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ACKNOWLEDGEMENT With a sense of gratitude and respect, I would like to extend my sincere thanks to the Western India Sea

Brine Pvt. Ltd. family for their kind attention, guidance and advice which has made my training a great pleasant and excellent experience. I sincerely thank Mr. Prakash Jiandani, factory in-charge who let me to fulfill my desire and dream to work at this prestigious organization. I m indebted to Mr. Biren Mehta, factory manager, who gave his kind advice, encouragement and support throughout the training tenure. I am obliged to Mr. Atul Sharma, Quality Manager, for his active involvement and support. I express profound thanks to Mr. Ravindra Jain, Purchase Manager, Mr. Bharat Rathode, Head of Electrical Department, Mr. Patel, Head of Maintenance Department, Kuashal Soni, Dispatch Officer and Mr. Mulchand Chuadhry, who had given me the detail information of their respective departments.

A PROJECT REPORT ON FUNCTIONS OF WESTERN INDIA SEA BRINE PRIVATE LIMITED

THIS REPORT EXPLAINS INDIAS SALT INDUSTRY, FUNCTIONS OF VARIOUS DEPARTMENTS, PROFILE AND SCOPE OF WISBPL, PROCESS FLOW OF MANUFACTURING OF SALT.

MULCHANDANI BHARTI D
25/05/2009

CONTENT
1. 2.

Introduction3 Description of Indias Salt Industry.4 2.1 State wise distribution of Salt production in India.. 4 2.2 Market leaders of Salt Industry5 2.3 Application of Salt in Industry.5 2.4 Regulation Body...6 2.5 Scope of Salt Industry..6 Unit Profile..7 Organization Structure..8 4.1 Procurement Management...8 4.2 Maintenance Management.10 4.3 Quality Management..10 4.4 Safety and Cleanliness Management.12 4.5 Packaging Management.13 4.6 Dispatch Management....14 Technical Detail16 Scope..17 Conclusion.17

3. 4.

5. 6. 7.

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INTRODUCTION
Salt in industry is used for two purposes. Firstly as a food product and secondly as a raw material. Total capacity of Indian salt industry is 170 lakhs metric tons per year. From these 120 lakhs mt per year is used for industry purpose and 50 lakhs mt is used as edible salt. Western India Sea brine is a salt manufacturing company with an annual production of 2.5 lakhs tons per year. It was incorporated in 1997 and is situated at salt city Chopadva, Kutch, Gujarat. The market share of it is 1.47 % and turnover is Rs. 60 crores. It manufactures various salt brands, viz. Annapurna for Hindustan Unilever Ltd., i-Shakti for Tata Chemicals Ltd., Everyday for RKMK, Sun Gold for Chirai Salt and Dandi for Dandi. The backbone system of WISBPL works on a sophisticated organizational structure. The process flow of manufacturing salt includes filtering, washing, drying, sieving, crushing, iodizing and packaging.

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2. DESCRIPTION OF INDIAS SALT INDUSTRY


The capacity of Indis Salt Industry is 170 lakhs metric tons per year. From these 120 lakhs mt per year is used for industry purpose and 50 lakhs mt is used as edible salt. From these 50 lakhs mt tons 30% (15 lakhs mt) is refined free flow iodized salt and 70% (35 lakhs mt) is non-refined iodized salt. INDIAS SALT INDUSTRY

2.1 STATE- WISE DISTRIBUTION OF SALT PRODUCTION

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2.2 MARKET LEADERS OF REFINED FREE FLOW IODIZED SALT Name Tata HUL ITC Others Production in Lakhs mt 7.5 1.5 1.5 4.5

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2.3 APPLICATIONS OF SALT IN INDUSTRY Edible Salt is used as a food product. Non-edible Salt in following Industries: Leather Industry for cleaning (In process) Rayon Industry (In process) Cold Storage as an anti-melting agent Fishing Industry as a preservative In Food processing as a additive Dye Industry if chloride agent is required Caustic Soda and Sodium Bicarbonate as a Raw-Material

2.4 REGULATION BODIES 1) Salt Department:

It estimates the salt production in a year

Verification of Raw Salt Regulation of Distribution

Permission for C and D supply

2)

Prevention of Food Adulteration (PFA): It provides following standards for salt industry.

Iodine: 30 ppm Water Insoluble: CaSo4, sand, stones, etc. Moisture: Max. 6% (in WI 0.15%) Matter Soluble other than NaCl: CaSo4, MgSo4, MgCl2

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NaCl: 96.2%

2.5 SCOPE OF SALT INDUSTRY Conversion from non-refined to refined salt Low Sodium Salt Iron fortified Salt

3. UNIT PROFILE
The WesternIndia Sea Brines Pvt. Ltd. is situated at salt city Chopadva, Kutch, Gujarat. It was incorporated in 1997. Initially the plant structure was made up of RCC, but after earthquake occurred in Gujarat in 2002, it was reconstructed and made earthquake proof. Mr. Jawerilal Nahata is Managing Director of this company. The main product of this unit is Iodized Free Flow Salt. The annual turnover of WISBPL is Rs 60 crores. The Plant capacity is about 2,50,000 tons per anum (TPA). The byproduct is Superfine. In WISBPL, following salt brands are made. Brand Name Annapurna i-Shakti Dandi
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Corresponding Firm Hindustan Unilever Tata Chemicals Ltd Dandi RKMK Chirai Salt

Everyday Sun gold

4. ORGANIZATIONAL STRUCTURE Managing Director Manager

Procurement Quality

Maintenance

Electrical Packaging

Production HRA

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FFS

Plant

Time Office

Security Office

Dispatch

Production Supervisor

Store

Plant Operator

Systems (SAP) 4.1 PROCUREMENT MANAGEMENT Following are the three major activities of this department.
1)

Planning of raw material and dispatching of final product: Planning of required raw material is done based on following parameters. o Weather Conditions o Rate of raw material in market Planning of dispatching of final product is done based on the following parameters. o Customer Requirement o Availability of rack and trucks for transportation of finished good

2)

Procurement of raw salt from various parties: Parties for raw salt procurement are decided based on following parameters. o Growth of Customer o Payment Policy o Market Impression For WISBPL, following are the three parties from where raw material is procured. o Chirai Salt Work o Gayatri Salt Work o International Salt

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With these parties Memorandum of Understanding (MOU) is prepared, which has following terms. o Quantity of lifting final product o Rate of product material o Payment (Terms and conditions) o Specification of quality
3)

Factory Planning: Following parameters are planned.

Month wise planning of production each customer Planning of plant running hours Planning for man power with contractor Planning for Raw material, Packaged material, fuel and additives

4.2 MAINTENANCE MANAGEMENT There are basically three types of maintenance processes.
1)

Shut down Maintenance: Under this process, maintenance is done after breaking down. Periodic Maintenance: Here maintenance is done regularly. Preventive Maintenance: Under this process, maintenance is done before breaking down.

2) 3)

4.3 QUALITY MANAGEMENT

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Activities of Quality department: In QD, quality of salt at various stages is analyzed with respect to specified measures, which are mentioned below. Appearance: White crystalline/free flow Dynamic Flow Rate (m/sec): Min 160 Bulk Density (gm/cc): 1.23 1.26 Non-white particles (No/gm): 30/250 Particle Size: 850 microns (18 mesh) Max 1% 710 microns (20 mesh) Min 84-86% 150 microns (100 mesh) Min 93% 150 microns (100 mesh) Max 7% Moisture: 0.2% Sodium Chloride (NaCl): 99% Calcium (Ca): Max 0.12% Magnesium (Mg): Max 0.1% Sulphate (So4): Max 0.3% Water Insoluble (CaSo4, SiO2, etc): Max 0.35% SiO2 allowed: 0.3% Potassium Ferro Cynide (as an anti-caking agent): Max 10 ppm Iodine: 30 ppm PH: 7

Quality Control Point (QCP): These are the points at which quality of material is checked.
QC P

We t Mill

Elutriati on Tank

Primary Tank

Thicken er

Centrifug e Machine

Fluid Bed Drier Raw Salt Storage hopper Ca: 0.12% Mg: 0.10% 850 u-Max 30% 150 u- Max 10% Moisture: < 4%

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Oversize Bucket Elevator

Storag e hoppe

Ca: 0.20% Mg: 0.50% 4000 u- < 40% Ca: 0.12% Mg: 0.10% Moist: < 0.15% 850 u-Max 30% Iodine: 40 ppm 150 u- Max 10% 150 u- < 20%

Distributio n Hopper

Form Filling and

Produc t Storag e Tank

Blende r

Surge Hoppe r

Bucket Elevator

Crushe r/Pin Mill

Vibro Sieve

Efficien cy: 850 u-Max 20% 150 u- Max 3% Iodine: Min 30 ppm 850 u-Max 20% 150 u- Max 3% 70%

SAMPLING PLAN Finished Product Spot sample: One sample shall be drawn out into a transparent pack every hour from the previous hours packed stock from every production line. Composite sample: 100 gms sample from each spot sample shall be drawn and mixed into a tub. The mixture shall be made into a heap. 50 gms sample shall be draw from all four corners of the heap and mixed together. This composite sample shall be used for analysis. Sample for Attribute Checking: One bag per 100 bags produced (of each SKU) shall be selected at random, evenly distributed over the lot. From each bag, draw 5 pouches for attribute and weight checking.
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Raw salt A sample from raw salt heaps shall be selected by factory QC team for whiteness, black particle content and sand before being moved to the factory premises. Each lorry shall be sampled and chemically checked for Ca++, Mg++ and physically checked for whiteness, stone, sand, rubber, iron and foreign material. Composite sample to be prepared by mixing 4 samples drawn from 1 feet depth from 4 corners of the lorry. Potassium Iodate One composite shall be prepared by sampling 2% of the unit packs (drums). Potassium Ferro Cyanide One composite sample shall be prepared by sampling 2% of the packs (drums). 4.4 SAFETY AND CLEANINGNESS MANAGEMENT Safety Measures: There are five types of safety adopted.
1)

Product safety: In product safety care is taken against entrance of foreign matters. Health safety: Here each man is equipped with safety shoes, helmet, jacket, goggles, hand gloves and a safety mask. Machinery safety: There are two types of machinery safety, viz. electrical and mechanical. Under electrical safety, proper earthing and insulation and interlock among more than two devices are supervised. Under mechanical safety, safety guards and smooth welding are supervised. Environment safety: In environment safety, all the standards provided by Gujarat Pollution Control Board (GPCB) are maintained.

2)

3)

4)

Cleanliness standards: For cleanliness, 5S standards are followed.

5S standards

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Seiri: Discard unnecessary items at work place.

Seiton: Arrange items in good order, A place for everything, everything in its place.

Seiso: Clean your work place thoroughly so that there is no dust on floors, machines and equipments.

Seiketsu: Maintain high standards of housekeeping at work place at all times.

Shitsuke: Train people to follow good housekeeping discipline independently.

4.5 PACKAGING MANAGEMENT Packaging department is divided into four sub-departments.

Plant Operator/FFS Operator: Plant Operator/FFS Operator continuously in charges the operation of plant/FFS. Production Supervisor: Based on the order production supervisor monitors the production of particular brand. Store In-charge: Storage in-charge supervises the available stock in store as well as systemic storage of final product. Dispatch: Under this sub-department ordering through SAP, weighing of trucks and loading of product is taken care.

4.6 DISPATCH MANAGEMENT


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There are two types of dispatching in WI.


1)

Direct Dispatch: In direct dispatch, following steps are followed. Step 1: RS enters his order through RS Net software. Step 2: Next day SAP operator finds the same on his SAP account. Step 3: Then SAP operator sends e-mail to depot operator to check the credit balance of RS available to HUL. If sufficient balance is available then truck is loaded for that RS else order is rejected. Step 4: SAP operator at WI prepares the invoice for RS and an Intercompany Bill for HUL. IB is prepared because HUL is working as a 2-party in WI. So, for WI it is a sale and for HUL it is a purchase. Two copies of IB are made. One is sent to HUL and one is kept with WI. Similarly four copies of invoice are made. Two are sent with truck driver, on e is sent to HUL and one is kept with HUL. SAP process for Direct Dispatch:Out Bound Delivery (OBD) and Picking (vl01n) Truck Entry (ymm277) Shipment (vt01n) Change Shipment (vt02n) Intercompany Bill (vf01) Invoice (vf31)

2)

Depot Dispatch: In depot dispatch, stock is transferred from HUL to HUL Depot. Here following steps are followed.

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Step 1: Depending on the requirement, depot operator contacts the corresponding planner. Step 2: Planner sends that information to SAP operator. Step 3: After getting required information about depot from STR (Purchase requisition No.) team, SAP operator gives order for loading. SAP process for Depot Dispatch.

Availing STR Preparing Stock Transfer Order (STO) (me21n) Out Bound Delivery (OBD) (vl10b) Picking (vl02n) Truck Entry (ymm277) Shipment (vt01n) Change Shipment (vt02n) Intercompany Bill (vf01) Stock Transfer Note (vf31) 5. TECHNICAL DETAIL
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The Belt Conveyor and vibrating Feeder feed the raw salt to Bucket Elevator. The Belt Conveyor is fitted with suspension magnets to remove iron particles from the raw salt. The Bucket Elevator moves the raw salt into Raw Salt Feed Hopper. After that raw salt is conveyed to wet mill (Hydro mill), where brine is added with raw salt with a ratio of 1:1. Wet mill is designed for grinding of salt mixed with brine at low rates of formation of fine salt particles, with variable grinding slot for optimum size reduction. In the wet mill parallel bar hammers are fixed on a shaft rotating at 750900 RPM. After that salt slurry enters into elutriation tank. In elutriation tank, impurities with lesser density than salts density are removed from upper side and impurities with higher density sets at the bottom and salt slurry without impurities is stored in the middle. From there slurry is sent in prime tank. In prime tank, fine material is separated from course material. Course material is sent into secondary wet mill for further crushing to make it fine. Then fine material is sent into washing tank. In washing tank, all soluble impurities such as MaSo4, Mgcl2, and CaCl2 are removed. Here slurry is clean up to 60%. Then it is sent into thickener, where slurry is concentrated upto 75%. Apart from it minor impurities are also removed here. From here slurry is sent into centrifuge machine. In centrifuge machine, brine and salt are separated. The outcome of centrifuge is salt with 4% moisture, which is then iodized while being conveyed through belt conveyor into the drier. In drier, salt is dried at 180 o c upto 0.15% of moisture. At the outlet of drier it is cooled upto 60 o c. After that it is fed into oversize (oversize: size of crystal is greater than specified size) bucket elevator and then to distributor hopper. After that it is fed into vibro sieve for sieving. After that fine material goes to product bucket elevator through product screw conveyor. Whereas, oversize material is sent to crusher and pin mill for further crushing and then again to the oversize bucket elevator. In this fashion recycling takes
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place. From product bucket elevator it goes into search hopper, where salt it distributed among various blenders. In blender silica is mixed through silica dozer. From the outlet of blender it goes to product silo for storage. Then it goes to Form Filling and Sealing (FFS) machine for packaging. 6. SCOPE Implementation of SAP in Store, Production and Quality departments

Optimum Automization

Utilization of digitized equipments

7. CONCLUSION
Western India Sea Brine Pvt. Ltd. is a salt manufacturing organization. The production of salt is approximately 2.5 lakhs tons per year. Along with it a byproduct called Superfine is made, too. The production of same is 25,000 tons per year. This organization works very systematically with each department equipped with latest technologies. All the standards meant for various activities are followed up strictly. The biggest strength of WISBPL is team work, which is highly appreciable. Apart from this, it can be also concluded that future scope of salt industry seems to be very bright. Low iodized salt for diabetes patients can be manufactured Conversion from non-refined iodized salt to iodized salt

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