PRESENTED BY:
SYED
FASIH AHMAD
History of Nimir
What is Aerosol?
Process
Detail of Process
Interlocking List
Shrink Machine
Health and Safety Environment
OBJECTIVES: Fire Fighting
The company formerly known as “Ravi Alkalis limited”, was incorporated in
1994. NIMIR Chemical Industry is a subsidiary of Knightsbridge Chemical
Limited Bermuda. We are proud of our technical and experienced workers who
are ready to face any challenge regarding plant installation, commissioning,
expansion, maintenance and production.
NIMIR Industry Chemical Limited (NICL) is a customer driven and result
oriented company which produce:
HISTORY OF Stearic Acid
NIMIR: Distilled Fatty Acid
Glycerin
Caustic Soda
Soap Noodles
And other daily use products are also manufactured like Soap, Hand sanitizer,
Shampoo, Body spray and Bath cleaners
It is a filling line. In this filling line different type of cans are filled according to
different customers. By definition “An Aerosol is a suspension of fine solid
particles or liquid droplets in air or another gas.”
NICL has given the name “Aerosol Plant” to the area where they started its
commercial production for different customers.
WHAT IS
AEROSOL?
PROCESS IN AEROSOL:
Following is the flow chart of whole process in aerosol:
Valve
Feeding Filling Star Gas Check
Elevator
Table Machine wheel House Weigher
& Sorter
Cap
Collecting Caping Elevator Actuator Water
Inkjet
table machine & Sorter Inserter bath
PROCESS IN AEROSOL:
FEEDING TABLE:
CE mark is added on the machine:
DETAILED PROCESS:
FEEDING TABLE:
Cans to be filled are placed on the conveyor and feeding of the cans on the line is carried out.
TECHNICAL INFORMATION:
SETTING:
SET THE MACHINE TO RUN
INSTRUMENT DETAIL:
SOV 5/2
Make # FESTO, Pressure # 1.8-8 Bar, 24-120 psi, Model # MFH-5-1/8-Ex, Total # 1
Air Regulator (5 Bar)
Make # FESTO, P1 max # 14 Bar / 210 psi, P2 max # 7 Bar / 105 psi, Model # MS4-LR-1/4-D6-AS, Total # 1
Cylinder (Moving piston)
Make # FESTO, Pmax # 10 Bar, Model # ADN-20
VALVE SORTER:
CE mark is added on the machine:
DETAILED PROCESS:
VALVE ELEVATOR & SORTER
The next step is Valve Elevator , which contain valves that are dropped into the sorter. It is automatic and manually
operated.
After that valves are sorted in a Valve Sorter and by pneumatic suction valves are drawn towards filling machine,
TECHNICAL INFORMATION:
INSTRUMENT DETAIL:
Valve Elevator:
Proximity Sensor
Valve Sorter:
SOV
Make # FESTO, Pressure # 1.8-8 Bar, 24-120 psi, Model # MFH-5-1/8-Ex
Proximity Sensor
Make # KGS, Model # Q45AD9FQ,MFR Code# 19350A, Total # 2
Air Regulator
LIQUID FILLING MACHINE:
CE mark is added on the machine:
DETAILED PROCESS:
LIQUID FILLING MACHINE:
In front of automatic and semi-automatic lines, the aerosol tubes to be filled are placed on conveyor table with an
automatic elevator system or manually. The empty cans that are placed on the wide rim section are turned into a single
row before entering a next unit.
There are 4 nozzles & liquid pistons, 2 valve inserter group, 2 valve crimper group on the unit. (Line#2 contains 6
nozzles & liquid piston).
The aerosol cans enters the machine, and they are transferred through starwheel model.
There must be aerosol tubes in front of inlet sensor to operate the machine.
If there is no tube at machine outlet sensor, machine keeps running.
The capacity of filling machine is 120 cans per min (360 cans per hour).
Liquid Filling Machine
TECHNICAL INFORMATION:
SETTING:
SET THE MACHINE TO RUN
INSTRUMENT DETAIL:
ON/OFF Valve
Make # Tork
Pressure Indicator
Make # Pakkens
Proximity sensor (Inlet + Outlet)
Make # KGS, Model # Q45AD9FQ,MFR Code# 19350A
Limit switch at Crimper
Make # Waircom, Type # Pneumatic (3/2)
SOV
STAR WHEEL/COMBINER:
CE mark is added on the machine:
DETAILED PROCESS:
STAR WHEEL/COMBINER:
Star wheel/Combiner is next step after filling of liquid in cans.
The star wheel only provide direction to the cans.
There must be aerosol tubes in front of inlet sensor to operate the machine.
If there is no tube at machine outlet sensor, machine keeps running.
PROPELLANT UNIT/GAS HOUSE:
CE mark is added on the machine:
DETAILED PROCESS:
PROPELLANT UNIT:
Propellant Filling Machine, is the unit that pressurizes the pressurized gas in the cylinder, after liquid filling, valve
inserting and crimping, to make the liquid spray when the product becomes a final product. This gas may be LPG,
nitrogen or pressurized air depending on the process.
Some customers products does not require gas to that product is simply by-pass through the gas unit.
There are 6 separate nozzles and gas pistons on the unit.
There must be aerosol tubes in front of inlet sensor to operate the machine.
If there is no tube at machine outlet sensor, machine keeps running.
The capacity of gas house ‘line#1’ is ‘230ml’ and ‘line#2’ is ‘600ml’.
Propellant Unit
TECHNICAL INFORMATION:
SETTING:
SET THE MACHINE TO RUN
CHECK WEIGHER:
CE mark is added on the machine:
DETAILED PROCESS:
CHECK WEIGHER:
Liquid filling and gas filling are performed with certain weight adjustment. The next step is Check Weigher.
Bottles enter the weighing device. The accuracy of the product weighed is checked.
Faulty products are separated at the end of weighing device.
There must be aerosol tubes in front of inlet sensor to operate the machine.
If there is no tube at machine outlet sensor, machine keeps running.
Check Weigher
TECHNICAL INFORMATION:
SETTING:
SET THE MACHINE TO RUN
WATER BATH:
CE mark is added on the machine:
DETAILED PROCESS:
WATER BATH:
The next step is Water Bath. The cans that contain gas are passed through water bath.
In this process we heat the cans up to 50-55 ℃. To check the compatibility of cans.
There must be aerosol tubes in front of inlet sensor to operate the machine.
If there is no tube at machine outlet sensor, machine keeps running.
Conveyor distance should be adjusted according to the diameter of cans.
The capacity of Water Bath is ‘860 cans’ per 4/5 min.
Water bath
TECHNICAL INFORMATION:
SETTING:
SET THE MACHINE TO RUN
ACTUATOR INSERTER MACHINE:
CE mark is added on the machine:
DETAILED PROCESS:
ACTUATOR INSERTER MACHINE:
The Actuator sorting and inserting machine allows that the liquid and propellant mixture in the aerosol tube to be blown
out.
The product with propellant filling are brought to the machine mounted form by means of a sorter according to the type
of actuator specified in the process. The actuator to the inserting machine by an air route are attached to the pin of valves
with hammering.
The actuator are transferred to the sorter with the help of vibration.
There is a main air valve. The air pressure is set to 7 bar with main air regulator. In sorter the false position actuator are
rejected by air blowing nozzles.
Infront of sensor is full sorter stops working.
Infront of sensor is full of machine the machine starts working and stops when sensor is empty.
Actuator Inserter
Machine
TECHNICAL INFORMATION:
SETTING:
SET THE MACHINE TO RUN
CAP ELEVATOR AND CAPPING MACHINE:
CE mark is added on the machine:
DETAILED PROCESS:
CAPPING MACHINE:
One of the final process is Capping. Propellant gas filled and actuator inserted products are packed by capping.
The caps are arranged in the same format by means of a sorter and brought to the place where capping are to be removed
via a conveyor. The capping heads take the caps, clamp them by hammering on a rotatory table and prepare them for
packing.
The cans enter into the machine, and they are transferred through starwheel mold.
Faulty position caps are rejected by air blowing nozzles
In front sensor of sorter is full, sorter stops working.
In front sensor of machine is full machine starts working and stops when sensor is empty.
If there in no cans at outlet sensor, machine keeps working.
Capping Machine
Cap Sorter Cap Elevator
TECHNICAL INFORMATION:
TECHNICAL INFORMATION:
SETTING:
SET THE MACHINE TO RUN
PNEUMATIC DIAGRAM OF CAPPING MACHINE:
INKJET UNIT:
CE mark is added on the machine:
DETAILED PROCESS:
INKJET UNIT:
The aerosol cans enter into the machine, and they are transferred through starwheel molds, injected spray system prints
serial no and date under the aerosol cans.
There must be cans in front of inlet sensor to operate the machine.
If there is no can at machine outlet conveyor, machine keeps running other is full the machine stops.
Inkjet Unit
TECHNICAL INFORMATION:
SETTING:
SET THE MACHINE TO RUN
PNEUMATIC DIAGRAM OF INKJET UNIT:
INTERLOCKING LIST OF AEROSOL
Machine Title Key Features Interlocking with Gas detector
Door Limit switch
Interlocking with Gas detector
Safety Clutch
No can no Fill Water Bath High Temperature Alarm
No valve no machine operation Low Water level Alarm
Liquid Filling Machine, Infeed Conveyer empty no machine operation
Valve Sorter & Elevator Door Limit switch
Output Conveyer full no machine operation
Safety Clutch
Interlocking with Gas detector
Infeed Conveyer empty no machine operation Door Limit switch
Output Conveyer full no machine operation Safety Clutch
Actuator Inserter Infeed Conveyer empty no machine operation
Ex-Proof Flame Detector
Actuator conveyer full stop sorter
Interlocking with Gas detector
No Actuator no machine operation
Interlocking with Gas House Door Output Conveyer full no machine operation
Extraction System Door Limit switch
Safety Clutch
No Extraction no machine operation
Infeed Conveyer empty no machine operation
Gas House No can no Fill Capping Machine, Sorter &
Elevator Cap Conveyer full stop sorter
Primary & Secondary Ventilation Cap sorter full stop Elevator Conveyer
Door Limit switch No Cap no machine operation
Output Conveyer full no machine operation
Emergency Stop Access: Inside & Outside
Safety Clutch
Infeed Conveyer empty no machine operation Inkjet Machine Infeed Conveyer empty no machine operation
Output Conveyer full no machine operation Output Conveyer full no machine operation
SHRINK MACHINE
SHRINK INTERLOCKING LIST
Machine Title Key Features
Infeed Conveyer empty no machine operation
Machine Security Doors are open
Oven Security Doors are open
Product fell in oven
Oven exit is full
Shrink Machine Gas Alarm
Flame Detector
Product failed
Upper Nylon Finished
Lower Nylon Finished
Emergency Stop
MIXING HALL 1 & 2
Following is the process in mixer area:
Storage
Ethanol Ethanol Ready
Tanks
Tank Yard Filter Batch
(1.5 Ton)
From Ethanol tank Yard material in transferred to mixing hall through diaphragm pump.
There is a filter to release the pressure created due to ethanol and then the ethanol is stored in storage tanks.
According to requirement different chemicals and Demin water in added with ethanol to ready the batch.
Following are the instruments in mixer area:
Ethanol Gas Detectors (10% Alarm, 20% Tripping)
Pressure Gauges
Mixer Hall # 1 VFDs (Both are of 5.5KW, 400v, 3 Phase)
Mixer Hall # 2 VFDs (Both are of 11KW, 15 Hp)
COMPRESSOR ROOM
DALGA KIRAN (ROTARY SCREW COMPRESOR)
Specification
Dryer
