Company profile:

Harika Chemicals Private Limited is a Private incorporated on 18 March 2014. It is

classified as Non-govt company and is registered at Registrar of Companies,
Vijayawada. It is one of the subsidiary unit of ADITYA BIRLA GRASIM industries
which is located in Ganjam near Odisha.

The company is involved in production of Chlorinated Paraffin Wax. For preparation

of CPW its requires chlorine gas as its main raw material, so the factory gets chlorine
gas from GRASIM industries which is 1/2km from Harika Chemicals using tankers.
The factory is currently maintaining 3 tankers to bring chlorine gas. Total revenue
generated by CPW per year is Rs 25.7 crore.

Major constraints:

 No proper infrastructure facility: the factory doesn’t have proper

warehouse facility where the reactors, tankers and the tankers which are
used to store the CPW are completely exposed to open environment.
 No proper agreements for purchase order: the factory is involved in
continuous production of CPW. Once the order is received they deliver
the product. As mentioned by the manager there are chances of cancelling
the order even after the purchase agreement has been made.
 No proper safety standards: The members who are working in the
factory are not using proper safety precautions while dealing with
hazardous gases and there is no proper display of any safety standards.

Capacity planning:

The company is involved in manufacturing of Chlorinated Paraffin Wax, for the

production of CPW the company is procuring its raw material Chlorine from GRASIM
industries, the company monthly consumes nearly 650-900 tons of chlorine from
GRASIM. The company also procures Paraffin wax from KLJ and Reliance. The
Paraffin is generally in liquid state this paraffin is brought through tankers to the
company. Monthly nearly 300-325 tons of paraffin is consumed.
 Fig.1.Annual productivity graph

MANUFACTURING PROCEDURE:

Initially the liquid Paraffin is heated at 60 degree temperature using large heaters then
this heated Paraffin is injected into the reactors from another side of the reactors
chlorine gas is injected inside and undergoes a reaction called EXOTHERMIC
REACTION.

In the reactors a fixed proportion of Paraffin and chlorine are mixed together to obtain
Chlorinated Paraffin Wax. A mixture of 3.5 tons of Paraffin is mixed with 4200 kg of
Chlorine. When these are mixed together it produces CPW as the final product and
Hydrochloric acid its by-product. The obtained CPW is stored in HDP drums. The Hcl
is initially stored into graphite tankers and then water is injected into these tankers
containing Hcl. This is again sent into bubbling tankers where these bubbling tankers
absorb the dangerous fumes produced by Hcl. The liquid is then sent and stored into
the FRP storage tankers.
The monthly productivity of CPW is 900 tons and the production of the by-product Hcl
is 1500 tons per month. The annual productivity of CPW is 10800 tons. There is a 50%
increment in the annual productivity of CPW compared to previous year productivity.

REACTORS USED:
There are totally four reactors where the chlorine gas and paraffin are mixed together.
Currently these four reactors are used for the production and in addition to these two
extra reactors were added.

inventory management:

The factory has to maintain safety inventory of paraffin since it is bringing paraffin
from different location through tankers. Once the stock levels are reduced they again
reorder and bring the paraffin. There is no requirement to maintain safety inventory for
chlorine because GRASIM unit is located nearer to this factory so it can bring the raw
material from GRASIM easily.chlorine is directly sent using pipeline from GRASIM
 unit to the factory or from filling station in GRASIM chlorine is filled into cylinders
and it is then sent to the factors

the company is holding two types of inventory :

 Paraffin oil
 Hcl

Storage tankers of HCL:

The by-product obtained is stored into tankers and are sent to Vizag Steel plant.

The following list outlines the major important points concerning hydrochloric acid
storage, recommended tank materials, temperature, storage life, and requirements:

storage tankers for paraffin oil:

initially when paraffin is brought to the factory it is in wax form from

KLJ(Largest Manufacturer and the Market Leader in Plasticizers & Polymer
Compounds in South Asia) and Reliance industries, so this paraffin wax should be

converted into liquid form so this wax is sent into Melter and then heated at 60
degrees then the solid wax is converted into paraffin oil this oil is stored into
separate tankers. When required this oil is sent into reactors using pipes

scheduling and sequencing:

loading: Loading is the amount of work that is allocated to a part of an operation. In

the factory there are currently 10 people who are involved in the overall operations,
they work in two shifts.
Sequencing

Scheduling :

Type of production : continuous production and type of grades.

Push system:

Monitoring and control : Hydrometer

Question : Are all the end products are as per the grade….

Recommendations:

Creating a demand for the other grades rather than the local grade.

Development of infrastructure, maintqig the appropriate agreemets with

the customers

Just in time