Industrial Processes - Presentation

Industrial Process
Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Contents
1 FACTORY PLANNING AND LAYOUT

2 PRODUCTION SYSTEM AND AUTOMATION
3 MATERIAL FLOW, PROCESS SEQUENCES AND AUTOMATION & CONTROL
4 INDUSTRIAL PROCESSES
i IRON, STEEL & NON-FERROUS METAL PRODUCTS
ii TEXTILE
iii DAIRY
iv VEGETABLE OIL
v CHEMICAL
vi PHARMACEUTICALS
vii PLASTIC
viii RUBBER

Contents
ix PAPER
x PRINTING, BINDING AND PUBLISHING
xi FOOD (BREAD)
xiii SOFT DRINK

Factory Planning and Layout
Plant Location:
“A plant is a place where men, materials, machines and equipment are brought together for manufacturing a
product”.
Three major consideration in the plant location are;

 The need to produce close to the customer
 The need to locate near the appropriate labour force
 Availability of raw material
A Valuer has to examine the plant site and its layout while assessing the value of the plant.

Plant Layout:
A plant layout is a systematic arrangement of various departments, machines, equipment and services of men
for economical, effective and efficient functioning of an organization for production of any goods. It includes;
 Space needed for material movement
 Storage & Hazardous materials storage
 Emergency escape & Product size
Types of Plant Layout:

Fixed Position Layout: Materials stays at fixed place and Machines are moving. Aircraft and Ship buildings are
examples of fixed position layout.

Process Layout:
Machines are fixed and Materials are moving. Small scale production units, repair and maintenance shops are
examples of process layout.
Product Layout:
The volume of production is high where separate production line is justified like Automobile Industries, TV,
Refrigerator, Air conditioner, Washing machine.

Group Layout:
Groups of different equipment performs a sequence of operation like Automotive component manufacturing.

Production System and Automation
Production system means manpower, materials, machines and methods in order to accomplish the
manufacturing operation of the company and part of the production systems are automated.
Type of Production:
Job Shop Production (One-off Production): Low volume production of customized products such as aircraft,
power plants, submarine, ships.
Batch Production: Product is prepared stage by stage over a series of workstations and different batches of
products are made. Bakery products, pharmaceuticals ingredients etc. are examples of such production.
Mass Production: Large volume to satisfy high demand and it is a continuous process to manufacture identical
parts.
 Quantity production: manufacturing of single parts on standard machines with the use of special dies,
moulds. Screws, nuts, nails are examples of such production
 Flow line production (Continuous): To manufacture high volumes of products with high production rates
and low costs. Separate dedicated flow line is created for each product. Dedicated machines are used to
manufacture the products at high production rates. Assembly lines of cars, bulbs, razors, chemical plants,
refineries are examples of such production.

Production System and Automation
Automation can be defined as the process of following a predetermined sequence of operations with little or
no human labour, specialized equipment and devices that perform and control manufacturing process.
Programmable Logic Controller (PLC) system is the most advance version of automation used in the industries
which is reducing space, saves energy, easy maintenance, economical, greater life & reliability, flexibility, less
project time. Automation in manufacturing plants can be implemented in manufacturing process, material
handling, inspection, assembly and packaging.
Type of Automation::
Fixed Automation or Hard Automation: Sequence of processing operations are fixed by the equipment
configuration. Many operations are integrated into a single piece of equipment. Production lines are designed to
produce a standardized product such as engine blocks, valves, gears and spindle. It has high production rates
hence used for mass production of parts. Examples of fixed automation include machining transfer lines found
in the automotive industry, automatic assembly machines.
Programmable Automation: Sequence of operations are controlled by a program so the same equipment is used
to produce different products. CNC, industrial robots and PLCs are examples of programmable automation.
Flexible Automation: It is an extension of programmable automation as there is no time lost for changeover
from one part type to another while programming the system. It has low production rates.

Material Flow, Process Sequences and Automation & Control
Material Flow:
One of the most important phase of the plant layout is to achieve an optimum effective flow of material through
the plant.
While designing a new plant layout, generally the flow patterns are decided earlier and then system facilities is
designed.
Flow Pattern Flow Pattern Characteristics and Place of Use
Straight, materials enters at one end and leave at other end. It is preferred in
Line Flow buildings having long length and less widths.
Paper Plant
Resembles line flow and used where buildings are more wide but less long.
L Type flow
Asphalt Mixing Plant
Preferred for rotary handling systems.

Circular Flow
Electric Bulb Industry

Supervision is simpler and preferred in square shaped buildings

U type flow
Electric Motor Industry
Preferred in production lines are longer than U type. The system is

S or inverted S compact, space has better utilized and supervision efficient.
Automotive Assembly Line
Combination of U and
Line Flow
Combination of Line
Flow and S type flow
Combination of Line and This system needs smaller building length as compared to line flow.
Circular

The material may be processed while moving upwards or

downwards in multi-storey buildings. In processing downwards,
Processing Upwards
gravity helps to bring the material down but all the material has to
be taken to the top storey.
Retraction type of
It involves more material handling cost as compared to (i) but finds
flow in multi-storey
better space and equipment utilization.
buildings
Such system may be adopted depending upon the process

Inclined Flow
characteristics.

Process Sequence:
Process is a sequence of operations and processes designed to create a specific product. It is nothing but the
turning materials into product. At every stage it covers one or more resources. These outputs then serve as an
inputs for the next stage until a known goal or end result is achieved.
Activities:
Production Planning: Required level of production in a specific time horizon.
Production Scheduling: Allocation of finite resources to meet the demand requirements such as capacity,
precedence, start and due dates.
Production sequence: Resource level ordering of jobs on a shared workstations.

Priority Rules for sequencing Jobs on shared machines:

First come, First served (FCFS): Jobs are assigned to a shared resource in the order in which they are placed
Shortest Processing Time (SPT): Jobs are ordered based on the length of the processing time means jobs with
shortest processing time are ordered first.
Longest Processing Time (LPT): Jobs with the longest processing time are order first.
Earliest Due Date (EDD): Jobs are ordered based on their required delivery dates means jobs with earliest due
dates are order first.

Automation & Process control:

Control in process industries refers to the regulation of all aspects of process.
Manipulated Variables: Valve Position, motor speed, damper position etc.

Controlled Variables: Temperature, Level, Position, Pressure, pH, density, moisture content, weight and speed
The control system must adjust the manipulated variables so the desired value or set point of the controlled
variables is maintained despite of any disturbances.
Process control system consists of four elements:

Process: It consists of an assembly of equipment and material related to manufacturing operation.

Example: Liquid level is placed under control includes components as a tank, liquid, flow of liquid into and out
of from the tank, inlet and outlet piping.
Measurement: It is conversion of the process variable into an analog or digital signal that can be used by the
control system and that device called a sensor or instrument. Typical measurements are pressure, level,
temperature, flow, position and speed.
Evaluation: The measurement value is examined, compared with the desired value or set point and the
corrective action needed to maintain proper control is determined and device called controller. The controller
can be pneumatic, electronic or mechanical.
Control: The control element in a control loops is the device which direct influence on the process or
manufacturing sequence.
In given example it will be a control valve that adjust the flow of liquid in a process.

Type of Process Control System:

Open Loop Control System: A control action is applied on the output of the system. It does not receive any
feedback signal to control or alter the output status.
Set point, Controller, Actuators, Process, Disturbances

Closed Loop Control System:

The output of the process affects the input control signal. The system measures the actual output of the process
and compares it to the desired output.
Comparator, Error Amplifier, Controller, Output Attenuator, Sensor Feedback

Primary Devices of Process Control System:

 Programmable Logic Control
 Distributed Control System

Industrial Process: Steel
Ferrous metals are those which have the iron as their main constituent.
Non-ferrous metals are those which have a metal other than iron as their main constituent.

Overall Process Flow Chart

List of Machine – Iron Ore Beneficiation Plant
1. Jaw Crusher
2. Cone Crusher
3. Ball Mill
4. Spiral Classifier
5. Magnetic Separator
6. Spiral Crusher
7. Magnetic Separator
8. Shaker

List of Machine – Pellet Plant
1. Conveyor
2. Dryer
3. Silo
4. Mixer
5. Balling Discs/Disc Pelletizer
6. Herath Layer Bin
7. Furnace Traveling Grate
8. Rotary Kiln
9. Annual Cooler
10. Bunker

List of Machine – DRI Plant
1. Conveyor
2. Crusher House
3. Product Storage/ Silo
4. Raw Material Handling System (RMHS)
5. Preheater
6. Rotary Kiln

List of Machine – Sinter Plant

2. Storage Bins
3. Mixing Drum
4. Rerolling Drum
5. Sinter Machine / Burner
6. Screen House
7. De dusting System

List of Machine – Blast Furnace Plant

2. Storage Hoppers
3. Vibrating Feeders
4. Blast Furnace
5. Pig Casting Machine

List of Machine – SMS Plant
1. Electric Arc Furnace

2. Slab/Billet Caster
3. Tunnel Furnace
4. Hot Rolling Mill

List of Machine – Coke Oven Plant
1. Raw Material Handling System RMHS)

2. Silo
3. Coal Crusher
4. Stamping Machine
5. Coke Oven Battery
6. Coke Screening

Process Flow Chart – Down Stream

List of Machine – Downstream
1. Pickling Line
 Uncoiler
 Shear & Welder
 Pickling Tank
 Exit looper
 Side Trimmer
 Recoiler
2. Cold Roll Mill
3. Galvanizing Process
 Uncoiler
 Shear & Welder
 Entry Looper
 Furnace
 Skin Pass Mill
 Recoiler
List of Machine – Downstream
4. Colour Coating Process

 Uncoiler
 Pre Treatment Tank
 Back Coater
 Oven
 Dryer
 Prime coater
 Top Coater
 Shearer
 Recoiler
5. Cut to Length
6. HR/CR Slitter
7. Sheet Corrugation Machine

Non Ferrous Metals and Alloys
Process Description of Aluminium

Aluminium is produced mainly from Bauxite (Al2O3, 2H2O) which is hard rated oxide of Aluminium. It’s
production cycle is as under;
Purified Bauxite first dissolved in molten electrolyte of electrical furnace known as Aluminium reduction cell
and then aluminium is separated out by electrolysis in Hoopes’ cell.
Aluminium reduction cell:

 When electric current is passed through the molten
electrolyte, the aluminium is collected at the cathode in
molten state and sinks at the bottom and is tapped off.
 Aluminium metal produced by the electrolysis of
alumina is 99% pure but contains impurities.
Process Description of Aluminium
Hoope’s Cell
 During electrolysis process pure aluminium will be collected at Cathode (middle of three layers) and will be
tapped off from c.

Process Description of Copper
Ore Cleaned, Crushed Calcined in Reverberatory Mixed with silica &

• To remove impurities Furnace coke
• Mixing
Refined Oxidized in Bessemer Smelted in blast

• Fire refining Converter furnace
(Reverberatory • To remove some impurities • Melting in Blast
Furnace) or and giving Blister Copper Furnace
Electrolytic refining

Industrial Process: Textile
Ginning Spinning Weaving Processing

Industrial Process: Textile (Spinning)
COTTON FIBRE IN MIXING AND CARDING (SLIVER) COMBING (SLIVER)

BALES BLOW ROOM (LAP) • Individualized • To remove short
• From ginning mill • Removing fibres fibres
impurities and
Homogenous
blending
RING SPINNING SPEED FRAME DRAW FRAME

• Yarn is twisted and (ROVING) (SLIVER)
YARN manufactured • To reduce the sliver • To make fibres in
diameter parallel to its
neighbour

Industrial Process: Textile (Weaving)
WARPING AND
AUTO CONER BEAMING
WINDING
•To collect number of warps
YARN FROM •To make conical ends from a creel and to
SPINNING package wind them in a sheet called
beam
CLOTH LOOM DRAWING SIZING

•Actual cloth is •Actual cloth is •Prior to weaving , •The yarn is
manufactured manufactured by threads must be impregnated with a
weaving yarns drawn into the drop paste which can
wires withstand the stresses

Industrial Process: Textile (Processing)
GREY CLOTH STITCHING SINGEING DESIZING

INSPECTION •To remove •To remove starches
protruding Fibres
BLEACHING SOURING CHEMICKING SCOURING

•For acceptable •To remove chlorine •To remove colours •To remove natural
whiteness Impurities
MERCERISATION DYEING PRINTING FINISHING

•To increase strength •To dye the fabrics •To print the fabrics
and shiny, silky
appearance

Industrial Process: Dairy (Ice Cream)
BLENDING PASTEURIZATION HOMOGENIZATION

• Ingredients are • To pasteurize mix • To make
weighed and blended homogenized mixer
together to produce Ice
Cream Mix
FREEZING FLAVOURING AGEING

• -40C TO -5 0C • To add any liquid • To allow time for fat
flavour to cool down and
crystallize
PACKAGING HARDENING DISPTACH

• -40C TO -5 0C • -35C • -180C TO -25 0C

Industrial Process: Dairy (Milk)
CENTRIFUGATION
REFRIGERATED • To remove
RAW MILK CHILLING
STORAGE sediments and fat
COOLING PASTEURIZATION HOMOGENIZATION STANDARDIZATION

• < 60C • Heating milk to • To prepare a • To adjust the ratio of
kill pathogenic uniform product fat and solids-not-fat
bacteria (SNF)
STORAGE
PACKAGING • < 70C

Industrial Process: Vegetable Oil

Industrial Process: Chemical (Dyes)
1. Glass lined reactor for Diazotization 2. Glass lined reactor for Coupling
3. Wooden plate and frame filter press 4. Vacuum Dryer
5. Mixer 6. Pulveriser
Industrial Process: Pharmaceuticals
Dispensing Sifter Mixer Dryer

• RM in powder • Sieved in sifter to • Mixed in mixer • Material dried in
form is weight remove foreign with binder to fluid bed dryer
particle form granules
Packing Coating Compression Granulator

• Container • For sugar & color • To get tablet in • To get desired
• Strip coating different size and sized granules
• Blister shape

Process Description of Paper
 Pulp Section :
Hydropulper High density Cleaner Turbo Separator

• Slushing waste paper • sand/pins is being • Plastic is being separated
separated out from the stock
Refiner Thickener Centricleaner stage

• Grinding to achieve • Its purpose is to thicken • Fine particles like sand
homogenous slurry the stock etc. are being separated
out
Continue….

 Paper Machine Section :

Continue….
Three stage Pressure Screen Head Box

Centricleaner • oversize material is • diluted stock is being
• Second stage being taken back by stored at a certain
cleaning section to the screen height to get proper
get better result velocity of slurry
Pre dry section Press section (three Wire part

stage)
• Paper web is being • Paper (woven wire)
dried out gradually •Water is being separated web is being formed
out by passing the paper
by passing through here itself and to
webs between two rolls
these steam heated nip without affecting the remove maximum
cylinder formation of the web water
Continue….
 Paper Machine Section :

Continue….
Size press Post dryer section Coating section After dryer section
• Coating is being • This is another • Coating is being • To remove
done to Improve the section of dryer for done to achieve remaining
print ability effect on gradual removal of uniform surface moisture
the paper moisture from the by chemical like
web. china clay.
Online cutter to reel winder

Pope reel Cylinder stack
• Sheet is being cut as per
• Paper is being wind • To flatten the sheet to
the requirement of the
up continuously on get a uniform thickness
customer and wind on the
cylinder
reels

Process Description of Moulding Process
 General Moulding Process :
Softened /Plasticized Moulded/ Formed

• Plastic polymer melt • Mould does the
by heating actual shaping of the
plastic
Removed Cooled
• It has removed after • Water cooling
achieving the Shape channel allow s to
solidify the Plastic.

Process Description of Injection Moulding Machine
 Injection Moulding Machine :

Process Description of Injection Moulding Machine
 Injection Moulding Machine :
Feed Hoper Reciprocating Heater

Screw • It is used to
• Feeding the raw
material such as • To transfer the convert plastic
plastic polymer material into polymer into
mould Liquid
Water Cooling Mould cavity

Channels • For achieving
• Its purpose to the required
solidify the liquid pattern of
plastic. plastic.

Process Description of Extrusion Process
 Extrusion Process :

Process Description of Extrusion Process
 Extrusion Process :
Feed Hoper Extruder Die

• Feeding the raw • Here, raw material is • It is used to give
material such as heated and cooled proper shape of
plastic polymer • After that it will pass material
through the die
Cut off Equipment Cooling Bath

Puller
• To cut the • It allows for further
• To pull the material
product as per cooling of material.
from the extruder.
requirement

Process Description of Tyre
 Tyre Manufacturing Process :

Process Description of Tyre
 Tyre Manufacturing Process :
Banbury Blending Milling Extruding

• Blending of • Shaping of rubber • It converts thick
Synthetic rubber & takes place and Heavy sheets
Natural rubber into thin sheets
with some specific
chemicals
Finishing
Curing Component Calendering
• To remove the Assembly
irregularities, • This is the process • It calender the
which are the where the • All the tyre thin and Sharp
generated on and green tyre is cured Components are steel wires
around the tyre in Dom Shape assembled between the two
Machine together to make thin layers of
“Green Tyre” rubber sheet.

Process Description of Soft Drink
 Soft Drink Manufacturing Process :
Water Treatment Syrup Manufacturing Concentrate preparation

•Water is treated and purified •Sugar, carbon powder, citric acid •Sugar syrup is mixed with acid
and settled for some time and water are heated to prepare flavour, colour and other
syrup ingredients along with treated water
Filling Proportionating unit Bottle washing

•Final product is filled in the •Concentrated ready syrup is mixed •Pre-inspected for chipped glass,
bottle. with treated filter water for dilution straw removing, rustiness and
depending upon the flavours in the washed with hot water
mixing tanks
Crowing Packaging & Storage

•To apply the cap /crown on •Pack in containers and stored
the bottle head in the godown

Process Description of Bread
 Bread Manufacturing Process :
Sifting Mixing Bulk fermentation

•Sifted flour yeast and water are blended together •Yeast produce carbon
•To remove any foreign
to form a light dough. dioxide gas
material present in Maida
Flour •All other raw-materials are blended to the dough •During the process dough
and mixed until the dough develops into a rises and becomes lighter
homogenous
Moulding Intermediate proof Dividing/Rounding

Panning
•Flattened into thin •Allows the dough to •The dough is divided into
•Passes through relax and become
sheets, rolled into small weights.
an oiling pliable and
machine cylindrical shape •After that the dough is
extensible. rounded into smooth even
surface.
Final Proof
•Dough pieces are Continue
allowed to rise to
the desired volume

Process Description of Bread
 Bread Manufacturing Process :
Baking Slicing Packing

•Baked in baking oven to •The bread is sliced into the •Pouch/bag fixed on
remove moisture and required number of slices wicket rods gets opened
yeast cells using a band slicer and a bread moves into it

Process Description of News Paper
 News Paper Manufacturing Process :

Process Description of News Paper
 News Paper Manufacturing Process :

News and Images sourcing Advertisement Image Processing Editorial Department
•News and Images are sourced Booking •The images are selected •The Editorial department
from professional agencies for print from the selects stories, articles and
•The Marketing team
like AP, AFP, PTI etc central basket by the images from the central
sells print space and
Editorial department basket
the advertisements.
Printing plate preparation Color Separation: Transmission to printing

centres
•The conventional method involved the •The digital page files are
transfer of the digital images to process films separated into the process •The final pages in the
with the help of Image setters and then color separations viz, Cyan, Portable Document Format
exposed on pre-sensitised printing plates. Magenta, Yellow and Black. are transmitted to printing
locations.
Web offset Printing

•The printing plates are mounted on web
offset machines where the newsprint is in
the roll form and the paper feed is
continuous.

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Industrial Process

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

1 FACTORY PLANNING AND LAYOUT

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Three major consideration in the plant location are;

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Types of Plant Layout:

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Flow Pattern Flow Pattern Characteristics and Place of Use

Preferred for rotary handling systems.

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Flow Pattern Flow Pattern Characteristics and Place of Use

Supervision is simpler and preferred in square shaped buildings

Preferred in production lines are longer than U type. The system is

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Flow Pattern Flow Pattern Characteristics and Place of Use

The material may be processed while moving upwards or

Such system may be adopted depending upon the process

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Priority Rules for sequencing Jobs on shared machines:

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Automation & Process control:

Manipulated Variables: Valve Position, motor speed, damper position etc.

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Process: It consists of an assembly of equipment and material related to manufacturing operation.

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Type of Process Control System:

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Closed Loop Control System:

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Primary Devices of Process Control System:

 Distributed Control System

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

1. Raw Material Handling System (RMHS)

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

1. Raw Material Handling System (RMHS)

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

1. Electric Arc Furnace

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

1. Raw Material Handling System RMHS)

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

4. Colour Coating Process

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Process Description of Aluminium

Aluminium reduction cell:

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Ore Cleaned, Crushed Calcined in Reverberatory Mixed with silica &

Refined Oxidized in Bessemer Smelted in blast

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

Ginning Spinning Weaving Processing

Private & Confidential | Intellectual Property of CVSRTA Registered Valuers Association

COTTON FIBRE IN MIXING AND CARDING (SLIVER) COMBING (SLIVER)