SOP for Operation and Cleaning of Compression Machine

OBJECTIVE

To lay down the procedure for the operation and cleaning of Compression Machines.

SCOPE

The procedure applies to assembling, operating and cleaning the compression machine

RESPONSIBILITY

Operator: Shall be responsible for operating and cleaning of equipment.

Supervisor: Ensuring that procedure is appropriately followed for optimum output and longer machine life span.

PROCEDURE

Operation of Machine

• Check the lubrication of the machine after every changeover.
• After cleaning, if the machine is not utilized within 24 hrs. clean the machine with lint free duster before use.

• At the end of the day, remove the upper punches and put it again after cleaning them with dusters.
• Record and sign the destruction details in respective product BMR.
• Wear a nose mask & hand gloves.

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• Rotations of the machine should be in a clockwise direction.
• Check punches are free in punch guides.
• Check punch's body is lightly smeared with oil.
• Check feed frame is properly assembled.
• Update the status board with details.
• Keep the machine OFF. & engage the clutch by pulling out the clutch lever.
• Keep the machine ON and rotate the machine by jog and complete the rotation of the turret to ensure proper setting of dies and punches.
• Load the blend in the hopper, if necessary adjust the height of the hopper.
• Keep the polythene-lined container below the chute.
• Rotate the machine by jog and increasing the sufficient pressure to form tablets
• Rotate the machine by jog and complete the rotation of the turret to ensure free rotation
• Disengage the clutch.
• Switch ‘ON’ the mains.

• Switch ‘ON’ the machine.
• Operate the clutch.
• Collect the sample tablets of one rotation & check the specifications as per the respective product BMR.
• Check the parameters of tablets as per the respective product batch manufacturing records.
• If necessary, adjust the parameters by setting the machine as per respective product BMR.
• Compress the batch as per standard parameters specified in the respective product BMR.
• Check the parameters are within limits, as per the frequency given in BMR.
• After completion of compression stop the machine by disengaging the clutch.
• After completion switch off the machine by pushing the OFF switch.
• Switch off the mains.
• Make the machine dust-free by a vacuum cleaner.
• Update the status board with details.
• Release compression pressure.

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Cleaning of Machine

Cleaning for product-to-product change over

• Update the status board with details.
• Release the pressure of the lower punch by rotating the pressure wheel spring anti-Clockwise.
• Remove powder from a turret, upper punches, lower punches & machine by a vacuum Cleaner.
• Remove the hopper, upper punch locking plate per punches & feed frame by unscrewing the screws.
• Remove side guards by unscrewing the screws.
• Clean the upper punches with diesel and duster.

• Apply oil on the tip and body & store in the punch box.
• Unscrew the lower punch anti-turning device.
• Remove the lower punch window lock.
• Remove lower punches. Clean the lower punches with diesel and duster.
• Apply oil on the tip and body of the lower punches & store in the punch box.
• Unscrew the die-locking screw. Remove the dies with the help of Tommy.
• Clean the dies & keep them in a punch box.
• Clean the body of the machine from top to bottom with diesel and duster.
• Clean the die, apply oil to the screws & punch guides with diesel & duster.
• Remove the feed frame stand by unscrewing the screws.
• Wash the feed frame stand, feed frames & hopper with water till visually it is cleaned.
• Wash the feed frame stand, feed frames & hopper with 1% soap solution.
• Wash the feed frame stand, feed frames & hopper with water till the detergent is removed.
• Rinse the feed frame stand, feed frames & hopper with purified water.
• Send rinse sample for QC analysis.
• Keep the cleaned parts on a clean SS trolley. Allow them to dry.
• Take out the punch box & store in punch storage racks.
• If the machine is not used after cleaning within 24 hours, the Machine to be re-cleaned by following the procedure above.

Cleaning for batch-to-batch changeover

• Frequency of cleaning to be done after every 3 batches
• Clean the machine as per the above steps.

Setting of the machine for round punches

• Take the required punch set. Clean the dies with dusters from inside & outside.
• Ensure the cleanliness of machines change parts, machine, and de-dusting units & filter bags.
• Fix the dies in die cavities with the help of Tommy. Fix the dies by tightening the die-locking screw.
• Clean the lower punches with a clean cloth and smear the body of the punches with oil.
• Remove the oil from the tip.

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• Put the lower punches through the punch-loading plug.
• After putting all lower punches close the lower punch-loading hole by window lock.
• Tighten the punch anti-rotating pins to prevent the rotating of punches.
• Tighten the lower punches so tight that punches should move up & down after pressing only.
• Smear the oil to the body of the upper punches. Put the upper punches.
• Rotate the turret by hand wheel & check for setting.
• Fix the lower cam guards. Fix the feed frame stands & feed frames.
• Fix the hopper.
• Update the status with details.

Setting of the machine for shaped punches

• Take the required punch set. Clean the dies with dusters from inside & outside.
• Remove the upper punch cam plate. Place upper punches smeared with oil to the body & place the die with punch tip in the die cavity.
• Fix the die by hammering gently along with an upper punch and tightening the die-locking nut.
• Check the free movement of the upper punch & fix other punches in the same manner.
• Fix the upper punch cam plate. Rotate the machine by hand and & check the settings.
• Fix the removed piece on the upper punch cam plate.
• Fix the dies in die cavities with the help of Tommy. Fix the dies by tightening the die-locking screw.
• Clean the lower punches with a clean cloth and smear the oil on the body of the punches.
• Remove the oil from the tip.
• Put the lower punches through the punch-loading plug.
• After putting all lower punches close the lower punch-loading hole by plug.
• Tighten the punch anti-rotating pins to prevent the rotating of punches.
• Tight the lower punches so tight that punches should move up & down after pressing only.
• Put the upper punches. Rotate the turret by hand wheel & check for setting.
• Fix the lower cam guards.
• Fix the feed frame stands & feed frames.
• Set the scraper blade & ejector plate & ejection level. Fix the hopper.
• Update the status with details.

ABBREVIATIONS

SOP: Standard operating procedure

BMR: Batch Manufacturing Record.

SS: Stainless steel.

REFERENCES

Equipment manual

REVISION HISTORY

Nil

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