ADVANCED FOIL UNWINDING MECHANISM

COMPANY PROFILE

HLL Lifecare Limited (HLL) commenced its journey to serve the Nation in the area
of healthcare, on 1st March 1966, with its incorporation as a corporate entity under the
Ministry of Health and Family Welfare of the Government of India. HLL was set up in the
natural rubber rich state of Kerala, for the production of male contraceptive sheaths for the
National Family Planning Programme. The company commenced its commercial operations
on April 5, 1969 at Peroorkada in Thiruvananthapuram. The plant was established in
technical collaboration with M/s Okomoto Industries Inc. Japan. Two most modern plants
were added, one at Thiruvananthapuram and the other at Belgaum in 1985.
The production facility at Peroorkada has emerged as one of the largest single
manufacturing plant in the world for the production of Condoms, with a capacity to produce
over 1 Billion Condoms a year. With the addition of this capacity, HLL today has an annual
production capacity of 1.316 billion condoms.
The manufacturing unit at Peroorkada was set up by HLL in 1969 with the technical
collaboration using Japanese technology. The plant is equipped with modern production,
inspection and quality control machines and equipment’s in international quality norms.
Condoms manufactured by this facility have CE mark and can meet a range of international
quality norms by WHO 2003 , ISO 4074:2002 ,SANS ISO 4074 , ASTM D 3492 , GOST4045-81 etc

. HLL is today a multi-product. after passing the incoming instruction made by material testing department are received from stores department. Naked condoms from QA are received batch wise and deferred batch coding will be then generated in the packing stage corresponding to QA batch. The facility is equipped with modern production. The plant which has an annual production of 1066 million pieces condoms undergone continuous modernization over the years. Following departments are functioning in PFT i) Production Planning and Control (PPC) Department and Material Procurement and Control (MPC) Department ii) Primary Production Department iii) Quality Assurance Department iv) Electronic Testing Department v) Packing Department vi) Material Testing Lab vii) Purchase Department viii) Engineering Department ix) Human Resource Department x) Accounts Department xi) Stores and Sales xii) Safety Department xiii) System Department Packing section is one of the last step of Production Department of PFT. pouches. with a capacity to produce over 1 Billion Condoms a year. cartons. boxes etc. inspection and quality control machines and equipments in international quality norms. wallets. The production facility at Peroorkada has emerged as one of the largest single manufacturing plants in the world for the production of Condoms. Silicon oil. multi-unit organization addressing various public health challenges facing humanity. Foils.INTRODUCTION The manufacturing unit at Peroorkada was set up by HLL in 1969 with the technical collaboration using Japanese technology.

Required quantity of silicon oil is dosed in the strips as part of machine operation. Thus 3 line packing is done in this machine. and naked condoms. Foil unwinding mechanism in the machine is having a lot of problems like varying tension in the foils. foil printing and primary packing in foil.  ST machine (Static Square Machine): This machine is used for square type foil. The so called problems are now reduced with the help of dead weights and supporting rollers. Here batch printing is done offline. Sealing temperatures provided here is 100oC. The machine under study is BRT machine ( Boryung Rotary Technology Machine) used for the packing of condoms. activities undertaken are dosing of lubricant. Quality of silicon oil dosed is as per customer standards. This machine is mainly used for Govt. Here condoms are fed in a vibrating tray and due to vibrations condoms are aligned on feeder. After completion of packing of a batch.Naked condoms are issued to packing machines for strip packing in foils as per the packing systems.170 mm foil is used. The speed of each line is 40 pieces/min. In this machine jumbo reel ie. Primary packing : The input materials using in this process are foil.  SS machine (Static Square Machine): This machine is used for square type foil. Strips are packed in pouches and wallets and then to cartons and boxes as per customer requirements. Here batch printing is done offline. Speed of machine is 60 pieces / min. it is informed to QA department for inspection. This machine is mainly used for domestic or export orders. Speed of machine is 60 pieces / min. This machine is mainly used for domestic or export orders.  BRT machine (Boryung Rotary Technology Machine): This machine is automatic machine. Here batch printing is done online using water based ink. . silicon oil. varying release rate of foil. For primary packing we are using 4 types of machines:  SR machines (Single Rectangular Machine): In this machine we are using squeeze type foil. But for the machine to be more efficient a new mechanism for foil unwinding should be implemented. Under Primary packaging. order and free supply. Speed of machine is 83 pieces / min.

OBJECTIVE The main objective of the project is to identify the problem of foil unwinding in the BRT machine ( Boryung Rotary Technology Machine) and to design and fabricate an advanced system for the same. .

tension in the foil. torque. slip etc.  Speed of the machine.  Propose a new mechanism for foil unwinding  Design of the new mechanism  Fabrication of the mechanism .METHODOLOGY  Data Collection  Includes collection of the drawing of the particular machine  Study about the current mechanism used for foil unwinding.