PLANT LAYOUT OF

PHARMACEUTICALS
Prepared by:

Guided by:

Kamal Kardani
Vishruti Choksi

Miss Shraddha Parmar

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

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.

11

Fixed Position or
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

Schedule-M

17

Semi solid preparation

30 M2 + 10 M2 for
ancillary

Parenteral preparation

Solid dosage form

Granulating
section
30 M2

compression
section
30 M2 + 20
m2ancillary

Filling of hard
gelatin cap.
25 M2 + 10
M2ancillary

Oral liquid
30 M2 basic
installation+ 10 M2
ancillary

Coating
30 M22 +
10
m22ancillary

Total 150 M2 mfg. area+ 20

m2ancillary svp or 150 M2 for
lvp
Filling
and
sealing

General

room

Aseptic Filling
and sealing

Powder
30 M2

Eye ointmennt. And

eye lotion
25 M2 + 10
m2ancillary

Suppositories
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.

Any Query

Thanking you..