SOP Title: Operation and Cleaning of Dust Extractor
- Objective:
To define procedure for Operation, Cleaning and Preventive Maintenance of Dust Extractor.
- Scope:
This SOP is applicable to Dust Extractor, used for extraction of dust generated during de-dusting and compression activity, in compression section.
- Responsibility:
- Production Department: To prepare and review the SOP. To follow the procedures laid down for the operation cleaning and preventive maintenance of Dust Extractor.
- Engineering Department: To perform the preventive maintenance of Dust Extractor.
- Quality Assurance Department: To provide line clearance prior to operation. To approve the Preventive Maintenance reports. To review and approve the SOP and Annexure.
- Accountability:
Head, Production Department, Head, Engineering Department and Head Quality Assurance
- Procedure:
- Definition:
- Production Associate: Executive or Operator of Production department or any personnel trained to perform duties as per this SOP.
- Quality Assurance Associate: Executive of Quality Assurance department or any personnel trained to perform duties as per this SOP.
- Engineering Associate: Executive or operator of engineering department trained to perform duties as per this SOP.
- Type A Cleaning: Dry cleaning with clean lint free cloth/ vacuum cleaner and removing the previous batch powder/material in the following cases,
- Remove the previous batch material.
- During end of the shift.
- Before starting the next batch of the same product.
- Type B Cleaning: Wet cleaning by using water in the following cases
- Removal of traces of the previous product, and is ensured by visually of the cleaned equipment.
- Change in product and same product having change in colour.
- Prior to execution of lower strength batches, after the execution of higher strength batches of the same product.
- After continuous five batches of the same product.
- After seven days of cleaning before use, if equipment is not in use.
- After replacement or repair of any product contact part.
- Monthly, if the cleaned machine is not used for production activity.
- Cleaning Solution: 1 ml of Teepol (soap solution) in 1000 ml of potable water (0.1% v/v)
- Breakdown: Any activity leading to operation of machine other than the set parameters and / or unusual sound or vibration observed in the machine.
- Preventive Maintenance: Maintenance activity performed to ensure that the equipment will function smoothly and to avoid breakdowns. These activities are performed monthly, quarterly and half yearly.
- Procedure
- Definition:
| Precautions | ||
| 5.2.1 | Wear proper personal protective equipment like nose mask and gloves before starting the cleaning operation. | |
| 5.2.2 | Check that, dust extractor suction pipe is properly fitted to the nozzle of the dust extractor. | |
| 5.3 | Operation | |
| 5.3.1 | Before starting the operation, visually check the Dust Extractor is properly cleaned and line clearance is taken from QA. | |
| 5.3.2 | Switch “ON” the MCB then switch “ON” the machine by pressing green colour start button provided on the dust extractor. | |
| 5.3.3 | During operation, shake the filter bag manually after two hours with the help of handle provided. | |
| 5.3.4 | After completion of de-dusting Switch “OFF” by pressing red colour push button. | |
| 5.3.5 | Label the as Dust Extractor “ To be Type A cleaned” or “To be Type B Cleaned”. | |
| 5.3.6 | Record the activity in equipment log book as per Annexure. | |
| 5.4 | Cleaning: | |
| 5.4.1 | Type A Cleaning( Batch to Batch Cleaning) | |
| 5.4.1.1 | Mention on the area status board as “Under Cleaning” prior to initiation of cleaning process. | |
| 5.4.1.2 | Switch `OFF’ the `Main’ switch of the Dust Extractor. | |
| 5.4.1.3 | Clean the external surface of the Dust Extractor with dry clean duster. | |
| 5.4.1.4 | Shake the filter bags with the hand then open the door of filter bag chamber by unscrewing the wing nuts. | |
| 5.4.1.5 | Clean the dust adhered to inside part of chamber with vacuum cleaner. | |
| 5.4.1.6 | Remove dust from dust tray with vacuum cleaner. | |
| 5.4.1.7 | Remove the filter bags and clean it with vacuum cleaner. | |
| 5.4.1.8 | Clean the outer side of filter bag chamber with clean dry duster. | |
| 5.4.1.9 | Fix the filter bags properly after checking its cleanliness and intactness. | |
| 5.4.1.10 | Fix the door of filter bag chamber by tightening the wing nuts. | |
| 5.4.1.11 | Start the dust extractor and check for its proper working and suction at usage point. | |
| Note: Before use, ensure that tray of dust collector is clean. Check that filter bag chamber is clean and filter bags are intact.
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| 5.4.2 | For Type B (Product to Product) Cleaning: | |
| 5.4.2.1 | Mention on the area status board as “Under Cleaning” prior to initiation of cleaning process. | |
| 5.4.2.2 | Clean the external surface of the Dust Extractor with moist duster. | |
| 5.4.2.3 | Remove all labels, documents, products from the machine as well as from the area. | |
| 5.4.2.4 | Affix “To be Type B” Cleaned” status label and switch “OFF” the main electric supply. | |
| 5.4.2.5 | Open the door of filter bag chamber by unscrewing the wing nuts. | |
| 5.4.2.6 | Shake the filter bags with hand. | |
| 5.4.2.7 | Clean the dust adhered to inside part of chamber with nylon brush/vacuum cleaner. | |
| 5.4.2.8 | Remove dust from dust tray with vacuum cleaner. | |
| 5.4.2.9 | Remove the filter bag and transfer in a poly bag and shift to the cleaning area. | |
| 5.4.2.10 | Clean the dust extractor outer surface and chamber initially with moist clean cloth ,then with dry clean cloth. | |
| 5.4.2.11 | Cleaning of filter bags: | |
| 5.4.2.11.1 | Initially remove the dust accumulated on filter bag by using compressed air at pressure 1-2 kg/cm2 from either side. | |
| 5.4.2.11.2 | Wash the filter bag with 15-20 litres of potable. | |
| 5.4.2.11.3 | Dry the cleaned filter bag with compressed air then with humidifier.(mild compressed air should be applied during drying to avoid damage of filter bag) | |
| 5.4.2.11.4 | After drying the filter bag, transfer the cleaned filter bag to the dedicated area of the dust extractor. | |
| 5.4.2.11.5 | Wash the suction pipe with potable water and apply 0.1% cleaning solution Finally wash with potable water to remove the traces of soap solution. | |
| 5.4.2.12 | Record the usage and cleaning activity in equipment log book refer Annexure. | |
| 5.4.2.13 | After successful completion of cleaning process, mention on the area status board as “Type B Cleaned”. | |
| 5.4.2.14 | Cover the dust collector with clean poly bag. | |
| Frequency: Clean the dust extractor
1. During product changeover 2. Whenever major maintenance done to the dust extractor 3. After continuous five batches of the same product. 4. Same product with change in colour. 5.Monthly, if it is not used for production activity. |
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| 5.5 | Breakdown | |
| 5.5.1 | If breakdown occurs during operation, hold the activity. Inform to the Head Production. | |
| 5.5.2 | Fill the “Complaint Note” and submit to Engineering Department. | |
| 5.5.3 | Fill the “Incident Report” and submit to Quality Assurance Department. | |
| 5.5.4 | If the breakdown is major, stop the dedusting /compression activity. Unload the tablet /granules from the compression machine/dedusting machine only, if required for breakdown rectification. | |
| 5.5.5 | Store the tablet/granules unloaded in a closed container with proper status label. | |
| 5.5.6 | After completion of repairs, the operations can be resumed. Perform Type A or Type B cleaning. | |
| 5.5.7 | Collect and file a copy of the “Complaint Note” certifying that the repair works have been successfully completed. | |
| 5.5.8 | Record the repair completion activity in Equipment Log Book. | |
| 5.6 | Preventive Maintenance | |
| 5.6.1 | Perform the preventive maintenance as per Annexure. | |
| 5.6.2 | If preventive maintenance activity is outsourced, the values are to be transcribed in the Annexure and external party certificate to be attached. | |
- Abbreviation :
| Abbreviation | Expansion |
| SOP | Standard Operating Procedure |
| % | Percentage |
| v/v | Volume By Volume |
| kg/cm2 | Kilogram Per Square Centimetre |
| TAB | Tablet |
| BMR | Batch Manufacturing Record |
*Note – Ready to use SOP available in “DOWNLOAD” Section.