PLANT LAYOUT OF

PHARMACEUTICALS

Prepared by: Guided by:

Kamal Kardani Miss Shraddha Parmar
Vishruti Choksi

PG DEPARTMENT OF PHARMACEUTICAL SCIECES

SARDAR PATEL UNIVERSITY- VALLABH VIDHYANAGAR.
 Contents
2

Introduction
Importance
Types of plant layout
Sample layouts
References
 Introduction
3

Plant Layout:
Arrangement of physical facilities such as
Machinery
Equipment
furniture etc. within the factory building in such a manner so
as to have quickest flow of material at lowest cost & with
the least amount of handling in processing the product
from the receipt of material to the shipment of finished
product.

Pilot Plant:
It is the part of the pharmaceutical industry where a lab scale
formula is transformed into a viable product by development of
practical procedure of manufacture.
 Importance
4

An ideal plant layout should provide the optimum

relationship among output, floor area & manufacturing
process.
Flexibility of operation
Easy production flow
Make economic use of building
Promotes effective utilization of manpower
Employees convenience
Safety
Comfort at work
Maximum exposure to natural light & ventilation
 Types of Layout
5

There are 3 types of plant layout:

Manufacturing units
Traders
Services Centers And Establishment
 Manufacturing Units
6

It divides in to four type

Product or line layout
Process or functional layout
Fixed position or location layout
Combined or group layout
 Product or Line Layout
7

Principles:
All the machine tools or other items of equipment must be placed
at the point demanded by the sequence of operations.
There should no points where one line crossed another line.
Materials may be fed where they are required for assembly but
not necessarily at one point. All the operations including
assembly, testing packing must be included in the Line.

Advantages:
Low cost of material handling, due to straight and short route
and absence of back tracking.
Continuous flow of work
Lesser investment in inventory and work in progress
Optimum use of floor space
8

Lower cost of manufacturing per unit

Disadvantage:
High initial capital investment in special purpose machine
Heavy overhead charges
Breakdown of one machine the whole production process
are stop.
Suitability Mass production of standardized products
 Process Layout
9

Principle
The distance between departments should be as short as
possible for avoiding long distance movement of materials The
departments should be in sequence of operations The
arrangement should be convenient for inspection and supervision

Advantages:
Lower initial capital investment in machines and equipments.
Breakdown of one machine does not result in complete work
stoppage
Supervision can be more effective and specialized
There is a greater flexibility of scope for expansion.
10

Disadvantage:
Material handling costs are high due to backtracking.
More skilled labour is required resulting in higher cost.
Work in progress inventory is high.
Needing greater storage space.
More frequent inspection is needed which results in costly
supervision.
 Fixed Position or
11
Location Layout
Principle:
In this type of layout, the major product being produced is
fixed at one location. Equipment labour and components are
not moved to that location. All facilities are brought and
arranged around one work centre.
Advantages:
It saves time and cost
The layout is flexible as change in job design and operation
sequence can be easily incorporated
Adjustments can be made to meet shortage of materials or
absence of workers by changing the sequence of
operations.
12

Disadvantage:
Production period being very long.
capital investment is very heavy.
Very large space is required for storage of material and
equipment near the product.
As several operations are often carried out simultaneously,
there is possibility of confusion and conflicts among
different workgroups.
 Combined Layout
13

Principle:
In most of industries, only a product layout or process layout
or fixed location layout does not exist. Generally, a
combination of the product and process layout or other
combinations are found, in practice.
 Traders
14

When two outlets carry almost same merchandise, customers

are attracted and kept by good layout. i.e. Good lighting,
Attractive colours, Good ventilation, Air conditioning, Modern
design. All of these things mean customer convenience,
customer appeal and greater business volume.
There are three kinds of layouts in retail operations today.
1. Self service or modified self service layout
2. Full service layout
3. Special service layouts
 Services Centers And Establishment
15

Services establishments, must give due attention

to customer convenience, quality of service,
efficiency in delivering services
 Sample Layout for Pharma Industry
16

SAMPLE LAYOUT OF A PRODUCTION DEPARTMENT SAMPLE LAYOUT OF F&D DEPARTMENT

 Space required as per
17
Schedule-M
Oral liquid Filling of hard
Semi solid preparation
30 M2 basic gelatin cap.
30 M2 + 10 M2 for
installation+ 10 M2 25 M2 + 10
ancillary
ancillary M2ancillary

Solid dosage form Parenteral preparation

Total 150 M2 mfg. area+ 20 Powder
Granulating
30 M2
section m2ancillary svp or 150 M2 for

30 M2 lvp
Filling Eye ointmennt. And
General
and eye lotion
compression Coating room
sealing 25 M2 + 10
section 30 M22 + m2ancillary
30 M2 + 20 10
m2ancillary m22ancillary Aseptic Filling
Suppositories
and sealing
30 M2
 Ancillary layout
18
 References
19

Pharmaceutical Production Facilities Design and

Applications Cole Graham c. Taylor & Francis e-Library, 2 nd
Edition, 2003, page no: 25-30.
Encyclopaedia of pharmaceutical technology, James
swarbrick , Informa Healthcare USA,3rd edition, Vol-5, page
no: 2879.
Pharmaceutical Jurisprudence, G. K. Jani, Atul prakashan,
7th edition, 2008-2009, page no:102.
Good design practices for GMP Pharmaceutical facilities,
Terry Jacobs, Adrew A. singore, vol-146, page no: 41-42
Pharmaceutical Industrial management, Mehta R.M, 3rd
edition, page no: 70-90.
 ?
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