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SOP on Operation of Rapid Mixer Granulator

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1.0 OBJECTIVE: To lay down a procedure for the operation of Rapid Mixer Granulator.
2.0 SCOPE: This procedure is applicable to the operation of Rapid Mixer Granulator located in the manufacturing area.
3.0 RESPONSIBILITY:
Operator, Officer, Executive – Production Department
Manager – Production Department
4.0 DEFINITION(S):
NA

SOP on Operation of Rapid Mixer Granulator
Rapid Mixer Granulator

5.0 PROCEDURE:
5.1 Machine Setting:
5.1.1 Ensure that the equipment and area are cleaned. Affix the ‘UNDER PROCESS’ label dully filled and signed on the equipment and record the observation in the Equipment Usage Log Sheet as per Given SOP.
5.1.2 Ensure that the compressed air and main electric supply is ‘ON’ from the service area.
5.1.3 Ensure the discharge valve is closed.
5.1.4 Turn the Control ‘ON/OFF’ switch on control panel to ‘ON’ position. The opening screen will open on MMI.
5.1.5 Ensure that Compressed air pressure on pressure gauge is approximately 4 Bar. If not, adjust by turning Lock knob in a clockwise direction to increase the pressure and anticlockwise to decrease the pressure.

5.2 Recipe Edit / Load
5.2.1 Touch ‘LOGING’ ON MMI. Keypad screen will open. Enter correct password.
5.2.2 Main menu screen will open and display:

WELCOME ADMINISTRATION
MODEOPERATION PROCESS PARAMETERS
BATCH DATA ALARM

5.2.3 Touch ‘MODE OPERATION’ on MMI. Operation mode on main screen will open.
5.2.4 Touch ‘AUTO’ on MMI. Auto mode main screen will open. Touch ‘RECIPE’ on MMI. Recipe Parameter ¼ screen will open.
5.2.5 Load Mixing-1time, Delay-1 time, Mixing-2 time, Delay-2 time, and Mixing-3 time as per respective BMR.
5.2.6 Touch ‘→’ on MMI. Recipe Parameter 2/4 screen will open.
5.2.7 Load Delay-3 time, Binder addition time, Granulation -1 time, Granulation -2, and discharge time as per respective BMR.
5.2.8 Touch ‘→’ on MMI. Recipe Parameter 3/4 screen will open.
5.2.9 Load impeller motor RPM (55-100), chopper delay time, chopper motor slow/fast / stop as per respective BMR for Mixing-1, Mixing-2, Mixing-3 and Binder addition.
5.2.10 Touch ‘→’ on MMI. Recipe Parameter 4/4 screen will open.
5.2.11 Load impeller motor RPM (55-100), chopper delay time, chopper motor slow/fast /stop as per respective BMR for Granulation-1, Granulation -2, and discharge cycle. Load end point current as per respective BMR.
5.2.12 Touch ‘→’ or ‘BATCH DATA’ on MMI. The batch data screen will open. Load batch number, lot number, and operator name.
5.2.13 Touch ‘SAVE’ ON MMI. Keypad will open. Give a suitable name or code for the loaded recipe touch ‘ENTER’ for confirmation. A warning screen will open with a message: 1) Save recipe or 2) overwrite recipe, if recipe with same name or code already exists. Touch ‘YES’ to save or overwrite the recipe / ‘NO’ for not saving or overwriting the recipe.
5.2.14 To load an already existing recipe touch ‘LOAD’ on MMI. The recipe list will open. Select the recipe and touch escape. Warning message ‘Load Recipe’ will appear. Touch ‘YES’ to load the recipe/touch ‘No’ for not loading the recipe.

5.3 Auto Mode Operation:
5.3.1 Select auto on operation mode main screen in step no. 5.2.2. Auto mode main screen will open.
5.3.2 Touch ‘AUTO CYCLE’ on MMI. The autocycle main screen will open.
5.3.3 Select binder addition ‘AUTO/MANUAL’ mode. Touch ‘RESET’ on MMI. Touch ‘START’ ON MMI. The process will start as per set parameters and stop automatically after completion of the mixing-1cycle. Touch ‘→’ on MMI. Process Parameter ¼ screen will open.
5.3.4 Touch ‘START’ to start the Mixing-2 cycle. The mixing-2 cycle will start as per set parameters and stop automatically after completion of mixing-2 cycle. Touch ‘→’ on MMI. Process Parameter 2/4 screen will open.
5.3.5 Touch ‘START’ to start Mixing-3 cycle. Mixing-3 cycle will start as per set parameters and stop automatically after completion of mixing-3 cycle time.
Note: If set delay time after completion of mixing-1, 2, and 3 cycles is zero, the machine will automatically go to next cycle.
5.3.6 Add Binder solution and touch ‘START’ on MMI. Granulation will start as per set parameters for granulation-1 and granulation-2 cycles and automatically stop after set time.
5.3.7 ‘CYCLE COMPLETED’ message will display on MMI if FBD bowl is not present below discharge, otherwise machine will automatically go to discharge mode and on completion of discharge cycle ‘Do You Want To Continue’ message will display on the screen. Touch ‘YES’ if discharge is not completed successfully otherwise touch ‘NO’. Discharge cycle will start as per set parameters and stop after a set time. On successful completion of discharge cycle touch ‘NO’ on MMI. Main screen will open.

5.4 Manual Mode Operation:
5.4.1 Select Maintenance on operation mode main screen in step no. 5.2.2. Maintenance Mode main screen will open.
5.4.2 To close and open Top Lid touch ‘CLOSE / OPEN’ respectively.

Related SOP: SOP on Procedure and Operation of Vibratory sifter

5.4.3 Touch on MMI. Keypad will open. Select impeller RPM.
5.4.4 Touch and hold ‘JOG’ on MMI. Impeller will run till jog key is engaged.
5.4.5 Touch ‘RUN’ to run/stop the impeller.
5.4.6 Touch Chopper motor ‘SLOW’ to run/stop chopper at slow speed. Touch Chopper motor ‘FAST’ to run/stop chopper at a fast speed.
5.4.7 Touch Purging Valve ‘ON/OFF’ to ON or OFF the purging air.
5.4.8 Touch spray pump ‘ON/OFF’ to ‘ON/OFF’ the spray pump.
5.4.9 Touch machine guard bypass ‘ON/OFF’ to ON/OFF the guards.
5.4.10 At the end of operation touch ‘MODE OPERATION’ on MMI. Mode selection screen will open.
5.4.11 Touch ‘MAIN MENU’ on MMI. Main menu screen will open.
5.4.12 Touch ‘WELLCOME’ on MMI. Opening screen will open.
5.4.13 Turn ‘OFF’ the control panel and affix the ‘TO BE CLEANED’ label dully filled and signed on the equipment.
5.4.14 Record all the observations in the equipment Usage Log Sheet as per the given SOP.

6.0 ABBREVIATION(S):
BMR: Batch Manufacturing Record
FBD: Fluidized Bed Dryer.
MMI: Man-Machine Interface
RMG : Rapid Mixer Granulator
MMI: Man-Machine Interface
BMR: Batch Manufacturing Record

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