SOP FOR OPERATION AND CLEANING OF ROLL COMPACTOR
OBJECTIVE: To lay down the procedure for operation and cleaning of Roll Compactor.
SCOPE: This procedure is applicable for operation and cleaning of Roll Compactor.
RESPONSIBILITY: It is the responsibility of operator and production supervisors to follow the procedure as prescribed in this SOP during use of Roll Compactor.
Officer/Supervisor or designee of IPQA is responsible for the line clearance and verification of the related documents along with ensuring the compliance of SOP.
Technician/Officer or designee of engineering department is responsible for the maintenance/repair work of the machine if any break down occurs during the operation.
Manager/Executive or designee of Production department is responsible for giving the training on regarding tasks and review the related records.
ACCOUNTABILITY: Head of the Production Department.
PROCEDURE:
Pre-start up (In the beginning of shift):
Ensure that no remnants of previous product/batch are present.
Visually check the equipment and area for its cleanliness.
Ensure “cleaned” label status on the equipment.
Check the cleanliness of the room.
Check the material kept in the room and ensures that it is of the same batch to proceed.
Check the room temperature and relative humidity and record it in BMR. If it is not within the limit inform the maintenance department and do not proceed till it gets rectified.
Operation:
General Instruction
Replace “cleaned” label with “Under process” label.
Take line clearance from IPQA and record in BMR.
Bring the material near to the equipment, to be compacted.
Turn the release valve, clockwise to close.
Open Roll Pressure Valve.
Set Hydraulic Pressure.
Start water circulation through rolls and hopper if required.
Start roll motor.
Run machine in no load condition for short time.
Start feed screw motor.
Set feed screw speed by speed regulator.
For Manual Mode :
Switch ON the main power supply.
On touching the Main Menu button, LOGIN screen will pop up.
Press Start button to START the roll motor and Stop button to STOP the roll motor.
To start the feed screw motor press START button.
Press STOP button to stop the feed screw motor.
Set the RPM of the roller as per product specification mentioned in BMR.
After completion of compaction, switch off the machine by pressing Red stop button.
Auto Mode:
Start the machine in Auto mode.
Press the RECIPE option to set different Parameters.
Press START button to start the Auto cycle.
Both motor run in forward direction to press FORWARD RUN button.
Both motor run in forward direction to press same REVERSE RUN button.
User can monitor the actual time and start the machine.
After completion of compaction, switch off the machine by pressing Red stop button.
Replace “Under process” label with “To be cleaned” label.
Record the equipment operation details in activity log book.
To stop the machine
Stop feed screw motor.
Run machine for short time.
Stop roll (main) motor.
Release hydraulic pressure.
Stop water circulation after few minutes.
After completing of operation affix the “To be cleaned” status label and fill the “Equipment Log Book”.
Cleaning:
Cleaning at the time of batch changeover/same product of ascending potency(Type-A):
Remove loosely stacked powder from the machine by using vacuum cleaner and lint free mop.
Dismantle the machine in the following sequence and keep parts on pallet.
Charging hopper
feed screw (auger)
Discharge chute.
Clean the dismantled parts by using vacuum cleaner and lint free mop.
Clean the machine with a dry lint free mop.
Clean the room thoroughly.
Assemble the cleaned dismantled parts.
Affix “CLEANED” status label and record the cleaning details in activity log book
Cleaning at the time of product changeover/same product of descending potency/preventive maintenance of the contact parts(Type-B):
Put “OFF” the electrical supply.
Remove loosely stucked powder from the machine by using vacuum cleaner and lint free mop.
Remove the four hex bolts on the top plate.
Close the roller valve provided below the top plate at the same time open the Feed Screw (auger valve).
Close the hydraulic pump valve and pump it by the help of handle for lifting the variation assembly for removal of hopper.
Note: Do not lift beyond the danger mark, marked on the piston column.
Turn the variation plate sideways to have space for removing the Hopper.
Dismantle the hopper by loosening the wing nuts.
Dismantle the feed screw (auger) by loosing tie bolt provided on the top of reduction gearbox fixed on variation plate, while removing the tie bolt hold
The feed screw (auger) otherwise, chance of feed screw falling down there.
Wipe out the residues using lint free cloth.
Dismantle the machine in the following sequence and keep parts on pallet.
SS covering plate
Charging hopper
Discharge chute.
Clean the exterior of the machine by vacuum cleaner and lint free mop.
Wash the dismantled parts with purified water.
Rinse all above parts with sufficient quantity of purified water.
Rinse the machine and the dismantled parts with purified water and intimate to IPQA to collect the rinse water sample.
IPQA will send the rinse water sample to Q.C. department to confirm the absence of previous product.
Dry the dismantled parts using dry lint free mop.
Sanitize all cleaned parts with 70% IPA and assemble.
Assemble the machine. Cover the hopper & delivery chute with polythene bags.
Affix “CLEANED” status label and record the cleaning details in activity logbook.