Materials & Streams Report

April 13, 2015

for Tugas2_SPF_AuliaRahmi-EtriDianK-SandraMonica
1. OVERALL PROCESS DATA
Annual Operating Time
Recipe Batch Time
Recipe Cycle Time
Number of Batches per Year
MP = Undefined

2,078.55h
22.35h
22.35h
93.00

- Page 1 -

2.1 STARTING MATERIAL REQUIREMENTS (per Section)

Section

Starting Material Active Product

Amount
Needed
(kg
Sin/kg
MP)

Main Section

(none)

Unknown Unknown Unknown Unknown

(none)

Molar
Yield
(%)

Mass
Yield
(%)

Gross
Mass
Yield
(%)

Sin = Section Starting Material, Aout = Section Active Product

2.2 BULK MATERIALS (Entire Process)

Material
Active Ingredie
Carton Box
Deionized Water
Emulsifier
Emulsifying Wax
Excipient
Foam Stable
Ointment
Pallet Box
Tube Plastic
Water
TOTAL

kg/yr

kg/batch

186
20,150
12,812
5,580
670
22
2,678
2,232
60,450
806
102,178
207,764

2.000
216.667
137.760
60.000
7.200
0.240
28.800
24.000
650.000
8.667
1,098.693
2,234.026

kg/kg MP

- Page 2 -

2.3 BULK MATERIALS (per Section)

SECTIONS IN: Main Branch
Main Section
Material

kg/yr

kg/batch

186
20,150
12,812
5,580
670
22
2,678
2,232
60,450
806
102,178
207,764

2.000
216.667
137.760
60.000
7.200
0.240
28.800
24.000
650.000
8.667
1,098.693
2,234.026

% Total

kg/yr

kg/batch

100.00
100.00

186
186

2.000
2.000

% Total

kg/yr

kg/batch

100.00
100.00

20,150
20,150

216.667
216.667

% Total

kg/yr

kg/batch

100.00
100.00

12,812
12,812

137.760
137.760

Active Ingredie
Carton Box
Deionized Water
Emulsifier
Emulsifying Wax
Excipient
Foam Stable
Ointment
Pallet Box
Tube Plastic
Water
TOTAL

kg/kg MP

2.4 BULK MATERIALS (per Material)

Active Ingredie
Procedure
Main Section (Main Branch)
P-3
TOTAL

Carton Box
Procedure
Main Section (Main Branch)
P-6
TOTAL

Deionized Water
Procedure
Main Section (Main Branch)
P-4
TOTAL

kg/kg MP

kg/kg MP

kg/kg MP

- Page 3 -

Emulsifier
Procedure
Main Section (Main Branch)
P-1
P-2
TOTAL

Emulsifying Wax
Procedure
Main Section (Main Branch)
P-1
P-2
TOTAL

Excipient
Procedure
Main Section (Main Branch)
P-3
TOTAL

Foam Stable
Procedure
Main Section (Main Branch)
P-1
P-2
TOTAL

Ointment
Procedure
Main Section (Main Branch)
P-1
P-2
TOTAL

Pallet Box
Procedure
Main Section (Main Branch)
P-8
TOTAL

% Total

kg/yr

kg/batch

50.00
50.00
100.00

2,790
2,790
5,580

30.000
30.000
60.000

% Total

kg/yr

kg/batch

50.00
50.00
100.00

335
335
670

3.600
3.600
7.200

% Total

kg/yr

kg/batch

100.00
100.00

22
22

0.240
0.240

% Total

kg/yr

kg/batch

50.00
50.00
100.00

1,339
1,339
2,678

14.400
14.400
28.800

% Total

kg/yr

kg/batch

50.00
50.00
100.00

1,116
1,116
2,232

12.000
12.000
24.000

% Total

kg/yr

kg/batch

100.00
100.00

60,450
60,450

650.000
650.000

kg/kg MP

kg/kg MP

kg/kg MP

kg/kg MP

kg/kg MP

kg/kg MP

- Page 4 -

Tube Plastic
Procedure
Main Section (Main Branch)
P-5
TOTAL

Water
Procedure
Main Section (Main Branch)
P-1
P-2
P-3
TOTAL

% Total

kg/yr

kg/batch

100.00
100.00

806
806

8.667
8.667

% Total

kg/yr

kg/batch

13.78
13.78
72.45
100.00

14,076
14,076
74,026
102,178

151.354
151.354
795.984
1,098.693

kg/kg MP

kg/kg MP

2.5 BULK MATERIALS: SECTION TOTALS (kg/batch)

Raw Material
Active Ingredie
Carton Box
Deionized Water
Emulsifier
Emulsifying Wax
Excipient
Foam Stable
Ointment
Pallet Box
Tube Plastic
Water
TOTAL

Main Section
2.000
216.667
137.760
60.000
7.200
0.240
28.800
24.000
650.000
8.667
1,098.693
2,234.026

- Page 5 -

2.6 BULK MATERIALS: SECTION TOTALS (kg/yr)

Raw Material
Active Ingredie
Carton Box
Deionized Water
Emulsifier
Emulsifying Wax
Excipient
Foam Stable
Ointment
Pallet Box
Tube Plastic
Water
TOTAL

Main Section
186
20,150
12,812
5,580
670
22
2,678
2,232
60,450
806
102,178
207,764

2.7 DISCRETE MATERIALS (Entire Process)

Material
Tube In
Carton Box In
Pallet Box In

Entities/yr

Entities/batch

1,612,000
80,600
4,030

17,333.333
866.667
43.333

Entities/yr

Entities/batch

1,612,000
80,600
4,030

17,333.333
866.667
43.333

Entities/kg MP

2.8 DISCRETE MATERIALS (per Section)

SECTIONS IN: Main Branch
Main Section
Material
Tube In
Carton Box In
Pallet Box In

Entities/kg MP

- Page 6 -

2.9 DISCRETE MATERIALS (PER MATERIAL)

Tube In
Discrete Stream
Main Section (Main Branch)
Tube In
TOTAL

Carton Box In
Discrete Stream
Main Section (Main Branch)
Carton Box In
TOTAL

Pallet Box In
Discrete Stream
Main Section (Main Branch)
Pallet Box In
TOTAL

% Total

Entities/yr

Entities/batch

100.00
100.00

1,612,000
1,612,000

17,333.333
17,333.333

% Total

Entities/yr

Entities/batch

100.00
100.00

80,600
80,600

866.667
866.667

% Total

Entities/yr

Entities/batch

100.00
100.00

4,030
4,030

43.333
43.333

Entities/kg MP

Entities/kg MP

Entities/kg MP

2.10 DISCRETE MATERIALS (Entities/batch): PER SECTION

Raw Material
Tube In
Carton Box In
Pallet Box In
TOTAL

Main Section
17,333.333
866.667
43.333
18,243.333

2.11 DISCRETE MATERIALS (Entities/yr): PER SECTION

Raw Material
Tube In
Carton Box In
Pallet Box In
TOTAL

Main Section
1,612,000
80,600
4,030
1,696,630

- Page 7 -

3. STREAM DETAILS
Stream Name
Source
Destination
Stream Properties

Emulsifying Wax
INPUT
P-1

Foam Stable
INPUT
P-1

Emulsifier
INPUT
P-1

Ointment
INPUT
P-1

0.00
25.00
1.01
1,258.08
0.06
14.39
0.58

0.00
25.00
1.01
994.70
0.42
24.96
1.00

0.00
25.00
1.01
1,258.08
0.50
14.39
0.58

0.00
25.00
1.01
1,258.08
0.20
14.39
0.58

0.000
3.600
0.000
0.000
3.600
2.862

0.000
0.000
14.400
0.000
14.400
14.477

30.000
0.000
0.000
0.000
30.000
23.846

0.000
0.000
0.000
12.000
12.000
9.538

Activity (U/ml)
Temperature (C)
Pressure (bar)
Density (g/L)
Total Enthalpy (kW-h)
Specific Enthalpy (kcal/kg)
Heat Capacity (kcal/kg-C)

Component Flowrates (kg/batch)

Emulsifier
Emulsifying Wax
Foam Stable
Ointment
TOTAL (kg/batch)
TOTAL (L/batch)

- Page 8 -

Stream Name
Source
Destination
Stream Properties
Activity (U/ml)
Temperature (C)
Pressure (bar)
Density (g/L)
Total Enthalpy (kW-h)
Specific Enthalpy (kcal/kg)
Heat Capacity (kcal/kg-C)

Emission 1
P-1
OUTPUT

P1 Out
P-1
P-3

DI Water Heated DI Water

INPUT
P-4
P-4
P-3

0.00
62.50
1.01
1.05
0.00
15.14
0.24

0.00
28.80
7.77
1,180.79
1.36
19.50
0.68

0.00
25.00
1.01
994.70
4.00
24.96
1.00

0.00
50.00
1.01
985.59
7.99
49.91
1.00

0.000
0.000
0.000
0.000
0.012
0.000
0.004
0.016
15.452

0.000
30.000
3.600
14.400
0.000
12.000
0.000
60.000
50.814

137.760
0.000
0.000
0.000
0.000
0.000
0.000
137.760
138.493

137.760
0.000
0.000
0.000
0.000
0.000
0.000
137.760
139.774

Foam Stable 2

Emulsifier 2

Ointment 2

INPUT
P-2

INPUT
P-2

INPUT
P-2

0.00
25.00
1.01
1,258.08
0.06
14.39
0.58

0.00
25.00
1.01
994.70
0.42
24.96
1.00

0.00
25.00
1.01
1,258.08
0.50
14.39
0.58

0.00
25.00
1.01
1,258.08
0.20
14.39
0.58

0.000
3.600
0.000
0.000
3.600
2.862

0.000
0.000
14.400
0.000
14.400
14.477

30.000
0.000
0.000
0.000
30.000
23.846

0.000
0.000
0.000
12.000
12.000
9.538

Component Flowrates (kg/batch)

Deionized Water
Emulsifier
Emulsifying Wax
Foam Stable
Nitrogen
Ointment
Oxygen
TOTAL (kg/batch)
TOTAL (L/batch)

Stream Name
Source
Destination
Stream Properties
Activity (U/ml)
Temperature (C)
Pressure (bar)
Density (g/L)
Total Enthalpy (kW-h)
Specific Enthalpy (kcal/kg)
Heat Capacity (kcal/kg-C)

Emulsifiying
Wax 2
INPUT
P-2

Component Flowrates (kg/batch)

Emulsifier
Emulsifying Wax
Foam Stable
Ointment
TOTAL (kg/batch)
TOTAL (L/batch)

- Page 9 -

Stream Name
Source
Destination
Stream Properties
Activity (U/ml)
Temperature (C)
Pressure (bar)
Density (g/L)
Total Enthalpy (kW-h)
Specific Enthalpy (kcal/kg)
Heat Capacity (kcal/kg-C)

Emission 2
P-2
OUTPUT

P2 Out
P-2
P-3

Excipient Active Ingredient

INPUT
INPUT
P-3
P-3

0.00
62.50
1.01
1.05
0.00
15.14
0.24

0.00
28.80
7.77
1,180.79
1.36
19.50
0.68

0.00
25.00
1.01
994.70
0.01
24.96
1.00

0.00
25.00
1.01
994.70
0.06
24.96
1.00

0.000
0.000
0.000
0.000
0.000
0.012
0.000
0.004
0.016
15.452

0.000
30.000
3.600
0.000
14.400
0.000
12.000
0.000
60.000
50.814

0.000
0.000
0.000
0.240
0.000
0.000
0.000
0.000
0.240
0.241

2.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
2.000
2.011

Component Flowrates (kg/batch)

Active Ingredie
Emulsifier
Emulsifying Wax
Excipient
Foam Stable
Nitrogen
Ointment
Oxygen
TOTAL (kg/batch)
TOTAL (L/batch)

- Page 10 -

Stream Name
Source
Destination
Stream Properties
Activity (U/ml)
Temperature (C)
Pressure (bar)
Density (g/L)
Total Enthalpy (kW-h)
Specific Enthalpy (kcal/kg)
Heat Capacity (kcal/kg-C)

P3 Out
P-3
P-5

Tube In
INPUT
P-5

Tubed Cream
P-5
P-6

Carton Box In
INPUT
P-6

0.00
25.00
1.01
1,073.54
6.42
21.25
0.85

0.00
25.00
1.01
2,521.33
0.07
7.03
0.28

0.00
25.00
1.01
1,093.80
6.49
20.79
0.83

0.00
25.00
1.01
1,173.66
2.99
11.87
0.47

2.000
0.000
137.760
60.000
7.200
0.240
28.800
24.000
0.000
260.000
242.190

0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
8.667
8.667
3.437

2.000
0.000
137.760
60.000
7.200
0.240
28.800
24.000
8.667
268.667
245.628

0.000
216.667
0.000
0.000
0.000
0.000
0.000
0.000
0.000
216.667
184.608

Component Flowrates (kg/batch)

Active Ingredie
Carton Box
Deionized Water
Emulsifier
Emulsifying Wax
Excipient
Foam Stable
Ointment
Tube Plastic
TOTAL (kg/batch)
TOTAL (L/batch)

- Page 11 -

Stream Name
Source
Destination
Stream Properties
Activity (U/ml)
Temperature (C)
Pressure (bar)
Density (g/L)
Total Enthalpy (kW-h)
Specific Enthalpy (kcal/kg)
Heat Capacity (kcal/kg-C)

Tubed Cream in
Wrapped Cream
Carton
P-6
P-7
P-7
P-8

Cream in Pallet
Box
INPUT
P-8
P-8
OUTPUT

Pallet Box In

0.00
25.00
1.01
1,128.06
9.48
16.81
0.67

0.00
25.00
1.01
1,128.06
9.48
16.81
0.67

0.00
25.00
1.01
1,173.66
8.97
11.87
0.47

0.00
25.00
1.01
1,153.72
18.45
13.98
0.56

2.000
216.667
137.760
60.000
7.200
0.240
28.800
24.000
0.000
8.667
485.333
430.235

2.000
216.667
137.760
60.000
7.200
0.240
28.800
24.000
0.000
8.667
485.333
430.235

0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
650.000
0.000
650.000
553.824

2.000
216.667
137.760
60.000
7.200
0.240
28.800
24.000
650.000
8.667
1,135.333
984.059

Component Flowrates (kg/batch)

Active Ingredie
Carton Box
Deionized Water
Emulsifier
Emulsifying Wax
Excipient
Foam Stable
Ointment
Pallet Box
Tube Plastic
TOTAL (kg/batch)
TOTAL (L/batch)

- Page 12 -

4. OVERALL COMPONENT BALANCE (kg/batch)

COMPONENT
Active Ingredie
Carton Box
Deionized Water
Emulsifier
Emulsifying Wax
Excipient
Foam Stable
Nitrogen
Ointment
Oxygen
Pallet Box
Tube Plastic
Water
TOTAL

INITIAL

INPUT

OUTPUT

FINAL

IN-OUT

0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.346
0.000
0.105
0.000
0.000
0.000
0.450

2.000
216.667
137.760
60.000
7.200
0.240
28.800
0.000
24.000
0.000
650.000
8.667
1,098.693
2,234.026

2.000
216.667
137.760
60.000
7.200
0.240
28.800
0.025
24.000
0.008
650.000
8.667
1,098.693
2,234.058

0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.321
0.000
0.097
0.000
0.000
0.000
0.418

0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000

- Page 13 -

5. EQUIPMENT CONTENTS
V-101
Procedure

Operation

P-1
P-1
P-1
P-1
P-1
P-1
P-1
P-1
P-1

START
CHARGE-1 (Charge)
HEAT-1 (Batch Heating)
CHARGE-2 (Charge)
CHARGE-3 (Charge)
CHARGE-4 (Charge)
AGITATE-1 (Agitation)
TRANSFER-OUT-1 (Transfer Out)
CIP-1 (In-Place-Cleaning)

V-102
Procedure

Operation

P-2
P-2
P-2
P-2
P-2
P-2
P-2
P-2
P-2

START
CHARGE-1 (Charge)
HEAT-1 (Batch Heating)
CHARGE-2 (Charge)
CHARGE-3 (Charge)
CHARGE-4 (Charge)
AGITATE-1 (Agitation)
TRANSFER-OUT-1 (Transfer Out)
CIP-1 (In-Place-Cleaning)

V-103
Procedure

Operation

P-3
P-3
P-3
P-3
P-3
P-3
P-3
P-3
P-3
P-3
P-3
P-3

START
TRANSFER-IN-1 (Transfer In)
CHARGE-1 (Charge)
AGITATE-1 (Agitation)
TRANSFER-IN-2 (Transfer In)
TRANSFER-IN-3 (Transfer In)
AGITATE-2 (Agitation)
COOL-1 (Batch Cooling)
CHARGE-2 (Charge)
AGITATE-3 (Agitation)
TRANSFER-OUT-1 (Transfer Out)
CIP-1 (In-Place-Cleaning)

Time (in h)

Volume (in L)

0.000
0.670
2.750
3.080
3.410
3.740
4.240
4.660
4.740

0.000
2.862
2.976
17.403
41.272
50.814
50.814
0.000
0.000

Time (in h)

Volume (in L)

0.000
0.670
2.750
3.080
3.410
3.740
4.240
4.660
4.740

0.000
2.862
2.976
17.403
41.272
50.814
50.814
0.000
0.000

Time (in h)

Volume (in L)

0.000
0.500
0.830
0.997
1.417
1.837
2.087
21.087
21.167
21.417
22.100
22.350

0.000
139.774
140.017
140.017
190.980
241.890
241.890
240.180
242.190
242.190
0.000
0.000

- Page 14 -

- Page 15 -