Autoclave Presentation GP1

7/25/2019 Autoclave Presentation GP1

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A PROPOSAL FOR

DESIGN AND CONSTRUCTION OF AN AUTOCLAVE (STERILIZER)

PREPARED BY

PROJECT GROUP 1

SUBMITTED TO

PROTOTYPE ENGINEERING DEVELOPMENT

INSTITUTE (PEDI), ILESA

SEPTEMBER 2011


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EXECUTIVE SUMMARY

A commercial project proposal for the design andconstruction of an autoclave sterilizer is presented.The equipment is used for sterilizing non-ferrousutensils in hospitals, laboratories, homes, etc.

Methodology for production ill entail !A" design,out-sourcing of electrical components, fabricationof structural parts and circuit diagramming. Allequipment and professionals required are available

in #$"%, %lesa. &ith adequate materials on ground,ten complete set can be produced ithin 've ()*or+ing days. The proposed equipment is

estimated to cost , )/ per unit


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BACKGROUND

Project Description

Autoclaves are pressure vessels used to process partsand materials hich require e0posure to elevatedpressure and temperature. %t is essentially used for

sterilization, also for performing scienti'c e0periments,or carrying out industrial processes. Typically thechambers in autoclaves are cylindrical, becausecylinders are better able to ithstand pressures thanbo0es, hose edges become points of ea+ness that

can brea+. The high pressure ma+es them self-sealing(the ord 12auto22 and 12clave22 mean automaticloc+ing*, though for safety reasons most are also sealedmanually from outside.


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1! Princip"e o# Oper$tion

3nce the chamber is sealed, all the air is removed from it either bya simple vacuum pump (in a design called pre-vacuum* or bypumping in steam to force the air out of the ay (an alternativedesign called gravity displacement*. e0t, steam is pumpedthrough the chamber at a high pressure than normal atmospheric

pressure so it reaches a temperature of about 4 5 6//!. 3ncethe required temperature is reached, a thermostat +ic+s in andstarts a timer. The steam pumping continues for a minimum of 7minutes and a ma0imum of about ) 5 4/minutes (highertemperatures means shorter times* 5 generally long enough to +illmost micro organisms. The e0act sterilizing time depends on a

variety of factors, including the li+ely contamination level of theitems being autoclaved (dirty items +non to be contaminated illta+e longer time to sterilize because they contain more microbes*and ho the autoclave is loaded up (if steam can circulate morefreely, autoclaving ill be quic+er and more e8ective*.


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O%jecti&e $n' Scope

The main objective is to underta+ethe project as a #$"%-baseddevelopmental research. The scopeof the design is limited toe0termination of microbes thatcannot thrive above 4-6/ o!.


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MATERIALS AND METHODMat!"a# P#a$$"$%

S&N Pa!t' *+*$$t' Mat!"a# D'!"t"*$S"-"at"*$ N*

1. Inner Drum

Stainless Steel 2mm thick, 4 X 8ft22. Outer Drum

3. Cover

4. Insulating Drum i!re 1

". #eater #eating $lement In%ustrial gra%e &1.8k'( 1

). $lectro%es

Stainless

$lectro%e $I 3*8 1 +acket

. -olts an% nuts etallic De+en%s on #an%le 8

8. Safet/ valve etallic S+ring loa%e% 1

0. anual $haust alve etallic anual 1

1*.

ressure5em+erature

gauge 6 6 1


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11. 7asket Silicon

12. 5em+erature Controller 2

13. C- 6 1*m+s 1

14. -u99er 6 C 1

1". #an%le

ol/meric

aterial 4

1). Connecting 'ires 6 6 Several

1. o:er Chor% 6 1"m+s 1


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S/nUnit Process /Operation

Tools / Equipment /facilityrequired

Availability / location

of equipment /manpower

1 CAD Drawing AutoCAD (Autodesk) PEDI, Ilesa

2

Materials/components

purc!ase Cas! and con"e#ing "e!icle,

$

%

Mac!ining (cutting,

&oring, drilling, milling,

'acing etc)

MC, C*C/E*C lat!es,

+aser cutting m/c

PEDI, Ilesa EMDI,

Akure

-

.oining (welding, &olting,

ri"eting, &racing, etc)

Arc laser welding m/c,

electrodes

PEDI, Ilesa EMDI,

Akure

0 Coupling o' parts Electrical/mec!anical kits PEDI, Ilesa

Electrical wiring Electrical kit PEDI, Ilesa

1 3est running PEDI, Ilesa

T**#"$% P#a$$"$%


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11 Protot#pe de"elopment All pro'essionals PEDI, Ilesa

12

Ad"ertisement and

s!owcasing/e4!i&ition E4!i&ition team

3rade 'airs, e4!i&itioncentres, internet,

newspapers, 5ournal

pu&lication,

con'erence centres

1$

Ceding to 6MEs and

general marketing Marketing team PEDI, Ilesa

1%

3raining and

maintenance operations Maintenance team PEDI, Ilesa


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!( Met)o' P"$nnin*

This section highlights the basic steps involved in the designand construction. At this stage, the planning is less meticulousabout micro-sequencing of fabrication activities.

!A" design

#urchase of materials9components

Machining (cutting, boring, drilling, milling, facing etc.*

:ub-assembling of parts (elding, bolting*

$lectrical iring

;inal coupling of parts

#rototype development

Advertisement and shocasing9e0hibition

!eding to :M$s and general mar+eting

Training and Maintenance operations


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DESIGN DETAILS

P$rt Desi*n

Dr$+in*s

!over


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3uter "rum


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%nsulating ;ibre


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%nner "rum


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:ub Assembly "raing


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;inal Assembly "raing


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#ressure =auge

alve


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./ E#t!"a# D"a%!a+

5he electric %iagram for the tem+erature controller circuit is sho:n !elo:.

A.!:upply


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TEC-NICA. IN/ORMATION ON PRO0ECT

Bsiness P"$n

N2%er o# personne"3The project ill be carried outby 've ()* personnel

Unit cost3 The price of an autoclave ill varyenormously as a function of hat has been designedand built into it. %t is sensitive to some factors andinsensitive to others. The price ill depend largelyupon its diameter and to a much lesser e0tent uponits length. :ome of the features of an autoclave alloa ide range of options, and some of these can

a8ect price dramatically. %n considering acquisition ofan autoclave, it is prudent to ta+e nothing forgrantedB loo+ at all possible options and variations.

5h t !l ! l h th i f th t % th %%iti i th it


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SN Pa!t' *+*$$t' a$t"t3 $44 E't"+at4 C*'t (I$ Na"!a)

1. Inner Drum 2 sheets of 12**24**mm &2mm

thickness( "*,***2. Outer Drum

3. ;agging Drum &i!re( 1 !ag 3,"**.**

4. #eater 1 1*,***.**

". Stainless $lectro%es &$I 3*8;( 1 acket 1,"**.**

). -olts an% nuts 8 4**.**

. Safet/ valve 1 2,***.**8. anual $haust alve 2 1,8**.**

0. ressure5em+erature gauge 1 ",***.**

1*. Silicon 7asket 1 1,***.**

11. 5em+erature Controller 1 1",***.**

12. iniature Circuit -reaker &C-( 1 3,"**.**

13. -u99er 1 3,***.**

14. #an%le 4 3,***.**

1". Connecting 'ires


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N* *- Da3' N* *- At*#a5 P!*44

6 10

20 0

20 70

T"+ E't"+at"*$8

Cost of manufacturing 1 unit > < 1*),2**

Cost of manufacturing 48* units > < 1*),2** X 48*?nits

> < "*, 0),*** +er annum

7eneral $+enses &7$( > < 23*, *** +er month

> < 2, )*, *** +er annum


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=eneral e0penses include amount procured on maintenanceand repairs, communications, research and development,advertising e.t.c.

Total cost of production of 6D/ units per annum E )7,F7C,///

Therefore total cost of production for unit E )7, F7C,///96D/Gnits

E , )/

Unit price3The selling price9unit ill be )/, ///

Bre$45E&en Point3

This is the number of unit to be sold to give the total

production cost@rea+-$ven #oint E Total #roduction !ost 9 Gnit #rice

E )7, F7C, /// 9 )/, ///

E 7) units


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P$65B$c4 Perio'3

The paybac+ period for this project is the number of days forthe production cost to be realized.

#aybac+ #eriod E (Total no of "ays H @rea+-$ven #oint7 8 oof units produced

#aybac+ #eriod E (46/days H 7)Gnits* 9 6D/GnitsE D/ days

Total %ncome (#ro't* E Total e0pected sales 5 Total product cost(Total $0penditure*

Total e0pected sales E o of units produced H :elling price

E 6D/units H )/, /// E F4, ///, ///

Total %ncome E F4, ///, /// 5 )7, F7C, ///

Total %ncome E #ro't E D, 4C6, ///


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Potenti$" csto2ers3

#harmaceuticals I @iotech industries.

;ood research I quality assurancelaboratories.

Agriculture research I quality assurancelaboratories.

eterinary diagnostic laboratories. Gniversities, and all centers requiring

assured sterilization.


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9! M$n#$ctrin* .$6ot

$8ective Joor spaceK %n order toguard against production Joorhazards and at the same time adding

an e0tra margin of safety to thehole process of production, aminimum of Cft H Cft Joor space

ill be employed.


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SN PROCESS MACHINE TO BE

USED

MAN PO9ER

1. arking outcutting of

stainless steel sheets

eter rule, Steel rule,

lasma cutting

machine

2

2. ol%ing-en%ing -en%ing achine 3

3. 'el%ing 'el%ing achine 2

4. 7rin%ing 7rin%ing achine 2

". -oring C


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9( Desi*n .i2it$tions $n' Constr$ints

Tec)nic$" "i2it$tions3They includeK

;olding of the stainless sheet to a uniform cylinder.

The polymeric handle ill have to be purchased locallyfrom scraped materials due to huge cost of producing

ne ones.M$npo+er "i2it$tions3 $0perts needed to handle

some technical aspects (e.g. bending of the stainlesssheet into a uniform cylinder* are not readily available.

/in$nci$" "i2it$tions3These led to%nability to visit e0isting sites here autoclaves are

used

%mproper mar+et survey for component2s price '0ing


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Conc"sion

This project proposal is a prototype of an e0istingconventional autoclave machine hich is yet to be producedin igeria. %t has the capability of satisfying its users in the#harmaceuticals I @iotech industries, ;ood research Iquality assurance laboratories, Agriculture research I qualityassurance laboratories, eterinary diagnostic laboratoriesB Gniversities,and all centers requiring assured sterilization. This provides aready mar+et for our product. :ince the conventional

autoclave sells for 4)/, /// or more, and ours ould go for )/,/// the price ill favourably compete ith theconventional ones and of good standard to meet thespeci'cations of A:M$9:3.


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Reco22en'$tion

;urther improvement can be made on theautoclave by incorporating a solenoid valve forpurging instead of the manual e0haust valve, aater level sensor can also be incorporated to

protect the heating element, and a timer toindicate end of sterilization cycle.

Lesearch is still ongoing by the group inachieving this.

%n vie of the above, e recommend that theinstitute embar+ on this project for massproduction.

Autoclave Presentation GP1

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Transcript of Autoclave Presentation GP1