Mechanics & Process Variable Involved in Cigarette Production

Tobacco is a product processed from the dried leaves of plants in the genus Nicotiana. It can be used as a pesticide, and extracts form ingredients of some medicines and is commonly consumed as a drug. The product manufactured from the leaf is used in cigars and cigarettes, snuff, pipe tobacco, chewing tobacco and flavored shisha. Few believe the word tobacco may have actually originated from India as tambākū; (तंबाकू)

India has 96,865 registered tobacco farmers and many more who are not registered. In 2010, there were 3,120 tobacco product manufacturing facilities in all of India. Around 0.25% of India’s cultivated land is used for tobacco production. Since 1947, the Indian Government has supported growth in the tobacco industry. India has seven tobacco

research centers, located in Chennai, Andhra Pradesh, Punjab, Bihar, Mysore, West Bengal, and Rajahmundry. The Indian Government and several states have taken multiple measures to reduce Cigarette smoking. Smoking in public places is banned in many states, it is not allowed to be portrayed in movies, and warnings are posted on cigarette packs.

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Fig 1. 1-Tobacco leaf

Fig 1. 2-Caffeine molecular structure

1 Introduction to Tobacco

Tobacco is cultivated annually, and can be harvested in several ways. In the oldest method still used today, the entire plant is harvested at once by cutting off the stalk at the ground with a tobacco knife. It is then speared onto sticks, four to six plants a stick and hung in a curing barn. In modern times, large fields are harvested mechanically, although topping the flower and in some cases the plucking of immature leaves is still done by hand.

Curing and subsequent aging allow for the slow oxidation and degradation of carotenoids in tobacco leaf. This produces certain compounds in the tobacco leaves, and gives a sweet hay, tea, rose oil, or fruity aromatic flavor that contributes to the "smoothness" of the smoke. Tobacco can be cured through several methods, including:

o Air cured tobacco is hung in well-ventilated barns and allowed to dry over a period of four to eight weeks.

o Fire cured tobacco is hung in large barns where fires of hardwoods are kept on continuous or intermittent low smoulder.

o Flue cured tobacco was originally strung onto tobacco sticks, which were hung from tier-poles in curing barns

o Sun-cured tobacco dries uncovered in the sun.

Fig 1. 3-Sun curing

Tobacco is consumed in many forms and through a number of different methods. Below are examples including, but not limited to, such forms and usage.

o Bidi are thin, often flavored cigarettes from India made of tobacco wrapped in a tendu leaf, and secured with colored thread at one end.

o Chewing tobacco is the oldest way of consuming tobacco leaves. It is consumed orally.

o Cigars are tightly rolled bundles of dried and fermented tobacco, which is ignited so its smoke may be drawn into the smoker's mouth.

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o Cigarettes are a product consumed through inhalation of smoke and manufactured from cured and finely cut tobacco leaves and reconstituted tobacco, often combined with other additives, then rolled or stuffed into a paper cylinder.

o Gutka is a preparation of crushed betel nut, tobacco, and sweet or savory flavorings.

o Hookah is a single or multi-stemmed (often glass-based) water pipe for smoking. Originally from India, the hookah has gained immense popularity, especially in the Middle East.

o Topical tobacco paste is sometimes recommended as a treatment for wasp, hornet, fire ant, scorpion, and bee stings. An amount equivalent to the contents of a cigarette is mashed in a cup with about a 0.5 to 1 teaspoon of water to make a paste that is then applied to the affected area.

o Tobacco water is a traditional organic insecticide used in domestic gardening. Tobacco dust can be used similarly. It is produced by boiling strong tobacco in water, or by steeping the tobacco in water for a longer period. When cooled, the mixture can be applied as a spray, or 'painted' on to the leaves of garden plants, where it kills insects. Tobacco is however banned from use as pesticide in certified organic production.

India ranks 4th in the total Tobacco consumption in the world. But India's cigarette consumption ranks 11th in the world. Out of the total production, only 19% of the total consumption of Tobacco is in the form of cigarette whereas 81% is in other forms like, chewing, bidi, snuff, Gutka paste, Jarda, hookah paste etc. The per capita consumption of

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cigarette in India is one of the lowest in the world in comparison to major Tobacco consuming countries like Zimbabwe, UK, Brazil, U.S.A and Pakistan. The annual level for demand of cigarette in India remains the same at 96 billion sticks as it was 15 years ago, despite the cumulative growth in population by nearly 35 percent during the same period. However the consumption of Tobacco has been a matter of national debate in view of the emerging anti-Tobacco drive in the country.

Tobacco is a traditional item of India's foreign trade. India is one of the leading Tobacco exporting countries in the world. India accounts for 5.8% of the international trade and ranks 5th after Brazil, U.S.A, Turkey and Zimbabwe. The principal markets for Indian tobacco are U.S.S.R, U.K, Japan and the Middle East countries.

Fig1.5 Areas under Cultivation & Production

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2 Overview of Cigarette

Even though tobacco has been known in the Americas for over three thousand years and was taken to Europe by the first explorers in 1492, it was initially consumed in pipes and in a primitive form of cigar, as well as being sniffed as snuff. Cigarettes, as we know them today, began being industrially produced in mid-19th century.

Even though they may look the same, cigarettes have differences in accordance with the preferences of the consumers. Cigarettes are a product that is manufactured using these basic ingredients: paper, filter, blend of tobaccos and flavoring agents that gives them their distinct sensory characteristics.

The main component of cigarettes is tobacco, a plant of the family solanaceae and it naturally contains nicotine as one of its components.

The ingredients are substances added to tobacco during cigarette manufacturing and they have different functions. As shown on cigarette packs, the basic ingredients used are a blend of tobaccos, sugars, cigarette paper, vegetable extracts and flavoring agents.

o Flavoring agents – Improve the characteristics of the cigarette smoke’s aroma, promoting a particular identity for that brand. For example: menthol

o Sugars – Homogenize the levels of sugars of the different types of tobacco used in cigarette production. Examples: sucrose, popularly known as sugar.

o Ameliorants – Improve the quality of the cigarette smoke’s aroma. Ex.: extract of licorice, from the licorice plant (Glycyrrhiza spp).

o Agglutinants – Keep the tobacco particles agglutinated to each other. They are used in the production of reconstituted tobacco. Example: starch, found in maize, rice and cereals in general.

o Moisturizers – Minimize the exchange of moisture between the product and the environment, besides facilitating processing the tobacco. Example: glycerin, found in tobacco, beer, wines and chocolate.

Ingredients must not be confused with the substances known as components. Components of smoke are generated during the combustion of cigarettes upon burning. Tar, nicotine and carbon monoxide are examples of some components of cigarette smoke.

Before being used, tobacco needs to be cured. The curing stage consists basically of drying the tobacco leaves. In the curing process, besides losing water and changing color, the leaves go through a series of biochemical transformations that define the specific flavor of each type of tobacco. Virginia tobacco is flue-cured in brick barns using firewood from forests planted for fuel as the source of heat. After curing, this tobacco

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turns orange. Burley tobacco is air-cured in ventilated barns that allow air to circulate naturally, removing moisture from the leaves. This tobacco turns brown. After curing, the tobacco is stored in storehouses where it awaits sale. The curing associated with different varieties produces the characteristics of aroma and flavor typical of each type of tobacco.

The combination of different types of tobacco in different proportions, associated with ingredients, is the tobacco blend that produces the flavor and aroma characteristic of each brand. Cigarettes vary as a function of the tobacco used and their design (length, circumference, type of filter, ventilation, etc.).

Cigarettes account for 85 %of the country's total tobacco exports. The per capita consumption of cigarettes in India is a tenth of the world average. India is exporting tobacco today to 80 nations which is over all the continents in the world. At present the Indian Tobacco Industry is providing livelihood to more than 25 million people in the country. In the unmanufactured tobacco exports, Flue Cured Virginia tobacco accounts nearly 75 % to 80 % export. The other varieties are- Burley, HDBRG, Natu, DWFC, Top leaf and Jutty are also exported which are used in making cigarettes. Non cigarette tobacco exported worldwide is Lalchopadia, Judi, and Rustica are used for chewing and making bidis. Around 8 % to 10 % non- cigarette tobacco is exported in throughout the world. According to the international trends, non-cigarette tobaccos are the dominating item in the national export. According to the current situation in the international tobacco market India is proved to emerge out as the favorable market for the Indian tobacco export. The prices of Brazilian export have almost equalized the most expensive American tobacco cost. Zimbabwean farm prices have also seen an upward trend. There are several advantages which can be put forth for favoring the Indian tobacco. Like low unit production cost, average export prices of tobacco in India, which are found more competitive than that of the prices of Brazil, USA, Zimbabwe.

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Fig2. 1-Dried tobacco

VST Industries Ltd. is a public conglomerate company headquartered in Hyderabad, India. The company manufactures and distributes cigarettes. Its Market Capitalization is 844.49, PE Value: 15.70 and Dividend: 5.49.The company has its registered office in Hyderabad. It started off as the formerly Vazir Sultan Tobacco Company, commonly known as VST and shares collaboration with British American Tobacco group of the United Kingdom. It is fully independent and registered as VST Industries Ltd in the year 1983.

Vazir Sultan Tobacco was started by Mr. Late Vazir Sultan in (1916 -1923). During the rule of Mir Osman Ali Khan in Hyderabad State the Vazir Sultan Tobacco Company Limited was incorporated on 10 November 1930, under the Hyderabad Companies Act No.IV of 1320 Fasli and now governed under the Indian Companies Act 1956. The name of the Company was subsequently changed to VST Industries Limited on 30 April 1983. The VST has its registered office at Azamabad, Hyderabad, India

Vazir Sultan Tobacco Company is more commonly known as VST. The company manufactures and distributes cigarettes under the brands names of Charms, Charminar, Gold, Dark Knight, Knights, and Kingston Etc. The company is headquartered in Hyderabad, India. It is 3rd largest cigarette manufacturing company in India. The company declared a dividend of 450% in 2011 making it one of the highest dividend yielding stocks in the Bombay Stock Exchange.

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Primary Manufacturing

Department

Fig3. 1-VST logo

3 Review of Industry

4 Production Tree Diagram

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Retailers

5.1 Cigarette Manufacturing Units

Manufacturer Hauni-Decoufle Manufacturer Hauni-Decoufle

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5 Secondary Manufacturing Department Details

Model 3D-85

Origin French-Germany

Year 2008

Alternate name LOGA-4

Cigarette production / min

8000/9000

Model DX-85

Origin French-Germany

Year 2010

Alternate name LOGA-5


8000/9000

Manufacturer Molins

Model 6180

Origin Germany

Year 2009

Alternate name MAX 2


4000/5000

Manufacturer Molmax

Model 6013

Origin Germany

Year 2004

Alternate name MAX 1


4500/5000

Manufacturer G.D

Model 121A

Origin Italy

Year 2007

Alternate name 121


9500/12000

5.2 Cigarette Packaging Units

Manufacturer G.DOrigin ItalyModel X-2

Manufacturer G.DOrigin ItalyModel X-2

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Year 2001Alternate Name GD-1Packs produced / min 320

Year 2002Alternate Name GD-3Packs produced / min 320

Manufacturer G.DOrigin ItalyModel X-2Year 2001Alternate Name GD-2Packs produced / min 300




Manufacturer G.DOrigin ItalyModel C800Year 2012Alternate Name GD-6Packs produced / min 600




6.1HOPPER

A cigarette starts its life cycle from Primary Manufacturing Department, where the tobacco is cured and dried. The raw tobacco consists of

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6 Components of the unit

1. Stem2. Leaf

Which has to be first separated before packing into a cigarette. This is achieved in Suction unit of Cigarette manufacturing unit. The raw material is bought in to auto feed of the unit. This is achieved by automatic suction pump which is centralized. The valve is triggered by an electronic sensor which measures the level of tobacco in the hopper and fills the brink up. The tobacco then falls on the lower chamber of the tower which is then picked up by the spiked drum. It then places in to a slow moving belt which conveyers it to jimmy door.

6.2 THE JIMMY DOOR:

It is a pocketed door which houses the section of collection of stem, which is filtered out and leaf proceeded forward for production. It contains a suction in the upper nylon belt also called as fast carrier belt. This is specially made conveyor belt of 10 mm thickness which is perforated for suction and it usually interchangeable. A suction pressure of 9.2 KPa is created by the squirrel cage electric motor affixed in the rear vicinity of the unit. This pressure is so set up that it lifts up only leaf component of tobacco leaving behind the stem part. Nylon belt under suction pushes it to the pocket disks.

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Fig 6. 1-Hopper

Fig 6. 2-Spiker drum

The section has houses 1 main pulley operated by pulley mounted on door and 8-10 idler pulleys for providing a proper tension.

6.3 POCKET AND TRIMMING DISK:

After separation the nylon belt carries the tobacco to the pocket disk. This disks have a small 4 pocket and so the name. The pocket is half on one and rest on other, which in motion forms pocket. It is customary for a smoker to have his cigarette of slightly higher filled at the front edge, which counteracts the frustration of early cigarette ash descend.

To encounter that the plain cutter disk followed by pocket disk is employed. The former

one separates any come over stem while the later one accumulates a bit higher tobacco to be formed the tip of cigarette. This pocket hold the tobacco till the rod goes from front to end. Pocket disk rotates at 2650 rpm while trimming at 1050.

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Fig 6. 3-Jimmy door

Fig 6. 5-Nylon belt chamber

Fig 6. 8-Disks assembly

6.4 ROD BOBBIN ASSEMBLY

The bobbin provides the thin paper of the cigarette. This special paper is made under stick supervision has most of the time are imported details of supplier has kept confidential. The bobbin assembly has two free spindle. This dual bobbin arrangement provides uninterrupted supply of cigarette paper. At the end of spindle at an appropriate diameter a fill sensor, which senses as soon as one spindle begins to runs out of bobbin.

An extension of the fresh bobbin is attached to the knife mechanism. The end of the new bobbin paper is stuck on the knife with a tape. As soon as the sensor sends the run out signal. This knife strikes the existing paper such that the new bobbin paper is attached to the flowing paper inflow. The exhausted bobbin is replaced and an extended end of the replaced paper is stuck on to the knife ready for next replacement. During this change over of cigarette paper machine speed (8000 cpm) is automatically brought down to half (4000 cpm). Also an alarm goes on during this change over to alert the operator to change the bobbin.The spindle is free to rotate so to control the speed, auto breaks on the spindle drums is employed. These get activated in response to level over which the paper runs. When the paper starts running at higher speed it pushes down the bell crank level, the other side to which is the brake pad which is pressed on the external spindle drum. Thereby reducing the speed, as soon as the speed reduced the force of bell crank reduces and breaks are released. This breaking and releasing actions engages so frequently such that it ends up providing the same speed of paper to machine on which the unit is set to. The unit is spun

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Fig 6. 6-Trimmin disk

Fig 6. 7-Pocket Disk

Fig 6. 9-Rod bobbin

Fig 6. 10-Bobbin motor

by the motor at the rear of the spindle mounting plate while the bobbin change over. The bobbins are keyed to the spindle by a push and lock mechanism which is computer controlled. In the event of removal the locks are pushed in by the computer and on the pressing of the button on near the knife area releases those locks outwards thus holding the bobbin to spindle. Bobbin is supplied in bulk from Asian countries. They are 6km long with 26.5mm width. Each weighing 3.975 Kgs.

6.5 SHOE AND GLUE SECTION

Tobacco after separation is put on to the flat running cigarette paper by the shoe. The paper undergoes though a die with progressively closes to form a circular envelope

encapsulating the tobacco to form a cigarette. It has in line glue section, an air blower section and a heater section. Fast moving tobacco falls on the dynamic paper rod. Tape is being moved at 100 rpm pulley. At the start of the pathway its flat, which gradually is closed up by the progressive continuous long narrow die. Before the total closer the upper lip of the paper gets glue

resin from the glue pump. Glue is pumped at pressure of 800mBar.This lip forms the overlap. To make it dry a heater is incorporated between which heats the rod to 180 C.

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Fig 6. 11-Glue section

Fig 6. 12-Heater section

Fig 6. 13-Overlap knob

This temperature is required because it has to transfer heat to very fast moving rod. Generally a 2mm overlap is kept.This assembly envelops and sticks the cigarette rod.For setting up the overlap width an adjusting nob is put into use. This is done to reduce or increase the perimeter of the cigarette rod. In case of any defect or failure due to many reasons the machine is stopped where breakage of rod is indispensable. The rod assembly area is always cleaned so that it moves without tiny hindrances. A small air through a nozzle is always directed towards the shoe in order that any steam is not entered into the rod, the diameter and pressure being very small. To stop the break rod from going into the cutting chamber an director is place in between, which in event of stoppage moves up causing the rod to divert to bin, the tobacco of which is again recycled for reuse.

The total rod assembly is 2m in length. It is kept uncovered for easy inspection.

6.6 CUT-OFF UNIT

This is where the continuous rod is sliced. The rod is set to cut the rod into 106 mm division each the tolerance being kept +0.06 to -0.06 mm.

There are two methods by which the rod is cut.

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Fig 6. 14-No go Fig 6. 15-Go

Fig 6. 16-Rod Conveyor

a) Ledgerb) Inclined Drum

The first being the undated method inclined drum is being explained. The drum is powered by the separate motor. On the outer casing of drum, two wafer knifes are placed which slices the rod. The runway are grooved for the cutting so that there is no hindrance in the motion of rods. The drum is placed inclined to a set angle so that the wafer knifes lie on same line of drum but cut at distance of 106mm of the rod. This angle is achieved with a huge trial and error method.

It has humidity and density sensors attached to it, any discrepancy found with respect to same will have the machine stopped at the very instance. The density depends on the type of brand. It is usually around 257 g/cc.

6.7 SPIDER

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Fig 6. 17-Ledger

Fig 6. 18-Inclined cylinder

Fig 6. 19-Sensors

Not present in the old model the spider drum is to lift the sliced rod and place in onto the drum. Because the individual rods has to be picked up. It has 8 elliptical shaped arms with suction on the pickers for lifting the rods. The arrangement is such that the arm at the same orientation at the particular position. Suction is such that it exists only at the left three positions. The arm picks the individual rods up and drops at the inlet drum. The length of the pickers is 83mm each. This peculiar mechanism is achieved by cams. The

boots are always pointed downwards.

6.8 CIG LENGTH CUTTING DRUM

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Fig 6. 20-SpiderFig 6. 21-Boot

Fig 6. 22-Round Cutter

Fig 6. 23-Cig length cutting drum

This is where the 106 mm rod is cut into 53 and 53 mm lengths. The round cutter is employed for this cutting. The abrasive disk in kept in contact with the lower knife which frequently sharpens the cutter. The adjustment of the contact force on cutter is done by the hex nut. The grinding wheel and cutter both are replaced when worn out of service. The cutter wheel is of 95 mm diameter and is made up of stainless steel. And the grinding wheel is of 4 inch in diameter and 2mm in thickness.

6.9 SEPERATING DRUM

This is the heaviest drum of all due to its mechanism. It has two halves which take the cut rods and separate them by 22 mm for the placement of filter. This is done by the two attached cylinders on the drums which gets separated at the end of half a revolutions. It has the big counter drum to support the dynamic movement of drums.

A 66mm filter rod of diameter 8mm is separated in three equal division by two round knifes in the Filter stagnation chamber. The divided filters are then passed on to the grading drum. This grading drum passes the filters to the Filter Alignment Drum.

6.10 FILTER ALIGNMENT DRUM

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Fig 6. 24-Separating drum

Fig 6. 25-Filter Alignment drum

Its purpose is to separate the three filters by a distance. It’s of diameter 14.5 cm. Rotates anticlockwise. This drum runs only when the rod is inserted. The filter are placed into three sections namely inner, central and outer groves. These groves are not in line

6.11 PLUG ALLIGNMENT DRUM

It aligns the three plugs into a line for fixing between the two rods. It too has three sections. The non-aligned groves of the filter alignment drum places the three plugs into three sections of plug alignment drums. The central one remains in central position. While the end one are sucked to the center by the central suction hole on the groves. By this all the plugs lie in the same circumferential lines ready to be joined with the rods. The central groves are open in the end while the inner and outer are closed at the ends to provide efficient suction. Each is of 11mm length to support the plugs. Plugs are received at 45 degree while they leave at 270 degree angle to plug guiding drum. It is of 15 cm

diameter.

6.12 PLUG GUIDING DRUM & CIG-PLUG ALIGNMENT DRUM

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Fig 6. 26-Plug alignment drum

It receives the two separated rods from the Separating drum and the plug from the Plug Guiding Drum on it. It also has the guide plates for the plug from the guiding drum on to the alignment drum. It has 20 rows on to which 15 are given the suction. This drum is simply supported on to the two ends. It has the diameter of 19.5 cm and width of 18.5 cm.

6.13 SWASH DRUM

It addition to regular drum it has the swash plate attached to both the ends. Swash plate has a concentric plate that is held to the base/core plate by tension springs. When in motion, swash plate expands due to centrifugal force. The main objective of the swash plate is to squeeze the incoming cig+plug+cig elements to properly so as to avoid any gaps in the assembly.

6.14 PENCIL PASTE ASSEMBLY

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Fig 6. 27- Swash drum

Fig 6. 28-PPA

This unit has the PCT bobbin, Glue section and the tapered drum. The glue is applied only to the ends of the PCT passed on to the rolling drum. PCT is of width 42 mm. For which a 10 mm overlap is on the rod while the rest is on the plug. The PCT has two spindles for continuity of the process while run outs. The Pickering drum controls the speed of PCT paper. The friction drums pulls the paper from the spindle The PCT glue section has a glue holder which puts the exact amount of glue into the glue chamber which is controlled by a level sensor. The flat section of 35mm at center and taper at ends such that it sticks to the center portion.

6.15 ROLLING DRUM

This is where the elements and PCT paper meets. It has 10 pins on each row. These pins are provided so as to take up PCT paper, which is then rolled up onto the cigarette at rolling plate affixed at bottom. The rolling plate area has no suction which helps in rolling of PCT around the elements. Ribs are provided to help achieve the proper roll. The suction is directed by the sleeves. These sleeves doesn’t rotate the drum is placed on them by steel ball bearing.

6.16 FINAL CUTTING DRUM

The final cut of Cig (52mm) +Plug (22mm) +Cig (52mm) into half is done here. A round cutter with the grinding wheel is attached at the bottom of the cylinder to achieve the cut.

6.17 TURNING DRUM

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Fig 6. 29-Rolling drum

Fig 6. 30-Turning drum

The final cut divided the two final cigarettes. But these are head to head which to be packed have to be in the same orientation. This is done in this drum by turning the inner row cigarettes to the same as the outer.

6.18 INSPECTION DRUM

It inspects each cigarette for through sensors. If loose ends or filter missing or less dense cigarette are found, the sensor sends the signal to the sensor at rejection drum. It notes the position of the defective cigarette and rejects by blowing air. The direction of air is so adjusted it faintly disturbs the rest of the cigarette in the drums.

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Fig 6. 31-Inspection drum

The quality control of the production and packagin is very strict and falls to stern norms.

Quality check can be :

I. Brandi. PCT

ii. Filtera.220 PDb. 300 PD

II. PCT waveringIII. Rough CuttingIV. Slant CuttingV. Seam

VI. Body marksVII. Black rings

VIII. Long and ShortIX. PCT Flaging

i. Improperii. Anchorage

X. Die smugXI. Loose Ends

XII. Length ChecksXIII. Weight Checks

A cigarette R&D machine which basically measure almost all the above check, however sometimes the naked eye inspection is also done on regular basis.

Company code is printed on each packet which is 4-5 digit number, which helps in identfing the mistake done by the operator

X YYY ZZZZZZ

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Fig 6. 32-LOGA unit

7 Quality Control

X= Shift

Y=Machine number

Z=Date

8. Troubleshooting of unit

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PCT Wandering Bobbin cross positionImproper glue adhesionDefective BobbinIdler gum roller gets corroded

Remedies Clean Idler glue roller

Adjust T guide

Rough Cutting Blunt Knife

Corroded grinding wheel

Reduced diameter of knife

Glue on knife

Remedies Change Knife

Slant Cutting Ledger angle improper

Remedies Change ledger settings

Seam Thick/Thin

Seam less or more than 2mm

Improper holder knob setting

Remedies Adjust till achieved

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Black Rings Improper filter rod conjuction

Remedies Check the plug allignment drumadjust swash plate

Black Rings Improper filter rod conjuction

Remedies Check the plug allignment drumadjust swash plate

Long and Short Plug guide improper

Swash plant inaccuracy

Cig plug allignment drum ineffective

Ledger misallignment

Remedies Adjust T guide

Redo ledger settings

As it was stated earlier that LOGA 4 and LOGA 5 were the production units in VST. Both of the machines belonged to same manufacturer i.e. Hauni, however LOGA 5 was purchased 2 years later than LOGA 4. Due recently the production of LOGA 5 has been dropped down due to frequent machine repairs. Also machine had to run at 80% maximum speed to decrease the frequency of problem.

The following is the Downtime analysis taken on the LOGA 5 during a 3 day survey

Average trays produced per hour = 68

Total cigarettes produced in that hour = 68 * 4200

= 0.285 M

Ideal Expected cigarette production = 0.45 M

Generation efficiency = 63.47%

Net time wastage = 14 min

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Rod inspecti

on

Rolling d

rum cle

an

Knives C

hanged

Cg bobbin ch

ange

PCT bobbin ch

ange

Paper

break @

garnatu

re

Tray j

am

Filter

rod jam

Brand ch

ange

Tipping p

aper

break

PCT pap

er inacc

uracy

Jam in

suction ro

d cnv

0

5

10

15

20

25

15-Jun18-Jun19-Jun

Chart 8. 1-Problem Occurrence of LOGA 5

9 Comparison of LOGA 4 & LOGA 5 units

Percentage time wastage = 17 to 20 %

A through servicing was carried out on the unit which is didn’t solve the problem. It was found that replacement of Roller Drum has yielded the positive result.

Conclusion on the result was reached by carrying out step by step inspection

Sensors were tested for possible malfunction, by the sensor board. It was found out that the display output was faulty. This didn’t solve the manufacturing problem though.

The rod conveyor belt was changed along with the nylon belt to ensure if the rod has any conflicting hindrances between the run. The belts seems to work fine though.

The suction pressure in the hopper was changed but it was found to be of negative impact on the unit

Brands with no requirement of garniture was inserted, so the garniture assembly was put off.

All the drums were rigorously cleaned The manual control stopped working, which was replaced Rolling drum pins were found to be missing which indicted possible rough

contact with the guiding plate, the plate was adjusted and the rolling drum was replaced completely

Long run achieved (mins):

I. 55 II. 45

III. 52IV. 53.5

Average long run =51 minutes which was considerable increases before the troubleshoot

Machine was now run at 7800 cpm

To compare the efficiency down time analysis comparison of a perfectly working LOGA 4 was done as follows.

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Rod in-spection

Rolling drum jam

Knives Changed

Cg bobbin change

PCT bobbin change

Tray jam Filter rod jam

Jam in suction rod cnv

nylon belt

change

0

1

2

3

4

5

6

7

8

9

Week 1Week 2

Chart 8. 2-Problem Occurrence of LOGA 4

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10. CONCLUSION

Hence a brief introduction on the components of the cigarette production unit was studied and analyzed. With the brief information an attempt to solve a problem statement “Increasing productivity of LOGA 5” was undertaken. The steps taken were proved to be effective in their course of action. Further deep study into the machinery would aim to remove all the existing problems. During the course of internship, basic knowledge of management skills were learned. Also the importance of finely structured work and work distribution was felt.

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11. References

[1] “Facts and Figure” Hauni, The Körber Foundation

[2] “Economic History Of Tobacco Production In India” Professor S K Goyal, Institute for Studies in Industrial Development, New Delhi, June 2004

[3] Annual Survey of Industries, 1997–98, Central Statistical Organization, New Delhi.

[4] Tobacco Board, Ministry of Commerce, Government of India. The Tobacco Atlas (3rd Edition). “Global cigarette consumption.” p. 33. www.cancer.org/downloads/AA/TobaccoAtlas3Revised/TA3_Chapter_7.pdf.

[5] TOBACCO Production Guide”, Kentucky & Tennessee, 2011-2012

[6] Description of the tobacco market, manufacturing of cigarettes and the market of related non-tobacco products” European commission, SWD(2012) 453 final

[7] Additives, Cigarette Design AND Tobacco Product Regulation, Kobe, Japan ,28 June-2 July 2006

[8] Tobacco Products Processing Detailed Study” U.S. Environmental Protection Agency Engineering and Analysis Division, Washington, D.C, November 2006

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http://www.cancer.org/downloads/AA/TobaccoAtlas3Revised/TA3_Chapter_7.pdf