Operation Procedure of Air Compressor and Dryer


1. OBJECTIVE

       To lay down a operation procedure of Air compressor and Dryer.

2.     RESPONSIBILITY

  • Assistant  – Engineering  –  To Follow the SOP
  • Executive – Engineering – To Comply the SOP

3.    PROCEDURE

       3.1   PRECAUTIONS

  • Ensure that air outlet valves of Air compressor and air inlet valve of drier are in open condition.
  • Keep ready air compressor and dryer.
  • Do not open the by pass valve when the dryer is in operation.
  • Do not adjust or tamper the safety devices.

      3.2 PRE START UP

  • Drain Condensed water from heat exchangers
  • Check for proper valve position of after cooler, air receiver and air drier
  • Keep discharge valve open condition before starting the compressor

3.3   OPERATION

  • Start the Air compressor by following the instructions displayed on MMI  of the PLC  
  • Drain all low points in compressor suction and discharge lines.
  • Drain condensate water from air receiver, pulsation bottles and moisture separators.
  • Switch on the dryer towers
  • Drain the water from pre, after and oil removing filters
  • Check and ensure there should not be any abnormal noise from the compressor
  • Record the operating parameters in Annexure-1 for every one hour
NOTE : OPERATING PARAMETER LIMITS
  • Lubrication Oil Pressure :        1.1 to 2.8 kg/cm
  • Interstage Air Pressure    :        2.0 to 3.5 kg/cm
  • Discharge Air Pressure    :        8.5 to 10 kg/cm
  • Load in Amps                  :       50

  3.4  SHUT DOWN

  • Switch off the power supply to the motor through the on-off switch on the starter cum control panel. The air compressor automatically unloads before stopping.
  • Switch off the supply for dryer towers
  • Drain the water from pre, after and oil removing filters
  • Close the outlet valve

4.         ABBREVIATIONS

MMI :   Main Machine Interface

PLC :    Programmable Logic Controller

5.         REFERENCES

Nil      

6.         ANNEXURES

6.1       Annexure- 1 -Daily log sheet of Air Compressor & Drier.

Preventive Maintenance of Air compressor & Dryer


  1. OBJECTIVE             

1.1       To lay down a procedure for Preventive Maintenance of Air compressor & Dryer  

2.     RESPONSIBILITY                                                  

  • Assistant    Engineering  – To Follow the SOP
  • Executive   Engineering – To comply the SOP

3.     PROCEDURE                       

  • 3.1 WEEKLY MAINTENANCE
  •  Clean the air intake filter with compressed air
  • Check and ensure the air compressor load is below 20 Amps during unloading and below 50 Amps during loading.
  • Check and ensure no air leakages in the system.
  • Check the condition of belts.
  • Check and ensure the automatic drain valve function
  • Check and ensure the by-pass valve of dryer  in closed condition
  • Check and ensure the function of the Dryer
  • 3.2 MONTHLY MAINTENANCE
  • Check and tighten the motor Bed Bolts.
  • Clean the contactor kits with carbon tetra chloride.
  • Open the motor terminal covers and tighten the terminals, replace terminal strip if terminals are broken.
  • Clean the control panel with air blower and ensure no control wires should hang, tag the wires with cable tag if it is hanging.
  • Check the oil level in air compressor, fill with oil if it is below the level.
  • Check for any leakages in the pipe lines connected to dryer and receiver.
  • Clean the automotive drain valve strainer
  • 3.3 QUARTERLY MAINTENANCE
  • Check  the alignment of the motor pulley and compressor pulley.
  • Regrease the motor Bearings.
  • Clean the inlet  discharge valves and replace if worn out or damaged.
  • Open and clean the main, exhaust, non return, automatic drain  and solenoid valves.
  • Check the Air suction and Discharge valves for worn-out  Parts, replace if required.
  • Replace the Compressor  cartridge oil filter.
  • Clean the oil strainer and oil cooler.
  • Clean the heat exchanger tube bundle assembly.
  •  Replaced  the suction filter element

 3.4  HALF YEARLY MAINTENANCE

  • Check and clean the contactors, replace the contactor kits if it is damaged.
  • Air inlet filter element to be replaced.
  • Clean all the filter elements of dryer
  • Replace the oil in the air compressor
  • 3.5 YEARLY MAINTENANCE
  • Check and ensure cylinder and cylinder heads are ok.
  • Check and ensure no vibration of driven pulley.
  • Check and ensure piston and packing rings are ok
  • Replace all elements of dryer once in a year
  • Check the physical condition of alumina, replace if required.
  • After cooler (Water Cooled)De-Scaling shall be done once in  year

4.  ABBREVIATIONS

Nil

5.         REFERENCES

Nil      

6.         ANNEXURES

6.1       Annexure – 1               List of Air Compressor.

6.2       Annexure – 2               Weekly Preventive Maintenance Check list

6.3       Annexure – 3               Monthly Preventive Maintenance Check list

6.4       Annexure – 4               Quarterly Preventive Maintenance Check list.

6.5       Annexure – 5               Half yearly Preventive Maintenance Check list.

6.6       Annexure – 6               Yearly Preventive Maintenance Check list.

Preventive Maintenance of Tablet Compression Machine


  1. OBJECTIVE             
  1.  To lay down a procedure for Preventive Maintenance of Tablet Compression Machine
  1. RESPONSIBILITY                                                  
  • Assistant – Engineering    – To follow the SOP
  • Executive – Engineering    – To Comply the SOP
  1. PROCEDURE           
  • Weekly maintenance
  • Check the machine rotation with hand wheel, it should rotate freely.
  • Check the hydraulic oil, gearbox oil levels, should be 3/4th of the oil chamber.
  • Check the punch lubrication oil level, maintain up to the mark.
  • Check the powder conveying system for proper functioning.
  • Check all the PU pipes and PU connectors for leakages.
  • Lubricate all moving parts with specified lubricant.
  • Monthly maintenance
  • Check all the movable parts for proper lubrication, if required lubricate them.
  • Check the gearbox oil level, Punch lubrication oil level and hydraulic oil levels, if required top up them with specifies lubrication oil up to the mark.
  • Check the PMM and feeder motors are moving freely, if required replace the bearings.
  • Check the condition of PLC terminals, contactors and relays, if required clean them with CTC.
  • Check all the inter locks working and limit switches condition, if required tighten the line connections.
  • Check the powder conveying system vacuum unit, if required clean the cylinder and the vacuum assembly.
  • Yearly maintenance
  • Check the oil seals of the gearbox, if required replace with new seals.
  • Drain the gearbox oil and refill with fresh oil up to the mark.
  • Check the bearings of all moving parts, brackets and motor, if found any abnormality replace the worn out bearings.
  • Check the hydraulic pump oil seals condition, if required replace the seals.
  • Check the timing belts condition, if required replace the damaged belt.
  • Check all the pneumatic and solenoid valves condition, if required replace the worn out items.
  1. ABBREVIATIONS
  • PU    :  POLY URETHANE
  • PMM:   PRESSURE MAIN MOTOR
  • PLC  :  PROGRAMMABLE LOGIC CONTROL
  • CTC  :  CARBON TETRA CHLORIDE   
  1. REFERENCES

Nil      

  1. ANNEXURES
  • Annexure-1      Weekly preventive maintenance checklist
  • Annexure-2      Monthly preventive maintenance checklist.
  • Annexure-3      Yearly preventive maintenance checklist

Preventive Maintenance of Blister Packing Machine


  1. OBJECTIVE             
  1. To lay down a procedure for Preventive Maintenance of Blister packing machine 230 XT, TR-100L.
  • 2. RESPONSIBILITY                                                  
  • Assistant – Engineering &Production  – To follow the SOP
  • Executive – Engineering &Production  – To Comply the SOP
  • 3. PROCEDURE           
  • Weekly Maintenance
  • Check all the movable parts for proper lubrication.
  • Lubricate the Punching tool ball case, Embossing unit, platen heater assembly and sucker arm unit for friction free movement.  
  • Check the platen heaters and sealing roller heaters for proper working.
  • Check the oil level in the gearboxes with level scale.
  • Check the FRL unit oil level and air leakages.
  • Quarterly Maintenance
  • Check the Vibrating coil for proper functioning, if required adjust the leaf springs for proper vibration.
  • Check the clutch for engaging and disengaging in running condition.
  • Lubricate all the movable parts including the guide rollers of the PVC or PVDC and Printed foil.
  • Check all the inter locks are working properly, if required tighten the line connections.
  • Check the stepped motor for proper working, if required adjust the line sensor for better sensing.
  • Check the objective-sensing camera for proper function, if required verify the data loaded.
  • Check the sealing roller and forming station heaters, if found any one failed replace the heater immediately.
  • Yearly Maintenance
  • Check all the Pneumatic cylinder seal kits, if found any damage replace the damaged kit.
  • Check the bearings of the sealing roller, indexing roller, inching roller, PVC or PVDC draw rollers and printed foil guide rollers, if found any damaged replace worn-out bearings.
  • Check the solenoid valves, coils and pneumatic valves condition, if required replace the damaged item.
  • Check the timer belt and pulley condition, if required replace the timer belt with new one.
  • Check the motor belts condition, if required replace with new belts.
  • Drain the gearbox oil and refill with new oil.
  • Check the platen heater plates and sealing roller for silicon synthetic polymer coating, if required recoat the silicon synthetic polymer for better performance.  
  1. ABBREVIATIONS
  • PVC : POLY VINILE CHLORIDE
  • FRL : FILTER REGULATOR LUBRICATOR
  • PVDC : POLY VINILE DIECHLORIDE
  1. REFERENCES

         Nil     

  1. ANNEXURES
  • Annexure-1           Weekly Preventive maintenance checklist.
  • Annexure-2           Quarterly Preventive maintenance checklist.
  • Annexure-3           Yearly preventive maintenance checklist.

Preventive Maintenance of Fluid Bed Drier


  1. OBJECTIVE             

1.1       To lay down a procedure for Preventive Maintenance of Fluid Bed Drier-20Kgs, 120Kgs.

  1. RESPONSIBILITY                                                  
  • Assistant – Engineering       – To follow the SOP
  • Executive – Engineering       – To Comply the SOP
  1. PROCEDURE           
  • Weekly Maintenance
  • Check the pneumatic cylinders and solenoid valves for proper working condition.
  • Check earthing bracket plungers for proper working, if required lubricate the plungers.
  • Check the product bowl trolley castor wheels for free movement, if required lubricate the wheel bearings.
  • Check the scrubber unit solenoid valves for proper working.
  • Monthly Maintenance
  • Check steam control valves and actuators for proper working ensure that no steam leak will be there in the lines and at actuators.
  • Check the filter bag-shaking cylinder, if required adjust the cylinder for proper function.
  • Check the pneumatic lines and cylinders for leakages, if found arrest the leaks.
  • Check the air pressure of the upper seal, if required adjust the pressure regulator and switch.
  • Clean the scrubber unit filter bags with water and dry with air, clean the collection container.
  • Check for the damper actuating pneumatic cylinder ‘O’ ring and replace if necessary.
  • Clean the inlet & outlet air handling unit pre-filters.
  • Check the inter locks are working properly.
  • Check the pneumatic valves and pressure switches for proper working condition.
  • Yearly Maintenance
  • Check the steam coil for leakages if found any arrest them or replace the steam coil.
  • Check the blower motor and impeller housing bearings for abnormality, if found replace the bearings, and check the impeller balancing.
  • Check the system filters and pre-filters, if required replace with new filters.
  • Check the exhaust module HEPA filter, if found any damage repair it or replace with new filter.
  • Check the upper seal and lower seals condition, if required replace with new seals.
  • Check the castor wheels condition, if required replace with new wheels.
  1. ABBREVIATIONS
  • HEPA : HIGH EFFICIENCY PERTICULATE AIR
  1. REFERENCES

         Nil      

  1. ANNEXURES
  • Annexure-1     Weekly preventive maintenance checklist
  • Annexure-2     Monthly preventive maintenance checklist.
  • Annexure-3     Yearly preventive maintenance checklist.

Preventive Maintenance of Automatic Capsule Filling


  1. OBJECTIVE                    
  1. To lay down a procedure for Preventive Maintenance of Automatic capsule filling line AF-40T, AF-90T, And AF-150T.
  • 2. RESPONSIBILITY                                                  
  • Assistant – Engineering       – To follow the SOP
  • Executive – Engineering      – To Comply the SOP
  • 3. PROCEDURE           
  • Weekly Maintenance
  • Check the oil level in the vacuum pump through view glass and refill the oil if required.
  • Clean the vacuum pump filter and filter chamber.
  • Check the powder mixing motor gearbox oil level with level scale and refill the oil if    required.
  • Switch-off all electrical lines and clean the panel with vacuum.
  • Check the Pneumatic cylinder of powder conveying system for proper functioning.
  • Monthly Maintenance
  • Clean and apply new grease to chain and cam assemblies in side the machine.
  • Check all movable parts and tighten all fittings of basic machine and line machines.
  • Check solenoid valve and clean the valve, ensure the coil is in working condition.
  • Check that all the sensors and inter locks of the machine are working properly.
  • Check all solenoid valves and coils of pneumatic controls are working properly.
  • Check the metal detector electrical lines and clean the detector head.
  • Check and clean the rejection cut out area and spring action of flap.
  • Drain the vacuum pump oil and top up with new oil.
  • Half -Yearly Maintenance
  • Check all the link mechanisms, if found any damage replace the link with bush assembly.
  • Check the tamping block springs, if found any damage replace the springs with new one.
  • Check the motor bearings of vacuum and dust collection system, if required replace with new bearings.
  • Clean the grease of sliding blocks rollers of turret and reapply the new grease to the rollers.
  • Check the Metal detector controller circuit; clean the circuit board and contactors with vacuum.
  • Check the pneumatic cylinder operation and tight the fastenings of the cylinder.
  • Yearly Maintenance
  • Check the seals of all shafts, if required replace the seals with new one.
  • Check the vanes of the vacuum pump, if required replace with new vanes.
  • Check the vacuum pump filter condition, if required replace with new one.
  • Check all the cams for proper wetness, if required re grease all the cam tracks.
  • Clean all moving segments with kerosene and apply new grease to the segments including bearings.
  • Check the condition of the main motor and line motor timer belts, if required replace the timer belts with new one.
  • Check all the machine alignments, if require realign the settings using Gauge pins with respective size.
  • 4. ABBREVIATIONS

Nil

  • 5. REFERENCES

Nil    

  • 6. ANNEXURES
  • Annexure – 1        Weekly preventive maintenance check list
  • Annexure – 2        Monthly preventive maintenance check list
  • Annexure – 3        Half- yearly preventive maintenance check list
  • Annexure – 4        Yearly preventive maintenance check list

Preventive Maintenance of Rapid Mixer Granulator


  1. OBJECTIVE            
  1. To lay down a procedure for Preventive Maintenance of Rapid Mixer Granulator-25, 250, 300Ltrs.
  • 2. RESPONSIBILITY  
  • Assistant – Engineering  – to follow the SOP
  • Executive –Engineering  – to comply the SOP
  • 3. PROCEDURE                      
  • Weekly Maintenance
  • Check the lubrication oil in the FRL unit and if required top up with specified lubricant.
  • Check the oil level in the gearbox through view glass and should be ¾Th in level.
  • Check the solenoid valves and coils condition.
  • Check the chopper motor gland and if required replace.
  • Check the pneumatic cylinder functioning.
  • Check the Lid gasket condition.
  • Monthly Maintenance
  • Check the gearbox oil condition and replace if required.
  • Check the tension of the motor belts and if required adjust the slackness.
  • Check and clean the Teflon ring, if found damage replace with new one.
  • Check the pneumatic cylinder seals and discharge chute seals and chopper motor seals, if damaged replace.
  • Check all electrical starters and contactor if required clean with CTC solution.
  • Check all the inter locks are working properly.
  • Check the PLC lines and controls for proper functioning.
  • 4. ABBREVIATIONS
  • FRL  – FILTER REGULATOR LUBRICATOR
  • CTC – CARBON TETRA CHLORIDE
  • PLC – PROGRAMMABLE LOGIC CONTROLLER
  • 5. REFERENCES         

         Nil

  • 6. ANNEXURES           
  • Annexure-1       Weekly preventive maintenance checklist.
  • Annexure-2       Monthly preventive maintenance checklist.

Preventive Maintenance of Octagonal Blender


  1. OBJECTIVE            
  1. To lay down the procedure for Preventive Maintenance of Octagonal blender 300, 500, 1000, 1500, 2250 Ltrs.
  • 2. RESPONSIBILITY  
  • Assistant – Engineering   – To follow the SOP
  • Executive – Engineering  – To comply the SOP
  • 3. PROCEDURE                      
  • Monthly Maintenance
  • Check the plumber block housing bolts, if required tight the bolts.
  • Check the gearbox and motor fastenings, if required tight the fastenings.
  • If the PCS is connected to the Blender check the vacuum pump oil level through view glass, if required top up with vacuum pump oil.
  • Lubricate all the bearings by using the grease gun.
  • Check the electrical lines, contactors and motor terminals, if required tighten the same.
  • Check the chain for slackness, if required tight the slackness and apply grease to the chain links. 
  • Check the inter locks for proper working.
  • Half-Yearly Maintenance
  • Check the gearbox oil viscosity, if required drain the gear oil and refill with new gear oil.
  • Check the taper roller bearings and oil seals of the gearbox, if required replace with new one.
  • Check the motor bearings for abnormality, if required replace the bearings with new one.
  • Check the chain and sprocket assembly, if required replace the sprocket with new one.
  • If the drive is motor-coupled check the coupling and the spider condition, if required replace the spider in the coupling. 
  • 4. ABBREVIATIONS  

          Nil

  • 5. REFERENCES         

          Nil

  • 6. ANNEXURES                       
  • Annexure-1     Monthly preventive maintenance checklist.    
  • Annexure-2     Half Yearly preventive maintenance checklist.

Preventive Maintenance of Multi Mill.


  1. OBJECTIVE             

1.1       To lay down the procedure for Preventive Maintenance of Multi Mill.

  1. RESPONSIBILITY                                                  
  • Assistant – Engineering       – To follow the SOP
  • Executive – Engineering       – To Comply the SOP
  1. PROCEDURE           
  • Monthly Maintenance
  • Check all the fastenings of the unit, if required tight all the fastenings.
  • Check the miller shaft roller bearings, if required clean the bearings and lubricate them.
  • Ensure that the unit is working in forward and reverse directions.
  • Check electrical lines, starter contactors, if necessary clean with CTC.
  • Check the caster wheels for free movement, if required lubricate the wheel bearings.
  • Half Yearly Maintenance
  • Check for the condition of belts, if the unit is belt drive and replace the belts if required.
  • Check for the condition of coupling spider, if the unit is coupling drive and replace the spider if damaged.
  • Check for the condition of Teflon gland packing / Mechanical seal, if necessary replace it.      
  • Check all the bearings of the unit and if required replace them with new bearings.
  • Check the motor winding resistance and AMPS condition should be with in the limits.
  • Check for proper earthing to the equipment.
4.      ABBREVIATIONS

       CTC : CARBON TETRA CHLORIDE

5.      REFERENCES

           Nil       

6. ANNEXURES

  •  Annexure-1     Monthly preventive maintenance checklist
  • Annexure-2     Half-Yearly preventive maintenance checklist.

Preventive Maintenance of Vibro Sifter


  1. OBJECTIVE            
  1. To lay down a procedure for Preventive Maintenance of Vibro Sifter – 12”, 30”.
  • 2.0 RESPONSIBILITY  
  • Assistant – Engineering  – To follow the SOP
  • Executive – Engineering – To comply the SOP
  • 3.0 PROCEDURE                      
  • Monthly Maintenance
  • Check the hopper supporting compression springs for tension and balancing of the hopper.
  • Check the motor amps and working condition should be with in the limits.
  • Check the lead weights for proper vibrating, if required increase or decrease the vibration according to the working action.
  • Lubricate the motor bearings by using grease gun.
  • Check the hopper holding clamps and gaskets, if required replace the gasket.
  • Yearly Maintenance   
  • Check the motor bearings condition for abnormality, if required replace the bearings.
  • Check the motor winding resistance, load current and starter contactors condition, if required clean the contactors with CTC or replace the contactors.
  • Check the castor wheels for free movement, if required clean the bearings and apply the grease to the bearings.
  • Check the condition of the compression springs, if required replace the springs with new springs.
  • 4.0 ABBREVIATIONS    
  • CTC : CARBON TETRA CHLORIDE
  • 5.0 REFERENCES           

Nil.

  • 6.0 ANNEXURES
  • Annexure-1    Monthly preventive maintenance checklist.
  • Annexure-2   Yearly preventive maintenance checklist.