 6.6 0.5 2.9 3.2

PLT86 40.2 0.5 14.9 0.3 4.7 0.2 15 6.2 0.4 7.3 0.4 1.1 1.2

BJ43 40.9 0.3 15.9 0.3 5.0 0.0 16 5.8 0.6 6.7 0.5 1.1 1.2

PLT87 40.7 0.3 16.3 0.3 5.0 0.2 16 6.8 0.4 8.1 0.5 0.8 1.2

Different parameter during old and new boiler operation at CRS dryer


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Appendix 7

Co

ver

des

ign

fo

r co

nve

yer

bel

t a

t C

TS b

in


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Appendix 8

Pa

n d

esig

n f

or

sam

plin

g a

t H

T


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Appendix 9

Sta

nd

des

ign

fo

r Se

rric

o T

rap


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Appendix 10

Admoist in ( time in mins:sec)

hopper to inlet Admoist

inlet to outlet of Admoist

Ex- admoist to bin Remark

2:00 2:50 30 Vibrating conveyer

12-15 sec

1:50 2:46 35 weighcon 45-55 sec

1:56 3:01 30 hopper to GFP

30-45 sec

1:45 2:51 30

1:55 2:45 35

1:55 2:55 35

2:00 2:50 35

1:50 2:50 35

Admoist out ( time in mins:sec)

hopper to inlet Admoist

inlet to outlet of Admoist

Ex- admoist to bin

1:40 8:50 30

1:40 8:40 35

1:56 8:46 35

1:36 8:30 30

1:50 8:30 35

1:30 8:45 35

1:35 8:40 35

1:40 8:40 35

CRS Out ( time in mins:sec)

Cutter to GFP

GFP to HT

HT to Ex-dryer

before 3:37 1:43 11:22

0:50 1:20 12:10

4:03 2:02 12:34

3:35 1:40 12:20

2:06 1:20 11:30

2:01 1:22 11:40

after 0:45 1:26 10:30

2:26 1:23 10:20

2:24 1:28 10:45

CRS In ( time in mins:sec)

Cutter to GFP

GFP to HT

HT to Ex-dryer

Before 0:51 1:07 7:00

0:45 1:05 6:20

0.47 1:20 6:45

0.46 1:10 6:40

0.46 1:08 6:10

0:45 1:00 6:30

0:52 0:58 6:16

1:00 1:07 6:20

After 1:00 0:55 6:00

13:12 13:55 6:05

Time at different point during process start and end at Admoist

Time at different point during process start and end at CRS Dryer


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Appendix 11

Grant Chart of total OJT period

s


81

An OJT Report On 3 Month Internship at Surya Nepal

Engineering

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