Incorporating Packaging Machine With Weighing Machine To Easy Packaging Of Solid Chemical Products.pdf

INCORPORATING PACKAGING MACHINE WITH WEIGHING MACHINE TO EASY PACKAGING OF SOLID CHEMICAL PRODUCTS A PROJECT REPORT Submitted by

1. KRUTARTH PATEL

120030119108

2. PARTH KOTADIA

120030119069

Guided by

Asst Prof. Jayendra B. Kanani In fulfilment for the award of the degree of

BACHELOR OF ENGINEERING in Mechanical Engineering Atmiya institute of technology and science, Rajkot

Gujarat Technological University, Ahmedabad

MECHANICAL ENGINEERING 2015-2016

CERTIFICATE This is to certify that the dissertation entitled “Incorporating packaging machine with weighing machine to easy packaging of solid chemical products” has been carried out by KRUTARTH S. PATEL (120030119108)under my guidance in fulfilment of the degree of Bachelor of Engineering in mechanical engineering (8th Semester) of Gujarat Technological University, Ahmedabad during the academic year 2015-16. Internal Guide:

External Guide:

Asst. Prof. J.B. Kanani

Mrs. M.S. Patel

Dept of Mechanical Engineering

Owner

AITS, Rajkot

Interchem, Surat

Prof. P.S.Puranik H.O.D. (Mechanical Engineering Department) AITS ,Rajkot

Place: Rajkot Date: 10th April, 2016

MECHANICAL ENGINEERING 2015-2016

CERTIFICATE This is to certify that the dissertation entitled “Incorporating packaging machine with weighing machine to easy packaging of solid chemical products” has been carried out by PARTH S. KOTADIA (120030119069) under my guidance in fulfilment of the degree of Bachelor of Engineering

in

mechanical engineering

(8th

Semester) of Gujarat Technological University,

Ahmedabad during the academic year 2015-16. Internal Guide:

External Guide:

Assist. Prof. J.B.Kanani

Mrs. M.S.Patel

Dept of Mechanical Engineering

Owner

AITS, Rajkot

Interchem, Surat

Prof. P.S.Puranik H.O.D. (Mechanical Engineering Department) AITS ,Rajkot

Place: Rajkot Date:10th April, 2016

GUJARAT TECHNOLOGICAL UNIVERSITY We hereby certify that we are the sole authors of this IDP/UDP project report and that neither any part of this IDP/UDP project report nor the whole of the IDP/UDP Project report has been submitted for a degree by other student(s) to any other University or Institution. We certify that, to the best of our knowledge, the current IDP/UDP Project report does not infringe upon anyone’s copyright nor violate any proprietary rights and that any ideas, techniques, quotations or any other material from the work of other people included in our IDP/UDP Project report, published or otherwise, are fully acknowledged in accordance with the standard referencing practices. Furthermore, to the extent that we have included copyrighted material that surpasses the boundary of fair dealing within the meaning of the Indian Copyright (Amendment) Act 2012, we certify that we have obtained a written permission from the copyright owner(s) to include such material(s) in the current IDP/UDP Project report and have included copies of such copyright clearances to our appendix. We have checked the write up of the present IDP/UDP Project report using anti-plagiarism database and it is in the allowable limit. In case of any complaints pertaining to plagiarism, we certify that we shall be solely responsible for the same and we understand that as per norms, University can even revoke BE degree conferred upon the student(s) submitting this IDP/UDP Project report, in case it is found to be plagiarized. Team: Name

Enrolment number

KRUTARTH PATEL

120030119108

PARTH KOTADIA

120030119069

Signature

Place: Rajkot Date: 10th April, 2016

Guide: Assist Prof. Jayendra.B. Kanani

ACKNOWLEDGMENTS Any accomplishment requires the effort of many people and this work is not different. And it is our prime duty to acknowledge the person who directly or indirectly helped us during completion of this report. So we take opportunity to heartily thank our project guide respected Assist. Prof. J.B. Kanani for his valuable guidance and touch of inspiration and motivation throughout the project work without whose help the work would not have been in the shape what it is. We also heartily thank our Head of Department Dr.P.S.Puranik who greatly helped us in our project work without whose help the work would not have been in the shape what it is. We also thank our Principal Dr. G.D.Acharya without whose guideline and motivation we would have not completed our project. Last but not the least, we heartily thanks our trustees and dignitaries without whose motivation our project works would not have been in the shape what it is. We are also thanking full to other relevant staff of workshop, library and department for their co-operation, help and guidance.

KRUTARTH PATEL

120030119108

PARTH KOTADIA

120030119069

Place: Rajkot

Abstract Packaging of chemicals is quite difficult and generally it is performed manually in small scale industries. The individual weighing machine and stitching machine are quite costlier for small scale industrial application. By performing manually, there is some amount of wastage of product and is quite longer process. Thus the main purpose of selecting this project is to safely packaging of solid chemical products. The advantages of packaging machine are safer in operation, less effort of labour, faster in operation, increase product packaging quality, simplify material handling and reduction in cost by combining weighing machine and stitching machine. Keywords: 1. Packaging 2. Safe operation 3. Increase product packaging quality 4. Simplify material handling 5. Faster operation

Contents Index Sr No.

Chapter

Page No.

1

Sodhyatra

01

2

Introduction

02

3

Company Profile

05

3.1

Production Details

05

Production Process Description

06

4.1

06

4

Flow Chart

5

Packaging Process Description

07

6

Literature review

08

7

Design And CAD Model

11

7.1 Storage Chamber

11

7.1.1

Introduction

11

7.1.2

Types

12

7.1.3

Material Used

13

7.1.4 Flow Control Mechanism 7.2

Measuring Chamber

13 15 15

7.2.2 Load Cell

17

7.3

7.2.1 Measuring Tank

Control Mechanism 7.3.1 Rack and Pinion Mechanism

17 17

7.4

Supporting Tank

21

7.5

Stepper Motor

23

7.6

Servo Motor

25

7.7

Grabber

25

7.8

Conveyor

27

7.9

Stitching Machine

28

7.10

Rectifier

28

7.11

Step Down Transformer

28

8

Working of machine

29

9

Cost of machine

32

10

Conclusion

33

11

Gujarat Technological University Activity

34

12

References

57

TABLE INDEX SR. No.

Name of Table

Page No.

1

Table 1 production detail of company

5

2

Table 2 Specifications pinion

21

3

Table 3 Specification of rack

21

4

Table 4 Stepper motor specification (flow control mechanism)

24

5

Table 5 Stepper motor specification (grabber mechanism)

24

6

Table 6 Servo motor specification

25

7

Table 7 Specification of conveyor belt

27

LIST OF FIGURES Sr. No.

Name of figure

Page No.

1

Process Flow chart for getting final product

6

2

Flow chart of Packaging operation

7

3

Storage Tank

11

4

Dimensions of storage tank

12

5

Flow control plate

13

6

Arrangement of Flow control plate

14

7

Dimension of Flow control plate

15

8

Weight measuring tank

16

9

Dimensions of Weight measuring tank

17

10

Rack and Pinion Mechanism in Weight measuring tank

18

11

Supporting tank

22

12

Dimensions of Supporting tank

23

13

Grabber mechanism attached in supporting tank

26

14

Gabber Arm

27

15

Machine Assembly

30

16

Programmable Logic control circuit for the operation of packaging machine

31

17

Centrifugal Hydro

34

18

Inventory

35

19

Transporting

35

20

Loading/Unloading

35

21

Floor Plan

36

22

AEIOU summary Canvas

38

23

Empathy mapping sheet

40

24

Ideation Canvas sheet

41

25

Product development sheet

43

26

Business model canvas sheet

44

GUJARAT TECHNOLOGICAL UNIVERSITY CERTIFICATE FOR COMPLETION OF ALL ACTIVITIES AT ONLINE PROJECT PORTAL B.E. SEMESTER VIII, ACADEMIC YEAR 2015-2016 Date of certificate generation : 12 April 2016 (14:48:15)

This is to certify that, Kotadia Parth Sureshbhai ( Enrolment Number 120030119069 ) working on project entitled with INCORPORATING PACKAGING MACHINE WITH WEIGHING MACHINE TO EASY PACKAGING OF SOLID CHEMICAL PRODUCTS. from Mechanical Engineering department of Atmiya Institute Of Technology & Science, Rajkot had submitted following details at online project portal.

Periodic Progress Reports (PPR)

Completed

Business Model Canvas (Image)

Completed

Business Model Canvas (Report)

Completed

Patent Drafting Exercise (PDE)

Completed

Final Plagiarism Report

Completed

Final Project Report

Completed

Name of Student :

Kotadia Parth Sureshbhai

Name of Guide :

Mr. Jayendra Babubhai Kanani

Signature of Student :

_____________

*Signature of Guide :

________________

Disclaimer : This is a computer generated copy and does not indicate that your data has been evaluated. This is the receipt that GTU has received a copy of the data that you have uploaded and submitted as your project work. *Guide has to sign the certificate, Only if all above activities has been Completed.

GUJARAT TECHNOLOGICAL UNIVERSITY CERTIFICATE FOR COMPLETION OF ALL ACTIVITIES AT ONLINE PROJECT PORTAL B.E. SEMESTER VIII, ACADEMIC YEAR 2015-2016 Date of certificate generation : 12 April 2016 (14:45:17)

This is to certify that, Patel Krutarth Sanjaybhai ( Enrolment Number 120030119108 ) working on project entitled with INCORPORATING PACKAGING MACHINE WITH WEIGHING MACHINE TO EASY PACKAGING OF SOLID CHEMICAL PRODUCTS. from Mechanical Engineering department of Atmiya Institute Of Technology & Science, Rajkot had submitted following details at online project portal.

Periodic Progress Reports (PPR)

Completed

Business Model Canvas (Image)

Completed

Business Model Canvas (Report)

Completed

Patent Drafting Exercise (PDE)

Completed

Final Plagiarism Report

Completed

Final Project Report

Completed

Name of Student :

Patel Krutarth Sanjaybhai

Name of Guide :

Mr. Jayendra Babubhai Kanani

Signature of Student :

_____________

*Signature of Guide :

________________

Disclaimer : This is a computer generated copy and does not indicate that your data has been evaluated. This is the receipt that GTU has received a copy of the data that you have uploaded and submitted as your project work. *Guide has to sign the certificate, Only if all above activities has been Completed.

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INCORPORATING PACKAGING MACHINE WITH WEIGHING MACHINE TO EASY PACKAGING OF SOLID CHEMICAL PRODUCTS A PROJECT REPORT Submitted by 1. KRUTARTH PATEL 120030119108 2. PARTH KOTADIA 120030119069 In fulfilment for the award of the degree of BACHELOR OF ENGINEERING in Mechanical Engineering Atmiya institute of technology and science, Rajkot Gujarat Technological University, Ahmedabad GUJARAT TECHNOLOGICAL UNIVERSITY We hereby certify that we are the sole authors of this IDP/UDP project report and that neither any part of this IDP/UDP project report nor the whole of the IDP/UDP Project report has been submitted for a degree by other student(s) to any other University or Institution. We certify that, to the best of our knowledge, the current IDP/UDP Project report does not infringe upon anyone’s copyright nor violate any proprietary rights and that any ideas, techniques, quotations or any other material from the work of other people included in our IDP/UDP Project report, published or otherwise, are fully acknowledged in accordance with the standard referencing practices. Furthermore, to the extent that we have included copyrighted material that surpasses the boundary of fair dealing within the meaning of the Indian Copyright (Amendment) Act 2012, we certify that we have obtained a written permission from the copyright owner(s) to include such material(s) in the current IDP/UDP Project report and have included copies of such copyright clearances to our appendix. We have checked the write up of the present IDP/UDP Project report

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using anti-plagiarism database and it is in the allowable limit. In case of any complaints pertaining to plagiarism, we certify that we shall be solely responsible for the same and we understand that as per norms, University can even revoke BE degree conferred upon the student(s) submitting this IDP/UDP Project report, in case it is found to be plagiarized. Team: Name Enrolment number Signature KRUTARTH PATEL 120030119108 PARTH KOTADIA 120030119069 Place: Date: Guide: Assist Prof. J.B. Kanani ACKNOWLEDGMENTS Any accomplishment requires the effort of many people and this work is not different. And it is our prime duty to acknowledge the person who directly or indirectly helped us during completion of this report. So we take opportunity to heartily thank our project guide respected Assist. Prof. J.B. Kanani for his valuable guidance and touch of inspiration and motivation throughout the project work without whose help the work would not have been in the shape what it is. We also heartily thank our Head of Department Dr.P.S.Puranik who greatly helped us in our project work without whose help the work would not have been in the shape what it is. We also thank our Principal Dr. G.D.Acharya without whose guideline and motivation we would have not completed our project. Last but not the least, we heartily thanks our trustees and dignitaries without whose motivation our project works would not have been in the shape what it is. We are also thanking full to other relevant staff of workshop, library and department for their co-operation, help and guidance. KRUTARTH PATEL 120030119108 PARTH KOTADIA 120030119069 Place: Rajkot Abstract Packaging of chemicals is quite difficult and generally it is performed manually in small scale industries. The individual weighing machine and stitching machine are quite costlier for small scale industrial application. By performing manually, there is some amount of wastage of product and is quite longer process. Thus the main purpose of selecting this project is to safely packaging of solid chemical products. The advantages of packaging machine are safer in operation, less effort of labour, faster in operation, increase product packaging quality, simplify material handling and reduction in cost by combining weighing machine and stitching machine. Keywords: Packaging Safe operation Increase product packaging quality Simplify material handling Faster operation Contents Index Sr No. Chapter Page No. Sodhyatra Introduction Company Profile Production Process Description Packaging Process Description GTU Activity Proposed Design Working Of Machine Cost Of Machine References List of Tables Sr. no. Table Name Page No. 1 Production Detail 5 2 Relative Weight table 29 3 Work Plan 40 4 Calculation of volume of material 38 5 Design Data for spur gear 39 List of Figures Sr. No. Figure Name Page no. 1 Production Process Flow chart 6 2 Flow chart of Packaging Operation 7 3 Centrifugal hydro 8 4 Inventory 9 5 Transporting 9 6 Loading/Unloading 9 7 Floor Plan 10 8 AEIOU Summary Sheet 12 9 Empathy Mapping Sheet 14 10 Ideation canvas Sheet 16 11 Product Development Sheet 18 12 Mechanical Weighing Scale 31 13 Hydraulic weighing Scale 31 14 Digital Weighing Scale 31 15 Stepper Motor 32 16 Working of Stepper Motor 33 17 Load Cell 34 18 Storage Tank 34 19 Measuring Tank 35 20 Warm and Warm Gear 36 21 Assembly of weighing machine 37 22 Working Of Weighing Machine 38 SODHYATRA First we visited in Rastriya Chemicals and Fertilizers Ltd., Macson, L.D. Chemicals, Interchem. All these industries produce chemical products. First two are large scale industries and another two are small scale industries. Observation: In Rastriya Chemicals and Fertilizers Ltd. And Macson: Weighing machine, conveyor belt and stitching machine assembly is used for packaging. In L.D. Chemicals and Interchem : Electrical weighting machine, manual transportation and stitching machine is used. Problem Facing: Two workers to four workers are required for each packaging assembly and 24 hours requirement of worker in large scale industries like Rastriya Chemicals and Fertilizers Ltd and Machson. Minimum three workers are required for each packaging section in small and moderate scale industries like L.D. chemicals and Interchem. Idea for Solving Problem: If combination of weighing and stitching machine is possible then one worker can operate 2 to 3 machines and no continuous observation is required. It reduces time of operation and reduce material wastage. INTRODUCTION Packaging can be defined as "the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use". Packaging also refers to "the process of design, evaluation, and production of packages". Packaging machines are used for packaging process. Packaging basically of two types. The single item such as water bottle can be regarded as the item that is primary packaging. Whereas a pack of bottles, shrink wrapped, would be regarded as the transport package used within the distribution chain is known as "secondary" packaging. It includes filling machines, sealing machines, wrapping machines, strapping machines, labelling machines and coding machines. In primary packaging there is direct contact with the product whereas secondary packaging is done outside of primary packaging. The selection of machine for primary and secondary packaging is depends on budget, integration, operating cost, machine technology and available floor space. Generally Stainless steel is used for packaging machine due to its strength, not affectivity with chemicals. Function of Packaging machine: For protecting product, packaging is necessary. In recent time packaging is done mainly through the use of packaging machinery. Machinery plays increasingly important roles such as: Improve labour productivity. Sliding blister sealing machine packaging machinery is much faster than manual packaging. One good example of this is the candy packing machine. Here, hundreds to thousands of candies can be wrapped in minutes. Ensure packaging quality. Mechanical packaging is particularly important for exported goods to achieve consistent packaging. Handle specialized requirements, such as vacuum packaging, inflatable packaging, skin packaging and pressure filling. Reduce labor and improve working conditions for bulky/heavy products. Protect workers from health effects brought by dust, toxic/hazardous products and prevent environmental contamination. Reduce packaging costs and save storage costs for loose products, such as cotton, tobacco, silk, linen, etc., by simply using compression packaging. Reliably ensure product hygiene by eliminating hand contact with food and medicines. 1.2 Types of Packaging products: Filling machine: Filling machine is used for food/beverage packaging. This is use for filling the bottle or pouch. The various types of filling machines are Auger/agitator filling machines, Flow filling machines, Tablet fillers and Positive displacement pump fillers. Sealing machine: Sealing machines are used for sealing the filled bags. Both liquid and solid can be bagged by using this packaging system. Strapping machine: Strapping means banding and bundling. It is the process of applying a strap to item to combine, hold, reinforce, or fasten it. Wrapping machine: It covers primary packaging. It is generally use for bulk packaging. Labelling machine: It is use for labialize the product. Cleaning machine: It is use for cleaning of final product. For example after manufacturing the gear, cleaning machine is used to remove dust particles before packaging. Drying machine: To remove the moisture from the product, drying machine is use. Sterilization machinery: It eliminates the biological agents (like virus) from the product. Container machinery: It is use for transporting container from one place from another place. Multifunction machine: It can perform multiple operations at the same time. Type of packaging machine according to degree of freedom: Automatic packaging machine Semi-automatic packaging machine 3. COMPANY PROFILE Company Name: INTERCHEM Address: Plot No. C1/1, G.I.D.C. Pandesara, Dist. Surat, Gujarat. Contact No.: 0291-2890766, 9825099266 Email Id: mailto:[email protected]@gmail.com Blogspot: interchem.blogspot.com Interchem produces dyes and chemicals. It has run since 1987. It produces mainly five products. The production rate is 30MT/ month/ product. It produces Ammonium Sulphate, Sodium Sulphate, Sodium Bi Sulphate, Gobar salt and Citro W. 3.1Production detail: Sr.No. Product Production (In MT/annum) 1 Ammonium Sulphate 360 2 Sodium Sulphate 360 3 Sodium Bi Sulphate 360 4 Citro W 360 5 Gobar Salt 360 .PRODUCTION PROCESS DESCRIPTION 4.1 Flow chart : R (Figure 1 Process Flow chart for getting final product) The process for getting the final product from the raw material is same as explain in flow chart. Raw materials are filled in mixing tanks as per product requirement. Then the raw materials mix with each other and brew. Then after some interval of time, the temperature decrease. Then it is transport to centrifugal hydro for filtering the chemicals. All the output of centrifugal hydro is mixed. It proceeds to weighing machine and then proceed to stitching machine for final packaging. Then it stores to inventory. 5.PACKAGING PROCESS DISCRIPTION Storage Tank Weighing Stitching Inventory (figure 2 Flow chart of Packaging operation) In packaging process raw material is supplied from storage tank to the weighing machine and then it

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supplies to the stitching machine. 6.GUJARAT TECHNOLOGICAL UNIVERSITY ACTIVITY 1) AEIOU Summary Sheet: (i)Activities: a) General Impression: Loading/ unloading Batch preparation Transporting Mixing Filtration Packaging b) Elements, Features and Special Notes: Maintenance of gearbox Replacement of V belt Replacement of stared Maintenance of motor c) Sketch/Photo- Summary of activities (figure 3.1 Centrifugal Hydro) (figure 3.2 Inventory) (figure 3.3 Transporting) (figure 3.4 Loading/Unloading) (ii) Environment: General Impression/Interaction: Noisy Environment Dusty Environment Elements, Features and Special Notes: Warm environment and increasing humidity while leakage Floor Plan (figure 3.5 Floor Plan) (iii) Interaction: General Impression/Interaction: Worker to worker Worker to Supervisor Supervisor to Manager Manager to Owner We to worker and supervisor Elements, Features and Special Notes: Owner to supervisor and worker while dispute Scene of Interaction: (iv) Objects: General Impression/Interaction: Centrifugal Hydro Boiler Mixing Tank Weighing machine Stitching machine Stared and vessel Elements, Features and Special Notes: Inventory of key objects: Storage of Raw materials: Sodium sulphate Ammonium sulphate Sodium chloride Sulphuric acid Finished Product: Sodium Bi sulphate Citro W Gobar salt Spare Machinery: Electric motor V belts (v) Users: a) General Impression: Manager Engineer Supervisor Quality control Department b) Elements, Features and Special Notes: Marketing department Stockholders Purchase department c) Scene of users in context: Textile industry Food industry Chemical industry (figure 4 AEIOU summary Canvas) (2) Empathy Mapping Canvas: (i) User: Workers Supervisor (ii) Stockholders: Manufacturing industry Traders (iii) Activates: Travelling Visit in industry Observation Interaction Identification of problem Listing the problem (iv) Story Boarding: Happy: After completing this project, it requires less manpower, in cost of packaging. So, it will helpful in maximizing the company’s profit. After completing this project, it will helpful to workers for operations, having less effort, quick operation and comparatively safer operation. Sad: It will reduce the requirement of workers. So it will not helpful in reduction of unemployment. If any fault occurs in machine, operation will delay until maintenance will complete. (figure 5 Empathy mapping sheet) (3) Ideation Sheet: (i) People: Workers Supervisor Engineers Managers Owner / Stockholders (ii) Activities: Getting permission for visiting industry Visiting in industry Observation Interaction Knowing working in industry Listing out problems+ Listing the machines in industry Try to identify the problem facing Interaction with faculties (iii) Situation/Context/Location: Hazardous environment Small scale industry Medium scale industry Large scale industry No foundation is required Traders Packaging of gains (iv) Props / Possible Solution: Manual packaging Using weighing machine, stitching machine and conveyor belt assembly Batch wise production (figure 6 Ideation Canvas sheet) (4) Product Development Canvas: (i) Purpose: Use for hazardous material handling Safer operation Reduction in time of operation Less manpower required Reduction of wastage of materials Accuracy (i) People: Worker Supervisor Engineer Stockholders (ii) Product Experience: Low cost Safety Automatic operation Quality Packaging (iii) Product Functions: Weighing Stitching Packaging (iv) Product features: Quick operation Quality packaging Easy material handling Use for hazardous materials Easy packaging (v) Components: Storage tank Controller Load cell Spur gears Gearbox Grippers Stitching machine Sliders Out body of machine (vi) Customer Revalidation: Maintenance Eco friendly Life span Repeatability Size Less space (vii) Reject, Redesign, Retain: (figure 7 Product development sheet) (5) Business Model Canvas Sheet (6) Business Model Canvas Report: BUSINESS MODEL CANVAS (BMC): Business model canvas is used to validate the market significance of products and services which will be of technology nature in this case. Technology projects are often solutions or processes that solve a technical problem. However the market implementation of such solutions also require that the problem solution is designed to overcome not just the technical barriers but also market and business related barriers of costs, customer reach and collaborations and those that pertain to the practical nature of limited initial capacities within the team. Thus business model canvas can be used to visualize such market problems and customer expectations. This exercise will increase the market potential and technology goods and services. This will make them more effective in market. This exercise will bring discussions on viability and cost effectiveness. It will enable students to have a clear understanding on the steps required to ensure that whatever solution they develop as their project should have a user who can afford it with desired needs. 1. KEY PARTNERS : A business partnership is when two commercial entities form an alliance, which may either be a really loose relationship where both entities retain their independence and are at liberty to form more partnerships or an exclusive contract which limits the two companies to only that one relationship. Our key partners are as follows: a) Production department b) Design expert c) Fabrication expert d) Suppliers e) Consumers f) Workers 2. KEY ACTIVITIES : As the title suggests, these are the most important tasks which must carry out in order to fulfil its business purpose. Key activities are different according to the business model of the organization carrying out the activity. The key activities which are used in our canvas are given below: a) Visited Small scale industry b) Observing Packaging operation c) Calculating packaging cost 3. KEY RESOURCES : Key resources are the main inputs that company uses to create its value proposition, service its customer segment and deliver the product to the customer. Key resources deal with the operational end of the business spectrum and define what kind of materials are needed, what kind of equipment is required and the types of people you need to employ. Key resources which are used are note down below: a) Patents b) Research papers c) Journals d) Reference books 4. VALUE PROPOSITIONS : In simple terms, a value proposition makes a case for why a customer should pick one product over another, citing the unique value the product provides over its contenders. The Business Model Canvas value proposition provides a unique combination of products and services which provide value to the customer by resulting in the solution of a problem the customer is facing or providing value to the customer. Our value propositions are as followed: a) Reliability b) Cost efficiency c) Time saving d) Accuracy 5. CUSTOMER RELATIONSHIPS : This building block dictates the nature of the relationships that an organization will develop with its various customer segments. The customer relationships that an organization opts for are based on the company’s business model and greatly impact the overall customer experience. Following are the customer relationships that are utilized : a) Loyal relationship b) True facts about products c) Co-operative 6. CHANNELS : This building block defines how an organization communicates with and provides value to its chosen customer segment. Channels are the touch points through which an organization liaises with its customers and as such, play a huge role in defining the customer experience. Our channels are given as follows: a) Social media b) Technical fair c) Community blogs d) Advertising 7. CUSTOMER SEGMENTS : Customer Segment block is to present the list of Personas, organized by Customer Segment. If you have more than one segment. It is always recommended to prioritize them. The customer segments includes following factors: a) Chemical Packaging b) Sand Packaging c) Grain Packaging d) Fine powder packaging 8. COST STRUCTURE : Cost Structure business block provides a list of Cost Structure elements with notes on their relationship to Key Activities. Look at what kind of characteristics most cost structures display; cost structure have fixed and variable costs and they can have benefits of economies of scale or economies of scope. This block consist of following terms: a) Component cost b) Marketing cost c) Maintenance cost d) Cost of workers e) Working cost 9. REVENUE STREAMS : This building block elaborates the earnings a business gets by subtracting the costs from the revenue generated from each customer segment. Where customers are generally considered the heart of the business, revenues are automatically likened to the arteries. Organizations must evaluate the worth of the value they provide to each customer segment. Revenue streams are given below which are used: a) Cost feasibility b) Ease of availability c) No brokerage fees d) Direct sale of product e) Payment by EMI option (7) Periodic Progress Report 1 1. What Progress you have made in the Project? Ans: Visited In industry, Observing the work and environment, checking the chances of improvement and doing detailed study on them. Then arranging that improvement in ascending order as per them requirement and selecting most appropriate improvement as a project that helps to industry for increasing production rate. 2. What challenge you have faced? Ans: Communication gap due to language barrier with workers, Poor initial response, Less practical knowledge, Lack of punctuality, Some

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processes were unknown to us. 3. What support you need? Ans: Reference of experienced guide and Some literature related to the processes. 4.Which literature you have referred ? Ans: Journals, research papers, and patents. (8) Periodic Progress Report 2 What Progress you have made in the Project? Finding patterns and research papers related to project title. Finding components and concepts help to solving the problem and understanding them. What challenge you have faced? Patterns are not easily available related to project title. What support you need? Expert notes and literatures related to materials and mechanism is required. Which literature you have referred? Reference books, research papers (9) Periodic Progress Report 3 What Progress you have made in the Project? Get permission from industry as well as collage for performing project in industry. Prepare canvas sheets (AEIOU, Empathy, Ideation, Product Development) What challenge you have faced? It was time consuming process to get the permission. What support you need? Need quick support from industry and collage. Which literature you have referred? Refer formats given in PMMS for preparing canvas sheets . (10) Periodic Progress Report 4 What Progress you have made in the Project? Preparing Pattern Search Analysis Report. Collect data from industry which is helpful for the performance of project work. Initialize project work. What challenge you have faced? Face difficulty to submit online PSAR. Difficulty facing to understand questions while completing PSAR. What support you need? Better website support for completing online submission. Proper guidelines required for better understanding questions. Which literature you have referred? Refer company’s previous records of production for the collection of data. (11) Periodic Progress Report 5 What Progress you have made in the Project ? We learn about Stitching machine mechanisms and types. We also select proper type of stitching machine for our project work. What challenge you have faced ? We do not have proper knowledge about some component of stitching machine. What support you need ? We do not find proper literature related to stitching machine. So, we need proper guidance related to stitching machine. Which literature you have referred ? Internet. (12) Periodic Progress Report 6 What Progress you have made in the Project ? We learn about conveyor mechanism. We are completing Patent Drafting Exercise. What challenge you have faced ? We do not get proper design procedure of conveyer belt. What support you need ? We do not find proper literature related to conveyer belt. So, we need proper guidance related to conveyer belt design. Which literature you have referred ? Machine design by V.B. Bhandari (13) Parodic Progress Report 7 What Progress you have made in the Project ? We learn about grabber mechanism. We are completing Business Model Canvas. What challenge you have faced ? We confused while selecting the grabber mechanism mountings and operation. What support you need ? We want more convenient mechanisms for operating grabbers. Which literature you have referred ? Patents (14) Parodic Progress Report 8 What Progress you have made in the Project ? We are designing and programming the circuit for automatic operation of packaging and completing project report. What challenge you have faced ? We getting errors while programming. What support you need ? We are getting help from electrical department. Which literature you have referred ? Programing books. (15) Patent Drafting Exercise Form 1 (16) Patent Drafting Exercise Form 2 (17) Patent Drafting Exercise Form 3 Proposed Design Storage Chamber 7.1.1 Introduction: Storage tanks are ampules that hold liquids, solids, compressed gases (gas tank) or mediums used for the short- or long-term loading of heat or cold. Generally, tanks are used for storage purpose of materials. Tanks are available in different types according to the requirements or applications. 7.1.2 Types: According to shapes: Cylindrical Square Rectangular Conical Round According to application Atmospheric Tanks High Pressure Tanks Thermal Storage Tanks Milk Tank Septic Tank Mobile Storage Tank According to position Horizontal Vertical Inclined 7.1.3 Martials used : Generally steel and concrete are mostly used. Rather than this glass reinforced plastic, thermoplastic, and polyethylene are also used. These materials provide chemical resistance in case of use for chemical storage. 7.1.4 Flow control Mechanism : Dimension of rectangular Section : 150 mm x100 mm x120 mm Density of sodium Bi Sulphate = 1.48 gm/cm3 Mass in rectangular section = Density * Volume = (1.48x150x120x100)/(1000x1000) = 2.664 Kg Force applied = mass x Acceleration due to gravity = 2.664 x 9.81 = 26.13 N 7.2 Measuring Chamber 7.2.1 Measuring Tank: Measuring tanks are the ampules used for measuring of weight or contains. It is also used for providing protection while filling materials in packages. Generally aluminium or steel are used. But nowadays thermoplastic or alloy irons are used for their better quality. It is not connect rigidly. Design Of measuring Tank : Assumption : Design is based on Sodium Bi Sulphate So, Density of sodium Bi Sulphate = 1.48 gm/cm3 Volume = mass x Density = 50 x1000 / 1.48 = 33783.78 cm3 Length = Width = Height = 32.33 cm So, Take Length = Width = Height = 40 cm Thickness of Walls = 3cm 7.2.2 Load Cell : Load cell is used to measure loads applied on measuring tank. Load cell is transducer that is create an electrical signal which value is equal to the applied potency on the tank. Load cell is connected with the rigid support and measuring chamber. Control Mechanism 7.3.1Rack and Pinion Mechanism: Rack and Pinion mechanism is used to convert the rotary motion into linear motion and vice versa. Rack and pinion is used to control the flow of material. There is A.C. motor is connected with the pinion. A.C. motor drives the pinion and torque is transmitted to the rack with the meshing of tooth. (i) Design Of Pinion : Force applied on the plate: Mass on plate = 50kg Acceleration due to gravity = 9.81m/s Co efficient of Friction for Steel = 0.5 to 0.8 Normal Force = Mass x Acceleration due to gravity = 50x9.81 = 490.5 N Frictional Force = Co efficient of Friction x Normal Force = 0.8 x 490.5 = 392.4 N Resultant Force = √{(Normal Force)2 + ( Frictional Force)2} (Required) = √ { 240590.25+ 153977.76} Freq = 628.15 N Now, Assumption: Pitch Circle Diameter (d) = 100 mm Number Of teeth on pinion(zp) = Number Of teeth on pinion(zg) = 18 So, Module (m) = d/z = 100/18 = 5.55 mm = 6 mm Addendum (ha) = 1 x m = 6mm Dedendum (hf) = 1.25 x m = 7.5mm Working depth = 2 x m = 12mm Minimum total depth = 2.25 x m = 13.5mm Tooth thickness = 1.5708 x m = 9.42 mm Minimum clearance = 0.25 x m = 1.5 mm Fillet radius at root = 0.4 x m = 2.4 mm Face width thickness (b) = 6 x m = 36 mm Circular Pitch = π x d/z = π x 100/18 = 17.45 mm Young’s Modulus (yg) = 0.308 Material of pinion = Grade C45 (Steel) Brinell Hardness Number ( BHN) = 200 Speed (N) = 10 rpm Bending stress (σb)= 264.87 N/mm2 Bending Force (Fb) = σb x b x mx yg = 264.87 x 36 x 6 x 0.308 = 17.62127 KN Wear strength (Fw) = d x b x Q x K = 100 x 36 x 1 x 0.16 x (200/100)2 = 2304 N Where, Q = 2 x zg / (zp+zg) = 2 x 18/(18+18) = 1 K = 0.16 x (BHN/100)2 = 0.16 x (200/100)2 = 0.64 Velocity (v) = (π x d x N)/(60000*60) = (π x 100 x 10)/(60000*60) = 8.7266 x 10-4 m/s Force Transmitted (Ft) = P/v Feff = KaKmFt/ Fv Kv = 3/(3+v) = 3/(3+8.7266x10-4) = 0.9997 s/m Ka = Kb = 1 Fw = F.O.S x Feff 2304 = 2 x Ka x Km x Ft / Kv 2304 = 2 x 1 x 1 x P / (0.9997 x 8.7266x10-4) P = 1 W Now, P = 2xπxNxT/60 T = 1x60x60 / (2xπx10) = 57.296 N.m F x r = T F x 0.02 = 57.296 F = 2864.789 N Hence, Freq

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Interchem Manufactures of Dye intermediates, dyed & Chemicals & Textile Auxiliary

Date: 15th April 2016

Ref No. HR/Training/Apr/2016-3

To whomsoever It May Concern This is to certify that Mr. KRUTARTH PATEL and Mr. PARTH KOTADIA, students of 8th semester in Bachelor of Engineering in Mechanical from Atmiya Institute of Technology & Science – Rajkot has undergone for Industrial Defined project from 7th July, 2015 to 15th April, 2016 in our organisation and has completed the project. During their training, they have undergone for the study of “Incorporating packaging machine with weighing machine to easy packaging of solid chemical products” and acquired knowledge of the same. We wish them all the success for their future studies.

For Interchem

Mrs. Manisha Patel Owner

Factory & Office: Shed No. C-1, (Plot No. 1), P.O.: G.I.D.C. Estate, PANDESARA – 394221, Dist. Surat. Contact No. 0261-2890766 E-mail: [email protected]

1. SODHYATRA  Sodhyatra is started from Rastriya Chemicals and Fertilizers Ltd., Macson, L.D. Chemicals, Interchem.  All these industries are working in chemical manufacturing industries and working from a long time.

Observation:  In Rastriya Chemicals and Fertilizers Ltd. And Macson: Weighing machine, conveyor belt and stitching machine assembly is used for packaging.  In L.D. Chemicals and Interchem : Electrical weighting machine, manual transportation and stitching machine is used.

Problem Facing:  Two workers to four workers are required for each packaging assembly and 24 hours requirement of worker in large scale industries like Rastriya Chemicals and Fertilizers Ltd and Machson.  Minimum three workers are required for each packaging section in small and moderate scale industries like L.D. chemicals and Interchem.

Idea for Solving Problem:  If combination of weighing and stitching machine is possible then one worker can operate 2 to 3 machines and no continuous observation is required. It reduces time of operation and reduce material wastage.

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2. INTRODUCTION  Packaging can be defined as "the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use". Packaging also refers to "the process of design, evaluation, and production of packages".  Packaging machines are used for packaging process.  Packaging basically of two types. The single item such as water bottle can be regarded as the item that is primary packaging. Whereas a pack of bottles, shrink wrapped, would be regarded as the transport package used within the distribution chain is known as "secondary" packaging.  It includes filling machines, sealing machines, wrapping machines, strapping machines, labelling machines and coding machines.  In primary packaging there is direct contact with the product whereas secondary packaging is done outside of primary packaging.  The selection of machine for primary and secondary packaging is depends on budget, integration, operating cost, machine technology and available floor space.  Generally Stainless steel is used for packaging machine due to its strength, not affectivity with chemicals.

2.1 Function of Packaging machine: For protecting product, packaging is necessary. In recent time packaging is done mainly through the use of packaging machinery. Machinery plays increasingly important roles such as:  Improve labour productivity. Sliding blister sealing machine packaging machinery is much faster than manual packaging. One good example of this is the candy packing machine. Here, hundreds to thousands of candies can be wrapped in minutes.  Ensure packaging quality. Mechanical packaging is particularly important for exported goods to achieve consistent packaging.  Handle specialized requirements, such as vacuum packaging, inflatable packaging, skin packaging and pressure filling.  Reduce labor and improve working conditions for bulky/heavy products.  Protect workers from health effects brought by dust, toxic/hazardous products and prevent environmental contamination. 2|Page

 Reduce packaging costs and save storage costs for loose products, such as cotton, tobacco, silk, linen, etc., by simply using compression packaging.  Reliably ensure product hygiene by eliminating hand contact with food and medicines.

2.2

Types of Packaging products:

 Filling machine: Filling machine is used for food/beverage packaging. This is use for

filling the bottle or

pouch. The various types of filling machines are Auger/agitator filling machines, Flow filling machines, Tablet fillers and Positive displacement pump fillers.  Sealing machine: Sealing machines are used for sealing the filled bags. Both liquid and solid can be bagged by using this packaging system.  Strapping machine: Strapping means banding and bundling. It is the process of applying a strap to item to combine, hold, reinforce, or fasten it.  Wrapping machine: It covers primary packaging. It is generally use for bulk packaging.  Labelling machine: It is use for labialize the product.  Cleaning machine: It is use for cleaning of final product. For example, after manufacturing the gear, cleaning machine is used to remove dust particles before packaging.  Drying machine: To remove the moisture from the product, drying machine is use.  Sterilization machinery: It eliminates the biological agents (like virus) from the product.  Container machinery: It is use for transporting container from one place from another place.  Multifunction machine: It can perform multiple operations at the same time.

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2.3 Type of packaging machine according to degree of freedom:  Automatic packaging machine  Semi-automatic packaging machine  Manual packaging machine

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3. COMPANY PROFILE Company Name:

INTERCHEM

Mailing Address:

Plot No. C1/1, G.I.D.C. Pandesara, Dist. Surat, Gujarat.

Contact No.:

0291-2890766, 9825099266

Email Id:

[email protected]

Interchem produces dyes and chemicals. It has run since 1987. It produces mainly five products. The production rate is 30MT/ month/ product. It produces Ammonium Sulphate, Sodium Sulphate, Sodium Bi Sulphate, Gobar salt and Citro W.

3.1 Production detail: Table 1 Production Detail

Sr. No.

Product

Production (MT/ Annum)

1

Sodium Sulphate

3600

2

Sodium Bi Sulphate

3600

3

Ammonium Sulphate

3600

4

Citro W

3600

5

Citric Acid

3600

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4. PRODUCTION PROCESS DESCRIPTION 4.1 Flow chart :

R

Raw material

Weighting

Filling

Filtering

Waiting until it cools

Mixing

Weighting

Stitching

Dispatching

Inventory

Mixing of chemicals

(Figure 1 Process Flow chart for getting final product) The process for getting the final product from the raw material is same as explain in flow chart. Raw materials are filled in mixing tanks as per product requirement. Then the raw materials mix with each other and brew. Then after some interval of time, the temperature decrease. Then it is transport to centrifugal hydro for filtering the chemicals. All the output of centrifugal hydro is mixed. It proceeds to weighing machine and then proceed to stitching machine for final packaging. Then it stores to inventory.

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5. PACKAGING PROCESS DISCRIPTION Storage Tank

Weighing

Stitching

Inventory

(figure 2 Flow chart of Packaging operation) In packaging process raw material is supplied from storage tank to the weighing machine and then it supplies to the stitching machine.

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6. LITERATURE REVIEW: 1) Design and Development of Cost Effective Automatic Machine for Powder Packaging M. R. Saraf, V. V. Ruiwale, V. V. Kulkarni and S. M. Kulkarni Mechanical Engineering Department, MITCOE, Sri Savitribai Phule Pune University, Pune, Maharashtra, India

Abstract: The packaging industry has advanced leaps and bounds over the few years. The pouch packaging machines also known as Form Fill and Seal Machines (FFS Machines) are available over a wide capacity range. A low cost automated packing machine can be used by small enterprises which would help reduce their cost of plant. This low cost automated machine uses simple pneumatic, mechanical and electric systems. In this paper we have presented one such low cost pouch filling machine. An additional weighing and pouring mechanism has been added to increase the accuracy of the system. The process flow has been described in detail. Various processes involved in the pouch packaging are neatly aligned and properly timed to get optimum production rate. A mechatronics system, developed for this machine, which takes feedback from sensors and accordingly controls the manipulators has been introduced in this paper. A microcontroller system is used for this particular machine. A detailed cost comparison between a conventional machine and the one developed by us has been presented. Keywords: Low Cost Automation, Microcontroller, PLC

2) Design and fabrication of variable rack and pinion steering geometry R. Rajasekar, T. Kathireshan, Rohit G Prasad, M. Pradhyumnan Department of Automobile Engineering, Sathyabama University, Chennai, Tamilnadu, India Abstract: This paper analyses the feasibility of improving the steering behaviour in traffic situations using variable steering geometry. The design and fabrication of rack and pinion has been done by using soildworks software. The objective of this paper is basically to design and manufacturing a variable rack and pinion with higher to lower ratio in order to sensitize the steering for better manoeuvrability for Indian road condition or urban road condition. A 8|Page

variable-ratio steering, is a system that uses different ratios on the rack, in a steering system. At the centre of the rack, the space between the teeth is smaller and the space becomes larger as the pinion moves down the rack. In the middle of the rack, you will have a sensitive ratio and the response becomes a-base as you turn the steering wheel towards lock. This makes the steering more sensitive, when the steering wheel is close to its centre position and makes it easier for the driver to steer at low speeds. Keywords: Rack and Pinion, soildworks, steering geometry, sensitive ratio.

3) Pouch packing machines are commonly known as Form Fill and Seal Machines. There are classified as two main types– Vertical Form Fill and Seal Machines and Horizontal Form Fill and Seal Machines. Vertical Form Fill and Seal Machines (VFFS Machine) are used to pack regular shaped solid products or liquids while, Horizontal Form Fill and Seal Machines are used to pack irregular shaped products. In this paper we focus on the Vertical Form Fill and Seal Machines. VFFS machines are widely used in most of the industries to pack products of various sizes (depending on their weights). The VFFS Machines are again classified in two ways- According to their type of motion (Continuous motion and Intermittent motion) and According to their type of automation (Fully automated and Semi automated). In making of the pouch two seals have to be made horizontal and vertical as it will be further explained in detail. Intermittent motion machine makes the vertical seal while the film is in motion but for the horizontal seal the film stops whereas, the continuous motion machine makes the vertical and the horizontal seal without stopping the film. Hence, higher production rates can be achieved by the continuous motion machine. On the other hand, Fully automated machine requires no human intervention while Semi automated machines require humans to perform some part of packing operation. The machine discussed in the paper can be classified as an intermittent motion machine or fully Automatic machine.

4) Design and selecting the proper conveyor-belt Konakalla Naga Sri Ananth, Vaitla Rakesh, Pothamsetty Kasi Visweswarao Mechanical Engineering Departments, KLU Guntur Abstract: Belt conveyor is the transportation of material from one location to another. Belt conveyor has high load carrying capacity, large length of conveying path, simple design, easy 9|Page

maintenance and high reliability of operation. Belt Conveyor system is also used in material transport in foundry shop like supply and distribution of molding sand, molds and removal of waste. This paper provides to design the conveyor system used for which includes belt speed, belt width, motor selection, belt specification, shaft diameter, pulley, gear box selection, with the help of standard model calculation.

10 | P a g e

7. DESIGN AND CAD MODEL: In this project we are designing the packaging machine which is used for packaging of solid bulk materials. This machine is semi-automatic and operated by only one operator. There are several components used for compile the operation. The components used are storage tank, measuring tank, load cell, supporting tank, conveyor belt, stitching machine and grabber. The components and its design are explained below.

7.1 Storage Chamber 7.1.1 Introduction: Storage tanks are ampules that hold liquids, solids, compressed gases (gas tank) or mediums used for the short- or long-term loading of heat or cold. Generally, tanks are used for storage purpose of materials. Tanks are available in different types according to the requirements or applications.

(figure 3 Storage Tank)

11 | P a g e

(figure 4 Dimensions of storage tank)

7.1.2 Types: a) According to shapes:  Cylindrical  Square  Rectangular  Conical  Round b) According to application:  Atmospheric Tanks  High Pressure Tanks  Thermal Storage Tanks  Milk Tank  Septic Tank  Mobile Storage Tank 12 | P a g e

c) According to position:  Horizontal  Vertical  Inclined

7.1.3 Martials used : Generally steel and concrete are mostly used. Rather than this glass reinforced plastic, thermoplastic, and polyethylene are also used. These materials provide chemical resistance in case of use for chemical storage.

7.1.4 Flow control Mechanism :

(figure 5 Flow control plate)

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(figure 6 Arrangement of Flow control plate)

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(figure 7 Dimension of Flow control plate) Dimension of rectangular Section : 150 mm x100 mm x120 mm Density of sodium Bi Sulphate = 1.48 gm/cm3 Mass in rectangular section = Density * Volume = (1.48x150x120x100)/(1000x1000) = 2.664 Kg Force applied = mass x Acceleration due to gravity = 2.664 x 9.81 = 26.13 N

7.2 Measuring Chamber 7.2.1 Measuring Tank: Measuring tanks are the ampules used for measuring of weight or contains. It is also used for providing protection while filling materials in packages. Generally aluminium or steel are 15 | P a g e

used. But nowadays thermoplastic or alloy irons are used for their better quality. It is not connect rigidly. Design Of measuring Tank : Assumption : Design is based on Sodium Bi Sulphate So, Density of sodium Bi Sulphate = 1.48 gm/cm3 Volume = mass x Density = 50 x1000 / 1.48 = 33783.78 cm3 Length = Width = Height = 32.33 cm So, Take Length = Width = Height = 40 cmThickness of Walls = 3cm

(figure 8 Weight measuring tank)

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(figure 9 Dimensions of Weight measuring tank)

7.2.2 Load Cell : Load cell is used to measure loads applied on measuring tank. Load cell is transducer that is create an electrical signal which value is equal to the applied potency on the tank. Load cell is connected with the rigid support and measuring chamber.

7.3 Control Mechanism 7.3.1 Rack and Pinion Mechanism: Rack and Pinion mechanism is used to convert the rotary motion into linear motion and vice versa. Rack and pinion is used to control the flow of material. There is A.C. motor is connected with the pinion. A.C. motor drives the pinion and torque is transmitted to the rack with the meshing of tooth.

17 | P a g e

(figure 10 Rack and Pinion Mechanism in Weight measuring tank) (i) Design Of Pinion : Force applied on the plate: Mass on plate = 50kg Acceleration due to gravity = 9.81m/s Co efficient of Friction for Steel = 0.5 to 0.8

Normal Force = Mass x Acceleration due to gravity = 50x9.81 = 490.5 N

Frictional Force

= Co efficient of Friction x Normal Force = 0.8 x 490.5 = 392.4 N 18 | P a g e

Resultant Force = √{(Normal Force)2 + ( Frictional Force)2} (Required) Freq

= √ { 240590.25+ 153977.76} = 628.15 N

Now, Assumption: Pitch Circle Diameter (d) = 100 mm Number Of teeth on pinion(zp) = Number Of teeth on pinion(zg) = 18 So, Module (m) = d/z = 100/18 = 5.55 mm = 6 mm Addendum (ha)

1xm

= 6mm

Dedendum (hf)

= 1.25 x m

= 7.5mm

Working depth

=2xm

= 12mm

Minimum total depth

= 2.25 x m

= 13.5mm

Tooth thickness

= 1.5708 x m

= 9.42 mm

Minimum clearance

= 0.25 x m

= 1.5 mm

Fillet radius at root

= 0.4 x m

= 2.4 mm

Face width thickness (b) = 6 x m

= 36 mm

Circular Pitch = π x d/z = π x 100/18 = 17.45 mm Young’s Modulus (yg) = 0.308 Material of pinion = Grade C45 (Steel) Brinell Hardness Number ( BHN) = 200

Speed (N) = 10 rpm Bending stress (σb)= 264.87 N/mm2 Bending Force (Fb) = σb x b x mx yg = 264.87 x 36 x 6 x 0.308 = 17.62127 KN 19 | P a g e

Wear strength (Fw) = d x b x Q x K = 100 x 36 x 1 x 0.16 x (200/100)2 = 2304 N

Where, Q = 2 x zg / (zp+zg) = 2 x 18/(18+18) =1 K = 0.16 x (BHN/100)2 = 0.16 x (200/100)2 = 0.64 Velocity (v) = (π x d x N)/(60000*60) = (π x 100 x 10)/(60000*60) = 8.7266 x 10-4 m/s

Force Transmitted (Ft) = P/v Feff = KaKmFt/ Fv Kv = 3/(3+v) = 3/(3+8.7266x10-4) = 0.9997 s/m Ka = Kb = 1 Fw = F.O.S x Feff 2304 = 2 x Ka x Km x Ft / Kv 2304 = 2 x 1 x 1 x P / (0.9997 x 8.7266x10-4) P=1W Now, P = 2xπxNxT/60 T = 1x60x60 / (2xπx10) = 57.296 N.m Fxr=T F x 0.02 = 57.296 F = 2864.789 N Hence, Freq
Length of Rack = 17.45x18 = 314.1 mm Material Steel C45 Table 2 Specifications of Spur Gear(Pinion)

Specifications

Value

Material

Steel C45

Profile

20o Full Death

Pitch Circle Diameter

100 mm

Number of teeth of pinion

18

Module

6 mm

Addendum

6 mm

Dedendum

7.5 mm

Working Depth

1

3.5 mm

Tooth Thickness

9. 42 mm

Minimum Clearance

1. 5 mm

Fillet radius at root

2. 4 mm

Face Width radius

3

6 mm

Circular Pitch

1

7.45 mm

Table 3 Specifications of Rack : Specification

Value

Material

Steel C45

Linear Pitch

17.45 mm

Number Of Teeth

18

Length of Rack

14.1 Mm

7.4 Supporting Tank The purpose of supporting tank is only to give direction of material flow and to protect wastage of material. Supporting tank is shown in figure. At the bottom of the supporting tank, grabber is placed. The grabber is used to hold the bags. The grabbers are operated with th e help of stepper motor. 21 | P a g e

(figure 11 Supporting tank)

22 | P a g e

(figure 12 Dimensions of Supporting tank)

7.5 Stepper Motor: Stepper motor is an electromechanical device which converts electrical pulses into distinct mechanical movements. Stepper motor shaft rotates in step by step when electrical command pulses are applied to it in proper sequence. The direction of rotation is directly proportional to the sequence of pulses applied. It is used at storage tank (to control flow) and at grabber (to operate the grabber motion). Advantages:  The rotation angle of motor is proportional to the input pulse.  The motor has full torque at standstill (if windings are energized).  Excellent response to starting/ stopping/ reversing.  It is possible to achieve very low speed synchronous rotation which a load that is directly proportional to the shaft. Disadvantages:  Resources can occur if not properly controlled. 23 | P a g e

 Not easy to operate at extreme high speed. Calculations : Torque = 4 x 9.81/100 = 0.3924 Nm (i) For Flow control Mechanism: F x r x sinα = T 30 x 0.15 x sin 90 = T T = 4.5 N.m Table 4 Stepper Motor specifications (For Flow Control Mechanism): Model Number

34HS38-3008S

Step Angle

1.8o

Current

3.0 A

Body Length

98 mm

Resistance

1. 6 ohm

Inductance

8 Mh

Holding Torque

5 N.m

Detent Torque

2.2 N.m

Weight

3.2 Kg

Frame Size

86 x 86 mm

Shaft Length

32 mm

Number of leads

8

Lead Length

500 mm

Shaft Diameter

12.7 mm

Table 5 Stepper Motor specifications (For Grabber Mechanism): Rated Voltage

5.2

Current

6.5

Resistance

0.8

Inductance

15

Holding Torque`

22

Rotor Inertia

10900

Weight

8.4

Number of Leads

4

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7.6 Servo Motor: A servomotor is a rotary actuator or linear actuator that allows for precise control of angular or linear position, velocity and acceleration. There is a sensor is connected with the motor to know the response. It controls the motion and position with the help of response. The specifications of servo motor used to drive the pinion are as follows. Company : YUHAI, Zhejiang, China Table 6 Servo Motor Specification Motor Model

130 SY M10010

Rated Power (KW)

1

Rated current (KW)

4.5

Rated Speed (rpm)

10

Peak Speed (rpm)

1000

Rated Torque (N.m)

25

Peak Torque (N.m)

1300

Rotor Inertia (kg.m2)

1.94*10-4

Weight (Kg)

11.5

7.7 Grabber: Grabbers are use to hold the bags. It is attached on bottom of the machine and it is operated by the electric motor or hydraulic system or pneumatic system. It is operated manually as well as automatically. The grabber use for this machine is shown in figure.

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(figure 13 Grabber mechanism attached in supporting tank)

26 | P a g e

(figure 14 Gabber Arm)

7.8 Conveyor: Conveyor is a transporting panel which transport the material from one place to another. Conveyor is generally used for transporting bulk solid materials. It is also used for transporting the boxes, bottles, bags, etc. Table 7 Specification of Conveyor Belt Width of belt

400 mm

Length

1200 mm

Width of belt

395 mm

Installation tension

0.5% max.

Gear Motor:

230 V single phase and 230/400 V three phase with speed range 2 to 24 m/min 27 | P a g e

7.9 Stitching machine: Stitching machines are used for stitching purpose. Stitching machines were first used for the stitching of cloths at starting. But as time passes, it is used in other material stitching purposes like stitching of fibre bags, Plastic bags, etc. There are various types of machines are used as per their applications. There are mainly two types of stitching required like single stitch and double stitch. In the stitching of wearing cloths single stitch is used whereas in industries single as well as double stitch is used. For protecting from moisture and atmosphere double stitching is used for packaging.

7.10 Rectifier: A rectifier is an electrical device that converts alternating current, which periodically reverses direction, to direct current which flows in only in one direction. The process is known as rectification. Rectifiers have many uses, but are often found serving as components of DC power supplies and high-voltage direct current power transmission systems. Rectification may serve in roles other than to generate direct current for use as a source of power.

7.11 Step Down Transformer: A step down transformer has less turns on the secondary coil that the primary coil. The induced voltage across the secondary coil is less the applied voltage across the primary coil or in other words the voltage is “stepped-down”. It stepdown voltages form 440V to 33V.

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8. WORKING OF WHOLE MACHINE :  At initial condition, the measuring chamber is empty. At that time the bag is attached to the supporting tank and pushes the button. The controlling plates of measuring chamber are open but there is no any material. So wait for closing of them.  When the control plates are closed, the flow control mechanism operates due to sensor and material flow occurs. This material falls into measuring chamber.  Measuring chamber is not rigidly connected. There are load cell mounted on the walls of the measuring chamber. Load cell measures the weight of the material.  At initial condition when measuring chamber is empty, there is only weight of measuring chamber is applied on load cell. So, Take it as zero weight. Now when material weight is reached nearer to the 48Kg, the flow control mechanism starts to close and when the weight is of complete 50 Kg occurs, Flow control valve is closed.  One worker manually pushes button then the controlling plates of measuring chamber are open and the material fills in the bag passes through the supporting chamber.  One worker manually put the bag on supporting chamber as shown in figure and pushes the button.  When button pushes, the first operation occurs is to grab the bag, then signal passes to the servo motor mounted on measuring tank and through rack and pinion mechanism it opens the control plates.  After 5 seconds of complete opening of control plates, it closes again and signal passes to the control valve and control valve opens. At same time bag is filled with material and grabbers are in open position and bag is placed on conveyor belt.  Conveyor belt is in continuous motion and there is transport towards stitching machine. Stitching machine placed at a distance of 100cm from the machine.  Worker is locked the bag in the stitching machine and again go towards to grab the bag. And whole operation repeats.  Here the flow control valve is operate with the help of stepper motor, Control plates are operates with the help of AC servo motor and grabbers are also operates with the help of stepper motor.  The whole machine is operated with the help of the one worker. And it is semi-automatic.

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(figure 15 Machine Assembly)

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(figure 16 Programmable Logic control circuit for the operation of packaging machine)

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9. COST OF MACHINE : The total cost of machine includes various costs like material cost, component cost, manufacturing cost, inventory cost, transportation cost, labour cost, power consumption cost, etc.

Here we are considering the cost of material and components.

Total material usage cost = Rs. 24180/Cost of Load Cell = Rs.3150/Cost of stepper motor (used for flow control valve) = Rs.2816 /Cost of stepper motor (used for grabbers) = Rs. 50000/Cost of servo motor ( used for controlling plates) = Rs. 7630 /Cost of conveyor = Rs.70000 /Cost of Stitching machine = Rs. 27500 /Cost of rack and pinion = Rs.1000 /Cost of grabber = Rs. 400/Cost of 8051 microcontroller = Rs. 2400/Cost of Step down transformer = Rs. 5140/Hence total cost of machine = Summation of all above costs = 24180 + 3150 + 2816 + 50000 + 7630 + 70000 + 27500 +1000 +400 +2400 +5140 = Rs. 1,94,216/-

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10. CONCLUSION By working on this project, we conclude that the design suggested is quite helpful in packaging operation and reduce cost of packaging. The machine is semi - automatic and operated by a single person. There is no need of skill require to operate the machine. Due to semi – automation, the packaging time is less and quality packaging is done. This machine is economical in cost so small scale industries can also prefer it for packaging.

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11. GUJARAT TECHNOLOGICAL UNIVERSITY ACTIVITY 1) AEIOU Summary Sheet: (i)Activities: a) General Impression:  Loading/ unloading  Batch preparation  Transporting  Mixing  Filtration  Packaging

b) Elements, Features and Special Notes:

 Maintenance of gearbox  Replacement of V belt  Replacement of stared  Maintenance of motor c) Sketch/Photo- Summary of activities

(figure 17 Centrifugal Hydro)

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(figure 18 Inventory)

(figure 19 Transporting)

(figure 20 Loading/Unloading)

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(ii) Environment: (a) General Impression/Interaction:

 Noisy Environment  Dusty Environment (b) Elements, Features and Special Notes:  Warm environment and increasing humidity while leakage.

(c) Floor Plan:

(figure 21 Floor Plan)

(iii) Interaction: (a) General Impression/Interaction:

 Worker to worker  Worker to Supervisor  Supervisor to Manager  Manager to Owner  We to worker and supervisor (b) Elements, Features and Special Notes:  Owner to supervisor and worker while dispute.

(c) Scene of Interaction: 36 | P a g e

(iv) Objects: (a) General Impression/Interaction:

 Centrifugal Hydro  Boiler  Mixing Tank  Weighing machine  Stitching machine  Stared and vessel (b) Elements, Features and Special Notes:

(c) Inventory of key objects:  Storage of Raw materials: I. Sodium sulphate II. Ammonium sulphate III. Sodium chloride IV. Sulphuric acid  Finished Product: I. Sodium Bi sulphate II. Citro W III. Gobar salt  Spare Machinery: I. Electric motor II. V belts

(v) Users: a) General Impression:  Manager  Engineer  Supervisor

 Quality control Department 37 | P a g e

b) Elements, Features and Special Notes:

 Marketing department  Stockholders  Purchase department c) Scene of users in context:

 Textile industry  Food industry  Chemical industry

(figure 22 AEIOU summary Canvas)

(2) Empathy Mapping Canvas:

(i) User:  Workers  Supervisor

(ii) Stockholders: 38 | P a g e

 Manufacturing industry  Traders

(iii) Activates:  Travelling  Visit in industry  Observation  Interaction  Identification of problem  Listing the problem

(iv) Story Boarding:  Happy: After completing this project, it requires less manpower, in cost of packaging. So, it will helpful in maximizing the company’s profit. After completing this project, it will helpful to workers for operations, having less effort, quick operation and comparatively safer operation.  Sad: It will reduce the requirement of workers. So it will not helpful in reduction of unemployment. If any fault occurs in machine, operation will delay until maintenance will complete.

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(figure 23 Empathy mapping sheet)

(3) Ideation Sheet: (i) People:  Workers  Supervisor  Engineers  Managers  Owner / Stockholders

(ii) Activities:  Getting permission for visiting industry  Visiting in industry  Observation  Interaction  Knowing working in industry  Listing out problems+ 40 | P a g e

 Listing the machines in industry  Try to identify the problem facing  Interaction with faculties

(iii) Situation/Context/Location:  Hazardous environment  Small scale industry  Medium scale industry  Large scale industry  No foundation is required  Traders  Packaging of gains

(iv) Props / Possible Solution:  Manual packaging  Using weighing machine, stitching machine and conveyor belt assembly  Batch wise production

(figure 24 Ideation Canvas sheet)

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(4) Product Development Canvas: (i) Purpose:  Use for hazardous material handling  Safer operation  Reduction in time of operation  Less manpower required  Reduction of wastage of materials  Accuracy

(ii) People:  Worker  Supervisor  Engineer  Stockholders

(iii) Product Experience:  Low cost  Safety  Automatic operation  Quality Packaging

(iv) Product Functions:  Weighing  Stitching  Packaging

(v) Product features:  Quick operation  Quality packaging  Easy material handling  Use for hazardous materials  Easy packaging

(vi) Components:  Storage tank  Controller  Load cell  Spur gears 42 | P a g e

 Gearbox  Grippers  Stitching machine  Sliders  Out body of machine

(vii) Customer Revalidation:  Maintenance  Eco friendly  Life span  Repeatability  Size  Less space

(viii) Reject, Redesign, Retain:

(figure 25 Product development sheet)

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(5) Business Model Canvas Sheet

(figure 26 Business model canvas sheet)

(6) Business Model Canvas Report: BUSINESS MODEL CANVAS (BMC): Business model canvas is used to validate the market significance of products and services which will be of technology nature in this case. Technology projects are often solutions or processes that solve a technical problem. However the market implementation of such solutions also require that the problem solution is designed to overcome not just the technical barriers but also market and business related barriers of costs, customer reach and collaborations and those that pertain to the practical nature of limited initial capacities within the team. Thus business model canvas can be used to visualize such market problems and customer expectations. This exercise will increase the market potential and technology goods and services. This will make them more effective in market. This exercise will bring discussions on viability and cost effectiveness. It will enable students to have a clear understanding on the steps required to ensure that whatever solution they develop as their project should have a user who can afford it with desired needs.

1. KEY PARTNERS : A business partnership is when two commercial entities form an alliance, which may either be a really loose relationship where both entities retain their independence and are at liberty 44 | P a g e

to form more partnerships or an exclusive contract which limits the two companies to only that one relationship. Our key partners are as follows: a) Production department b) Design expert c) Fabrication expert d) Suppliers e) Consumers f) Workers 2. KEY ACTIVITIES : As the title suggests, these are the most important tasks which must carry out in order to fulfil its business purpose. Key activities are different according to the business model of the organization carrying out the activity. The key activities which are used in our canvas are given below: a) Visited Small scale industry b) Observing Packaging operation c) Calculating packaging cost 3. KEY RESOURCES : Key resources are the main inputs that company uses to create its value proposition, service its customer segment and deliver the product to the customer. Key resources deal with the operational end of the business spectrum and define what kind of materials are needed, what kind of equipment is required and the types of people you need to employ. Key resources which are used are note down below: a) Patents b) Research papers c) Journals d) Reference books 4. VALUE PROPOSITIONS : In simple terms, a value proposition makes a case for why a customer should pick one product over another, citing the unique value the product provides over its contenders. The Business Model Canvas value proposition provides a unique combination of products and services which provide value to the customer by resulting in the solution of a problem the customer is facing or providing value to the customer. Our value propositions are as followed: 45 | P a g e

a) Reliability b) Cost efficiency c) Time saving d) Accuracy 5. CUSTOMER RELATIONSHIPS : This building block dictates the nature of the relationships that an organization will develop with its various customer segments. The customer relationships that an organization opts for are based on the company’s business model and greatly impact the overall customer experience. Following are the customer relationships that are utilized : a) Loyal relationship b) True facts about products c) Co-operative

6. CHANNELS : This building block defines how an organization communicates with and provides value to its chosen customer segment. Channels are the touch points through which an organization liaises with its customers and as such, play a huge role in defining the customer experience. Our channels are given as follows: a) Social media b) Technical fair c) Community blogs d) Advertising 7. CUSTOMER SEGMENTS : Customer Segment block is to present the list of Personas, organized by Customer Segment. If you have more than one segment. It is always recommended to prioritize them. The customer segments includes following factors: a) Chemical Packaging b) Sand Packaging c) Grain Packaging d) Fine powder packaging 8. COST STRUCTURE : Cost Structure business block provides a list of Cost Structure elements with notes on their relationship to Key Activities. Look at what kind of characteristics most cost structures

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display; cost structure have fixed and variable costs and they can have benefits of economies of scale or economies of scope. This block consist of following terms: a) Component cost b) Marketing cost c) Maintenance cost d) Cost of workers e) Working cost 9. REVENUE STREAMS : This building block elaborates the earnings a business gets by subtracting the costs from the revenue generated from each customer segment. Where customers are generally considered the heart of the business, revenues are automatically likened to the arteries. Organizations must evaluate the worth of the value they provide to each customer segment. Revenue streams are given below which are used: a) Cost feasibility b) Ease of availability c) No brokerage fees d) Direct sale of product e) Payment by EMI option

(7) Periodic Progress Report 1 1. What Progress you have made in the Project? Visited In industry, Observing the work and environment, checking the chances of improvement and doing detailed study on them. Then arranging that improvement in ascending order as per them requirement and selecting most appropriate improvement as a project that helps to industry for increasing production rate. 2. What challenge you have faced? Communication gap due to language barrier with workers, Poor initial response, Less practical knowledge, Lack of punctuality, Some processes were unknown to us. 3. What support you need? Reference of experienced guide and Some literature related to the processes. 4. Which literature you have referred ? Journals, research papers, and patents.

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(8) Periodic Progress Report 2 1. What Progress you have made in the Project? Finding patterns and research papers related to project title. Finding components and concepts help to solving the problem and understanding them. 2. What challenge you have faced? Patterns are not easily available related to project title. 3. What support you need? Expert notes and literatures related to materials and mechanism is required. 4. Which literature you have referred? Reference books, research papers

(9) Periodic Progress Report 3 1. What Progress you have made in the Project? Get permission from industry as well as collage for performing project in industry. Prepare canvas sheets (AEIOU, Empathy, Ideation, Product Development) 2. What challenge you have faced? It was time consuming process to get the permission. 3. What support you need? Need quick support from industry and collage. 4. Which literature you have referred? Refer formats given in PMMS for preparing canvas sheets .

(10) Periodic Progress Report 4 1. What Progress you have made in the Project? Preparing Pattern Search Analysis Report. Collect data from industry which is helpful for the performance of project work. Initialize project work. 2. What challenge you have faced? Face difficulty to submit online PSAR. Difficulty facing to understand questions while completing PSAR. 3. What support you need? Better website support for completing online submission. Proper guidelines required for better understanding questions. 4. Which literature you have referred? 48 | P a g e

Refer company’s previous records of production for the collection of data.

(11) Periodic Progress Report 5 1. What Progress you have made in the Project ? We learn about Stitching machine mechanisms and types. We also select proper type of stitching machine for our project work. 2. What challenge you have faced ? We do not have proper knowledge about some component of stitching machine. 3. What support you need ? We do not find proper literature related to stitching machine. So, we need proper guidance related to stitching machine. 4. Which literature you have referred ? Internet.

(12) Periodic Progress Report 6 1. What Progress you have made in the Project ? We learn about conveyor mechanism. We are completing Patent Drafting Exercise. 2. What challenge you have faced ? We do not get proper design procedure of conveyer belt. 3. What support you need ? We do not find proper literature related to conveyer belt. So, we need proper guidance related to conveyer belt design. 4. Which literature you have referred ? Machine design by V.B. Bhandari

(13) Periodic Progress Report 7 1. What Progress you have made in the Project ? We learn about grabber mechanism. We are completing Business Model Canvas. 2. What challenge you have faced ? We confused while selecting the grabber mechanism mountings and operation. 3. What support you need ? We want more convenient mechanisms for operating grabbers. 4. Which literature you have referred ? 49 | P a g e

Patents

(14) Periodic Progress Report 8 1. What Progress you have made in the Project ? We are designing and programming the circuit for automatic operation of packaging and completing project report. 2. What challenge you have faced ? We getting errors while programming. 3. What support you need ? We are getting help from electrical department. 4. Which literature you have referred ? books.

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(15) Patent Drafting Exercise Form 1

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(16) Patent Drafting Exercise Form 2

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(17) Patent Drafting Exercise Form 3

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12. REFERENCES :  Design of machine elements by V.B. Bhandari  Theory of machines by S.S. Rattan  For rack and pinion design:

http://nptel.ac.in/courses/116102012/48

 BS ISO 6336-3:2006 Incorporating corrigendum June 2008  Automation of VFFS Machine High Performance and Modular VFFS Solutions for OEM by ROCKWELL AUTOMATION

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