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SOP for Operation and Cleaning of Compression Machine

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

SCOPE
Procedure applies to assembling, operation and cleaning of 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 machine after every change over.
  • After cleaning, if the machine is not utilized within 24 hrs. clean the machine with lint free duster before use.
  • At the end of day, remove the upper punches and put it again after cleaning with dusters.
  • Record and sign the destruction details in respective product BMR.
  • Wear nose mask & hand gloves.
  • Rotations of machine should be in clockwise direction.
  • Check punches are free in punch guides.
  • Check punches 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 machine ON and rotate the machine by jog and complete the rotation of turret to ensure proper setting of dies and punches.
  • Load the blend in hopper, if necessary adjust the height of hopper.
  • Keep the polythene-lined container below the chute.
  • Rotate the machine by jog and increase the sufficient pressure to form tablets
  • Rotate the machine by jog and complete the rotation of 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 respective product BMR.
  • Check the parameters of tablet as per respective product batch manufacturing record.
  • If necessary, adjust the parameters by setting the machine as per respective product BMR.
  • Compress the batch as per standard parameters specified in respective product BMR.
  • Check the parameters are within limits, as per frequency given in BMR.
  • After completion of compression stop the machine by disengaging the clutch.
  • After completion switch off the machine by pushing OFF switch.
  • Switch off the mains.
  • Make the machine dust free by vacuum cleaner.
  • Update the status board with details.
  • Release compression pressure.


Cleaning of Machine

Cleaning for product to product change over
  • Update the status board with details.
  • Release the pressure of lower punch by rotating pressure wheel spring anti Clockwise.
  • Remove powder from turret, upper punches, lower punches & machine by vacuum Cleaner.
  • Remove 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 punch box.
  • Unscrew the lower punch anti turning device.
  • Remove 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 punch box.
  • Unscrew the die locking screw. Remove the dies with the help of Tommy.
  • Clean the dies & keep in a punch box.
  • Clean the body of machine 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 feed frame stand, feed frames & hopper with 1% soap solution.
  • Wash feed frame stand, feed frames & hopper with water till detergent is removed.
  • Rinse feed frame stand, feed frames & hopper with purified water.
  • Send rinse sample for QC analysis.
  • Keep the cleaned parts on clean SS trolley. Allow them to dry.
  • Take out punch box & store in punch storage racks.
  • If the machine is not used after cleaning within 24 hours, Machine to be re cleaned by following above same procedure.

Cleaning for batch to batch change over
  • Frequency of cleaning to be done after every 3 batches
  • Clean the machine as per 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 die-locking screw.
  • Clean the lower punches with clean cloth smear the body of punches with oil.
  • Remove the oil from the tip.
  • Put the lower punches through punch loading plug.
  • After putting all lower punches close the lower punch-loading hole by window lock.
  • Tighten the punch anti rotating pins so as to prevent 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 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 upper punch cam plate. Place upper punches smeared with oil to the body & place the die with punch tip in die cavity.
  • Fix the die by hammering gently along with upper punch and tight the die-locking nut.
  • Check free movement of upper punch & fix other punches in the same manner.
  • Fix upper punch cam plate. Rotate the machine by hand wheel & check setting.
  • Fix the removed piece on upper punch cam plate.
  • Fix the dies in die cavities with the help of Tommy. Fix the dies by tightening die-locking screw.
  • Clean the lower punches with clean cloth and smear the oil to the body of the punches.
  • Remove the oil from the tip.
  • Put the lower punches through punch loading plug.
  • After putting all lower punches close the lower punch-loading hole by plug.
  • Tighten the punch anti rotating pins so as to prevent 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
SOPs : Standard operating procedures
BMR. : Batch Manufacturing Record.
SS : Stainless steel.

REFERENCES
Equipment manual

REVISION HISTORY
Nil

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