INDUSTRIAL

ATTACHMENT
ACME GLOBAL
Group Members:
Rafee Akand (1110011)
S.M. Rakibuzzaman (1110020)
Rajkumar Saha (1110077)
Rifat Hussain Chowdhury (1110167)

Overview

The ACME Laboratories Ltd. is a leading company for

manufacturing world-class and top-quality pharmaceutical
products in Bangladesh.They are currently producing more
than 500 products in different dosage forms covering
broader therapeutic categories which include antiinfective, cardiovascular, antidiabetics, gastrointestinal,
CNS, respiratory disease etc. among many others. The
success in local market prompted to explore the
international market and over the years ACME gained a
firm presence in South East Asia, Africa and Central
America and continuously discovering new horizons to
improve the quality of life for patients, to further the
success of customers and to help meet global challenges.
Through the outstanding knowledge, professionalism and
commitment of more than 7,000 employees, they are
consistently building upon facilities, capabilities and also
portfolio to meet the growing health care needs.

MANUFACTURING
UNITS
General Unit
Solid Dosage Unit
Cephalosporin Unit
LVP, Liquid and Semi-solid
Unit
Herbal and Ayurvedic Unit
Veterinary Unit

What do Pharmaceutical
Engineers
do?are involved in the conception, design
Pharmaceutical
engineers

construction,
and
operation
of
research
facilities
and
manufacturing plants, where they also are involved in the
conception, design, scale-up, manufacturing, and labelling and
packaging processes in the conversion of chemical and biological
materials into valuable pharmaceuticals and pharmaceutical
therapies. They have to implement FDA regulations, validation
assurance (VA), quality control, and maintain Good Manufacturing
Practices (GMP) compliant facilities. In addition to the safety of the
end product, they have to maintain a level of personal and
environmental safety.

STEAM GENERATION AND

DISTRIBUTION
Observation:

Four boilers

Capacity: 6 tonnes,
6.6 tonnes, 3
tonnes

All boilers were fire

tube boilers

All boilers were

shell and tube
boilers

Bi fuel boilers

Fig: Fire Tube

Boiler

BOILER ACCESSORIES:

70 feet chimney to vent exhaust gases

Pressure regulating valve

Pressure gauges

Anti scale dosing tank

Globe valve

Blow off valve

Feed water softener

PRV

Boiler Chimney

STEAM DISTRIBUTION
SYSTEM

Lacking: No economiser. So preheating of

feed water can't be done

HVAC SYSTEM
Things We Learnt About:
Air Handling Unit
Dehumidifier
Building Management System (BMS)
Chiller
Filters
Ducting System

FUNCTIONS OF HVAC:
Temperature Control
Relative Humidity Control
Creating Differential Pressure
Air Change Rate Control
Particle Counting

**The system performance is checked

after a finite time which is called Revalidation

AIR HANDLING UNIT

(AHU)

AHU has some important filters like Pre Filter, Bag

Filter and HEPA Filter. These filters have some
grades. Here Grade G4 Pre Filter, Grade F8 Bag
Filter and Grade H13 HEPA Filter is used. HEPA
stands for High Efficiency Particulate Air. It is
situated at each terminal of every room.

HEPA FILTER

BAG FILTER

DEHUMIDIFIER
It is used to control the relative humidity of air. It can be of two types:
1. Ceiling Mounted
2. Portable
There is a desiccant bed inside the dehumidifier. It receives the
moisture and maintain the RH.

Desiccant Dehumidifier

BUILDING MANAGEMENT SYSTEM

(BMS)

BMS is a computerised system to control

chilled water flow and air flow.

BMS

CHILLER
They are placed on rooftop of the building.
Chilled water is supplied to the cooling coil of
AHU. When air flows over the cooling coil, the air
becomes cold.

CHILLER

CREATING DIFFERENTIAL
PRESSURE

In the Solid Dosage Unit, negative pressure is

in the rooms and positive pressure is in the
corridor so that air of different rooms cant be
mixed together.

In case of Liquid Dosage Unit, there is positive

pressure in the rooms and negative pressure in
the corridor. For creating negative pressure,
return air is kept greater than supply air.

POWER GENERATION AND

DISTRIBUTION

ACME Pharmaceutical has two power generation units.

One unit generates power for SDU and LDU and the other
unit generates for General Unit.

Manufacturer of the power generation engines is

CATERPILLAR

The first unit has the production capacity of 9.1 MW and

the other is capable of producing 7.3 MW

The industry has three sources to meet the demand of

the power: Gas Generators, Diesel Generators and REB
line supplied by the government

AREA COVERED BY THE

GENERATORS
Solid Dosage Unit
Liquid Dosage Unit
General Unit Production Area
Herbal and Ayurvedic Production Area
Agromech Beverage
Sinha Printers
Cephalosporin Unit

GENERATORS OVERVIEW
The first unit has four gas generators and two diesel
generators
The second unit has three gas generators and three diesel
generators
The engines have 16 cylinders each
Consumable products of the engines are air filter and
lubrication oil
The maintenance is done in hourly basis
All these generators are low voltage generators
There were cooling towers to cool down the generators

SYNCHRONIZING PANEL
This panel is very important to maintain the frequency of the AC current produced by
different generators.
Some parts of this panel are:
1. Incoming section
2. Bus bar coupler section
3. Bus bar trunking system
4. Electrical distribution
Bus bar system reduces the voltage drop to a great extent
Bus bar is also very useful during overhauling one unit. At that time, one unit can be
turned off while other unit runs normally

AUTO CHANGEOVER
Important part of the control panel room
In case of under voltage, over voltage or phase fail, the phase failure relay
turns off the full circuit to avoid accident

REB
LINE
Consists of two step down transformer
The voltage supplied by the government is 33
KV
The first transformer drops the voltage to 11
KV
The other transformer drops the voltage to 440
V
There are Power Factor Improvement Plants
Two OLTC plant increases the voltage if it goes
too low

DISTRIBUTION
Cephalosporin Unit ---------------> 900 KW
General Unit -----------------------> 1 MW
Agromech Beverage --------------> 1 MW
Sinha Printers ----------------------> 500 KW
Herbal Ayurvedic ------------------> 500 KW

Gas Generator

Cooling Tower

REB Line And Transformer

Auto Changeover

OLTC Panel

Synchronising Panel
PFI Plant

PRODUCTION MACHINERIES (SOLID

UNIT)

Three types of products are manufactured:

1. Tablet
2. Powder
3. Capsule
Three types of tablet machine:
1. Turret
2. Force Feeder
3. Die
Three types of coating:
1. Sugar Coating
2. Film Coating
3. Entire Coating

PRODUCTION PROCESS OF
TABLETS

PRODUCTION PROCESS OF
POWDER

Fluid Bed Drier

Coating Machine

Container Blender

Blister Machine

PRODUCTION MACHINERIES (LIQUID

UNIT)
ACME Pharma produces many popular orally
consumed and injectable liquid medicine doses.
We observed the machines and production
processes of said products.

EQUIPMENTS

Sugar dissolving/Processing Vessel (Capacity: 250 to 5000

L)

CIP Tank (Cleans the vessel periodically)

Transfer Pump

Packaging Machinery

INJECTABLE SALINE PRODUTION

INJECTABLE DOSES
PRODUCTION

ORAL LIQUID DOSES

PRODUCTION

OINTMENT PRODUCTION

Sugar Dissolving Vessel

CIP Tank

WATER PURIFICATION AND

DISTRIBUTION
Water is purified to a predetermined quality. This
water is used for producing medicine.

In the solid unit, the water purification plant

purifies 2000 L/hr and in the liquid unit, it
purifies 7000 L/hr. Water in the system is
circulated continuously. Purified water is piped
through different units of the production area.

PRE-TREATMENT FLOW
CHART

GENESYS FLOW CHART

1 Micron
Filter

Genesys
Storage
Tank

Primary
RO Filter

Degasse
r Unit

River
Suspensio
n Unit

Seconda
ry RO
Filter

UV Lamp

Storage
Tank

CEDI
(Continuous
Electron DeIonizer

WATER DISTRIBUTION
Pump

Cooling
Heat
Exchanger

Productio
n Units

UV Lamp

COMPRESSED AIR GEN. AND

DISTRIBUTION

THANK YOU
EVERYONE