+Acknowledgement

Firstly I would like to thank my supervisor MrGoitomG/mariam, who helps me any problems
that difficult for me during internship work. And also I would like to thank workers of APF who
opened desiccation for any difficult problem. I wish thanks to Advisors Nigsty, who help me,
mechanisms of preparing this project paper, my grateful thanks also go to for all Teachers those
are the chemical engineering staff and also my class mate students who helps by idea during the
preparation of project paper.

VOL1
EXSITIVE SUMMERY
It is clear fact that the knowledge Engineering cannot be up graded without practical experience
in each field of subject matter. This paper is written for practical fulfillment of internship
program which was planned to help apparent students to understand practical knowledge of
engineering projects. This includes design process, implementation, evaluation and management
in general.

The paper includes the background of the host company including its history, major production,
the overall function, process product and flow in to nine chapterdiagramam of the process and
etc.The content of the paper have been divided and topics covered including the introduction,
pharmaceutical production, discussion and experience gained and recommendation and
conclusion.Generally, from this internship I have developed how the machines can do in every
process of Addis pharmaceutical factory.

NOMENCRATURE:-

APF= ADDIS PHARMACEUTICAL FACTORY

DO=OUTER TUBE DIAMETER

VOL2
DI=INNER TUBE DIAMETER

K=CONDACTIVITY

HI=FINAL ENTALPY

HO=INITIAL ENTALPY

L=LENGTH

RFI=INITIAL FOULING FACTOR

RFO=FINAL FOULING FACTOR

PART I
GENERAL HISTORY OF MY HOSTING CAMPANY
1.1 Introduction

APF is the largest manufacturing company at Adigrat town.

VOL3
It has its own misson,visionandobjective of its organization to produce
qalitativeandqantitative products.

It has also somanymachineries,rawmaterialsandinputs to produce different types

of drugs.

1.2 Back ground

Addis pharmaceutical factory (APF) was established in 1992 to manufacture medicines.
Despite a gloomy picture of poverty and poor health services in the country.

APF plc is the largest pharmaceutical manufacturing company. Head quartered at Adigrat
town tigray regional state of Ethiopia. This is found 898km away from Addis Ababa in the
direction of north Ethiopia. This town is 2300meters above sea level. There is appositive sign or
good prospect from government side to the sector to improve the health situation including
pharmaceutical industry such as government builds health services and health educational
institutions and encourages private investors to involve in the sector by providing different
incentives. The general significant growth rate at present. There are eleven (11) pharmaceutical
factories and have their market share about 30% share of local market is taken by Addis
pharmaceutical factory (APF). Currently APF has been operating at about 50% production
capacity and its capacity growth is since 2009. The plant was constructed and equipped with
high technical production facilities.

Number of Workers and Departments

The company has a total of 799 works from those permanent workers are 549 and
temporary workers are 250 and the classification of the workers are like this.
Grade 6th- 8th. 46
Grade 9th- 12th 215
TVT. 67
Diploma 132
Degree.. 88
Masters and above.. 1

1.3. MISSION OF THE ORGANIZATIO

My hosting company has mainly the following missions.

VOL4
To participat actively ineconomic activities that ensure regional and national development.

To distribute produce to the To satisfy essential drugs demand of the country at

comfortable prices.

To contribute its part to fill the gap between the demand and supply of the medicines in
the country.
To produce safe effective and quality.

right place at the time.

1.4 VISSION OF THE ORGANIZATION

The vision of effort investment center is to be an exemplary corporate citizen, able to
continually and successful compete in the global market and involved in sustainable and
progressive development.

To be the country most valued company to patients, customers, employers, and

investors.
To beleader in qulity to sales, price and holders satisfaction in five year.

1.4OBJECTIVESOF THE COMPANY

1.4.1General objective of the company

To reach 90% capacity utilization based on the existing 30% on the single shift with
in the coming 3 years.

1.4.2Specific objectives of the company

To provide job opportunity for citizens.

To get abroad currency by exporting the product.
To produce quality at afford able price to help ill poor people.
To satisfay the segment necessary to pharmaceutical production area inorder to get
required temperature.

VOL5
1.5 Its main product and process

The company has been manufacturing more than 91 high quality pharmaceutical products of
different rapevtic categories including antibiotics gastro intestinal, central nervous system
drugs, cardio vascular drugs, antibiotic agents.

Addis pharmaceutical factory produces safe, effective and quality drugs and has an annual
production capacity of 1.2 billion tablets, 19 billion ampoules, 10 million vials, 500,000 capsules,
4million ointment tubes and 9.6 million bottles of syrup. The company has more than nine
production lines and fully equipped laboratories as well as the capacity to produce tablets,
capsules, syrups or suspension , dry powder for reconstitution, injection vial liquids, injection
ampoules, creams and ointments. The efficiency the high tech machineries and skilled man
power play important role to the production capacity.

The production capacity of the factory per hours by product line is as shown below

Line Product quality

Wet 1 and wet Chloroquine 250mg tablet Wet 1

2 tablet 140,000-420,000
Co-trimaxazole 480mg tablet tablets

Mag-trisilicate comp tablet Wet 2

140,000-420,000
Mebendazole 100mg tablet
tablets
Niclosamide 500mg tablet

Paracetamol 500mg tablet

Sadi for 525mg tablet

The ephedrine comp tablet

Dry tablet Acetyl salicylic 300mg 70,000-210,000 tablets

Vitamin C 500mg

VOL6
Ampicilline beta Amoxicillin250mg capsule 48,000caps
lactamic
Amoxilline 500mg capsule

Ampiciline 250mg capsules

Ampiciline 500mg capsules

Vials Ampcilline sodium 500mg injections 3200-900vials

Benz tine penicillin injection 1.2 MIU

Byzantine penicillin injection 1.4MIU

Penicillin g-sodium injection

Procaine penicillin 4MIU

General capsule Chloramphenical 250mg caps 180,000caps

Doxycycline 100mg caps

Metrondozole 250mg caps

Tetracycline 250mg caps

Syrup Chloroquine po4 syrup 6000bottles

Dipherhydramine 125 ml syrups

Ephedrine 125ml syrups

Piperazine citrate syrup

Paracetamo syrup

Ampoule Water for injection 10ml 40,20-14,400ampouses

VOL7
Table 1

1.6 Its main customers and user

Customer satisfaction is in terms of delivering quality and variety of medicines. Maintaining all
the time availability, keeping packaging and pressing interests of customers is the ultimate object
and performance of APF in its marketing endeavor.

Considerable changes have been observed through promotion efforts on image re

engineering and introduction to wholesalers pharmacies, drug shops and RDVs. Promotion
effort have been started targeting physicians in line with DACA rules. APF is constantly
introduce new products following to customer interests product varieties now reached to 91.

The factor is now implementing intensive market penetration with avoidable presses. The
distribution is done through domestic wholesalers, institution buyers and different sales and
distribution; Mekelle, Hawassa and Bahir Dar. APF products coverage is increasing through
time. The target is to attain distinctive competence of the local pharmaceutical market in the
short future through impact substitution, variety and availability.

APF has devoted a strong commitment to give the highest value to the professional
competence and high caliber presently the manpower mix includesdifferent professionals in all
departments working for value adding and knowledge transfer.

CHAPTER 2

2.PROCESS DESCRIPTION

2.1 Process description of utility

2.1.1 Water treatment plant;-This plant is designed to satisfy (produce) the requirement
necessary to pharmaceutical production such as de-mineralzd water and potable water. In water
treatment plant the following procedure must followed for design purpose.

Identities the water type and amount of imparities a viable in the water to the treated
Designed the process for the treatment of the identified water to obtain the required
specification.
Design the equipments necessary for the above process the followings key points
must be know before design
VOL8
 Size capacity corrosiveness- type mechanism ( operating) control

Sequence of water treatment

The main input of water treatment is row water pipe which comes from
height of 60 m Depth is connected with clarifier follow of the row water 5
M3/nr

Clarifier;- a strong that contain raw water separating three parts ( A.B.C) portion

Volume of clarifier portion A =10m3

portion B =3m3

-portion C =4m3

Raw water

A
Flot
Over flow C valv
e
Pipe B B

Fig.. 1

When how water from to the tanker A. unitreachesto max level since it reaches (water) above
the level the water push to float valve at this time the valve closed to the line (pike) the flow
from tanker A to tanker B, tanker B conation filters so when the water is flow to that tanker
Aluminum sulphate water flow. The filtered water that comes from clarifier inserted to sand
filter.

VOL9
Sand Filter;

- On the sand filter there is different type

Grit 200

Sand 0.4-0.7 Sand filter according to the size and

Material (type). Grit 1-2

- Sand filter is arranged according to

Fig.. 2 Drawing. Grit 3-5

Grit 6-8
In working position the manual valve must be opened. Back wash manual valve must close us
sonnies the timer display must be lock.

The back wash systems are gelded by timer on the times of back wash. The manual, (fneumo
the)

N.B Before the water flow into the tanker (180 m3) the dosing pump as sprayed the hypochlorite
solution molder to kill the bacteria growth.

The filleted water that comes from 180 m3

Car it tanker in seated to carbon filter,

Carbon filter: - water pup from storage tanker to carbon filler open the manual and on the
solenoid valve solenoid valve is a valve that open closed by means of electrically.

Carbon filter Back wash and sterilized (steam)

- On the time of back wash open the manual valve

- Back wash time for hour
- When Back wash is competed switch off the pump and the time. Close the
manual valve then sterilized with steam for about 20 minutes. So the
carbon filters clean and ready for the next operation.
- The filter water that comes from carbon filter is flow for two directions.
1, for potable water storage tanker (250 m3) line
2, for demi plant line
Potable water storage tanker (250 m3) :- The water flow to potable water
storage tanker after on the carbon filter Before flow the water to the tanker (250
m3) spray calcium hypochlorite to that tanker to kill bacteria growth.
Calcium hypochlorite
- Preparation 600 gm of water
- concentration 0.3%

VOL10
 - Dosing dose for every 2.5 micro meter
- Starke adjustment 100%

Chlorine neutralization for demi plant;-This process is in order to sends chlorine whether it
is present or absent.

Operation
Gauge
0.00
Electrical potable water
SODIUM
METAL
BISULPHATE

Sample

CATION
EXCHENGERFig ..3

When the water pass through the above line ( A) which send a simple of water to gauge in order
to check whether chlorine present or absent.

If the gauge read 0.00 there is no chlorine on the potable water line. But the gauge read
above 0.00 the water is contained chlorine solution this time. Sends to dosing pump.
Since the dosing pump is sprayed sodium metal bisulphate in order neutralized chlorine.

N.B The chlorine solution simply drains out.

Demi plant: - the potable water (free from chlorine) automatically passes to cat ion exchange.

- Conductivity after mixed bed 0.1 micro meters

- Demi plant nominal water flow rate 7000Lt/hr

Cat ion Exchanger:- After the calorimeter water passes through flow meter enters in to cat ion
exchanger form the top position. It has appositely charge resins which there by making the water
free of n charged particles in the water there by making the water free of n charged particles. The

VOL11
 cat ion Exchanger contains Resin. Quantity 650 Lt, color Light brown code Amberjack 1200 Lt
Then the water filter zed flow to Degasser.

Degasser:- water free from positively charged particles enters degasser from top and is
sprinkled where air is entering from bottom through blower this is done to escape any removing
gas. The water filtered flow to degasser

Anion exchanger: - The main advantage anion exchanger is n order to become free from UN
necessary solution.

Ion Exchange resins data

Resin Qty Color Code

S/N
Cat ion 650lt Light brown Amber jet 1200H
1
Anion 350L Yellowish white Amber jet 4600kg
2

Table.. 2

Pharmaceutical tanker: - water leaving an exchanger passes through 06 filters of 30 micro

meters each fixed in order casing this water is then .stored in ss tanker with capacity of 10.000 Lt
installed the section

5 micro meter filter is replaced after pressure gauge reading is <1bar.

The flow rate of the leaving ss tanker supply to production 5000-600 L/h.
Conductivity of demi water is less than 4 micro meter /cm
PH from demi water 5-7
The water of theorized flow to mixed bed

Mixed bed: - is demi water pass through two exchanger its mast be flow to mixed bed in order to
combine the ions.

- Mixed bed of nominal water flow rate ;8000Lt/hr

VOL12
S/N Regenerate Conc. Suction time Water flow

HCl 24it 20min 260Lt/hr

1 at33%
Na OH 34it at 40min 430Lt/hr
2 30%
Table..3 Mixed bed of regeneration data

The water of filtered flow to mixed bed UV (ultraviolet)

UV (ultraviolet):- is never allows for trots matting bacteria. There for sample is taken and used
production.

Type of UV (ultraviolet); 80w manufacture of UV; BWT GMBLL

Flow sheet of water treatment 250m3
tanker
After sand sample point
Clarifier Sand filter 180m3 tanker Carbon filter
raw water
tanker
Sodium hypochlorite Before sand sample

sample after carbon filter

Degasser Cat ion
Pharmaceutic 30metre Anion
exchanger
al tanker filter exchanger
Type equation here.
After UV sample
Production
Mixed bed 5 filter UV(ultraviolet
tanker )

Before UV sample

Fig :4

Regeneration time

VOL13
First of all be sure that the demi water contains 5 m3 in boiler tanker. After that check the caption
and onion valve is in open position. Before on the regeneration switch it must be check that
caption and anion tanker contain 90 L HCL and 56 L NaOH respectively.

Injector:- use to mixed the chemical ( NaOH or HCL) with demi water both the chemical water
are washed and drain

The washing time of HCL and NaoH was 20 and 40 mm respectively

The time needs fast wash 15 mints for cat ion and for minutes for anion Exchanger.

Maintenance of the water treatment plant

-Check the filter

-back washing of the processing properties and etc

2.1.2 Boiler;- the pure steam generator uses in industrial as heating mean. It has been project
and built to satisfy the pharmaceutical industries. The total capacity hold that inside shell of
boiler body is 6476Lt.the steam generator is essentially composed by,

-level electrically controlled for minimum and maximum

-Demineralization water pump

-safety valve, control pressure

The main component in order to produce steam are; 1. Demi water 2. Furnace
3.Condensate

As we know the demi water comes from water treatment. And furnace comes from the tanker
that is found behind the boiler house. And the third one, condensate returns to diaerator from the
production.

Furnaceflow through the boiler

First furnace enters to the day tanker. Since, a day tanker contains a thermo state that is heated
to the furnace in order to decrease the viscosity after heated the furnace flow to the burner. The
burner is connected with front door.

Furnace flow through the burner

After enter the furnace to the day tanker, pumped to the burner and enter to the mechanical pump
then inserts to the thermo state to reach maximum temperature (130) at this time the furnace

VOL14
becomes atomized. So, when the furnace passes through the nozzle, the furnace passes through
the filter hole. Because it become highly atomize (pressurized at temperature 130).the fuel
(spark) tube are with inner circle tube for passage of fuel gases on the burner. There is a damper
that flow air into the boiler. The air reaches up to inside the boiler hole. When the motor that
found on the burner is start on as soon as the mechanical pump automatically state. At this time
absolve the furnace to the thermostatic.

Fig: - internal part of boiler 4

VOL15
As it is stated in the above figure, the combustion has three passages. First passage, second
passage, and third passage. First goes to ward and return back by second holes or middle holes.
And again goes forward by the other or third holes. By this process water in changed to steam of
250cd and 8 bars. This steam is used to produce hot water by shell and tube mechanism to
produce pure steam 121dc temperature and pressure of 3 bars. Heat is transferred to the water
through the tube wall and the fuel gas transfer to the water almost 75% on the second tube.
Because, the first passage is starting to increase the heat gradually.

Flow of water in boiler

The water which enters to the boiler that comes from the director. The diaretor tanker is put out
side of the boiler house and uses the steam heat exchanger.

The diarator contains; - demi water, that comes from water treatment.

-condensate, that return from production.

Separation;-the water comes from diarator and pumped by centrifugal pumps type then it inters
in side of the boiler. Examples, if water level is down automatically, absolve the water from the
diarator.
water
Heat transfer on
boiler; - the heat transfer
or direction Tube wall fuel gas from fuel gas
to water due to change in
temperature (T).
water

Fuel gas

Water

Tube wall Fuel gas

VOL16
 110 Water

100

160 130

Example. Starting flow of fuel gas 160 centigrade at the same time, temperature of water 100
centigrade at the at the ending of flow gas become 130 and water become 110dc.T=160-
130=30. So 30 facilitate to increase temperature. There fore, 30 play a great role to
boiled the water. The capacity of the boiler with standing up to the pressure of 11.76 bar. The
temperature of the steam also enters to the boiler parallel with the pressure saturation.

Condensate pump; - the pump uses to pressure the condensate water to the diarator by means of
steam.

Operation; when the condensate water to the pump automatically push to the float valve, then the
valve float above the condensate water on the crank push(up ward).then the diaphragm . At this
Tim steam insert to the internal part of the pump, the steam by itself with highly pressurized and
pumped the condensate water through one way valve to the diarator. Steam is distributed to the
following listed bellow;

-chiller plant -pharmaceutical process

-Distillation plant -water treatment plant

-Condensate pump -hot water, heat exchanger and hot sanitary water.

Maintenance of boiler

-Check safety valve, properly closed and opened. compressed air filter

VOL17
 -Check de-mineralized water pumping. check boiler shuts down when the water

-Check the filter of the furnace. - Level is at very minimum (safety) level.

-Check the internal condensate pump

2.1.3 Compressor: -is a system of producing compressed cleaner air facilitates the
production process. The Compressor air which produces in the house two atlas copco machine
one for working condition. One for stand by

The power from the motor is transmitted to shaft through coupling LP-low
pressure and HP-high pressure
The machine which found in the plant with ZR3 pack since the air compressed in Lp and
Hp element the two elements with screw type rotor that mounted on ball and roller
bearings
Oil water air is inserted to the needed place.
Cooling system:-The main play a big role for calling are water that comes from calling tower
the motor are enclosed in sound insulated canopy.
Loading:-During loading operating the throttle valve is deepen and air suck continuously from
atmosphere since compressed is takes place.
The internal part of oil cooler with circulation of coil, the water flow through the coil. The oil
also cool by jacket system. Oil flow to compressor element in order to lubricate.
Unloading:-During unloading valve is open air compress not take place but simply circulated.
Air flow :-air which comes from atmosphere drawn through the filter in take silently then
open the throttle valve in to compressor elements the air compressed by screw method. When the
air compressed & take place the temperature of air (compressed) increase. So it needed cooling
system the automatically water pass through inter cooler as jacket system. at this time heat
exchange takes place. Since the moisture drain through moisture trap then again enter to the
second compressor element.

The compressor which inters to check valve is from to moisture trap to drain the moisture.

process flow sheet compressor air

AIR
Vio calling Air Storage Silcajel
Cold water
tower water compressor tanker filter
tanker machine

VOL18
 Hot water

Production filter Humidity air

(drying)

Fig 5 )

Circulation of oil system:- The oil pumped through oil cooler. Oil cooler

Oil filter compressor element oil pump oil cooler water is flow through the oil
cooler by jacket system the rotor bearing. On the time of unloading there is no suck air from
atmosphere. Simply closed throttle valve & check valve. But open the unloading valve.Air is
circulated without compressed the air, when gradually reaches 7 bar the unloading valve is
closed and the throttle valve & check valve is open.

Some important point about guage

Oil pressure =2-2.2 bar

Filterindicator:-Duringhloadinghlesshthank45ba
water temperature = 150c .(During loading)
Air T0 outlet =30-350c
Inter color = during in loading 2-251 bar
Air T0 low pressure out = 150-1600c
Air T0 high pressure out = 140-150c
Air temperature high pressure in = 350c
Max work pressure = 8 bar
Rotational shaft speed = 2980r/min
Year of manufacture 19
2.1.4 Chiller:-the chiller house contains the chiller which cools from 23to25.the chilled
water is designed only for HVAC system consumption .in the chiller house there is also the
pump set to supply chilled house there is also the pump set to supply chilled water to HAVC heat
exchanger as technical floor.

2.1.5 HVAC SYSTEM(heating ventilation and air conditioning system)

The plant (HAVAC)is designed to satisfy the segment necessary to Pharmaceutical production
area. the main objective of the area is in older to get the required temperature. with the different
area of production The plant designed to meet the required asked for pharmatcall sterilized area
and open area.

VOL19
 The plant is designed to supply air from atmosphere to sterilized area through the bag filter. the
bag filter efficiency 98%.

The humidity sense device is settled up to maximum relative humidity level of 45% connected
via electronic control to regulation valve on the coiling of the handing unit.

Humidity sensor is regulating the valve on the heating coil of air handling unit.

As you know the hopper filter high cost and strongly filter anr. so the plant. is realized to
partially circulation of air with an external fresh air supply. Due to good environmental air
conditions the corridor rooms are supplied with 100% External air.

Filter:- in HVAC fundamental components is that a actually removes

Air (out) from the production. And inter the fresh air to production area. Must be filtered the air
condition.

There are two types of filters; 1, Bag filter 2, pre filter

1, bag filter:- is disposal
2, pre filter:-can be washed to clean the dust collection in it.

When the air insert (pass) through the duct first pre filtered then bag filter.

Damper:- these are component used to limit the air flow by closing and opening.
Heat Exchanger:-due to the variation of the environment al condition hot water and chilled
water is supplied through coils of pipe to humidity and regulate the temperature of the air in let
according to specifications controlled.

Fans:- the main components of HAVAC which is used to suck in to and out of the room.

Maintenance on HVAC :-an air handling unit require an attention.-

Once a Check:-filter condition at weekly intervals, Clean, wash or renew replace if necessary.

Once a month:- check the condition door hinder.

-Once in six month:- check fan check inlet- check bearing check the condition of chiller
water

- once a year-check the damper-check the valve.

Make up air Filter fan heating and coil

VOL20
 Supply air

air

Control dumper

Return air ducts /option/

difusers
Fig Generalized forced air system 6

2.1.6 Electrical generator power:-The important of generator is the incase of emergency

situation .use the emergency push button to shat of the generator set immediately. The
capacity of the electrical generator power 1472 KW@400 V and HZ.

2.1.7 DISTILLATION PLANT;- distillation is the process of separation of two or more

species which has different boiling points.

Distillation operations description; the pharmastil multiple effect stills produce distilled water for
inject able use which meets the requirement of the international pharmacopeias.

The input of the plant are:-feed water

-feed steam

-cooling water

The output of the plant are:-distillate

-discharge

1.feed water:- the feed water is introduce at one point along the column shell. The column is
divided into on upper section and lower section and is immediately heated (tube side) into
exchanger by the condensate of pure steam by the distillate coming from the last column.
Pressure must be at least two bars more than that of steam quality of feed water de-mineralized
and filtered, free of amines, organic matters and silica (max, contractivity5u)

2. Feed steam:- the steam must be saturated dry free of oil and impurities which may scale the
exchanger surface, the pressure may be change from 3 to 8bar. The point is provided with a
safety valve calibrated 9bar. The steam enters the last column (shell side) and heats the feed
water tube. The feed water evaporates while the steam condenses and further cools in the heat
exchanger and drain as condensate.

VOL21
3. Cooling water:- the cooling water inters the column and further cools distillate which
iscooled and condensed by feed water,

_pressure of cooling water-2bar

_temperature of cooling water-inlet 15c to outlet 80c

_quality of cooling water-softened

Consumption of cooling water-depending on feed steam

4.Distillate:- the distilled water is chemically and bacterially pure sterile and pyrogen free.
Starting with softened water at 0F hardness it is possible to obtain a conductivity of 1s/cm, with
de-ionized water the conductivity is normally 0.2-0.5 s/cm.

The de-pacification is complete and PH is near 7.

The distilled water is produced at 97c atmospheric pressure.

The high quality of the distillate is obtained during the passage from liquid to vapor state per

Heater and final exchangers,

5. Discharges:-gas - must be free without back presser

Concentrate must be free without back presser

All pharmastills are provided with one per heater for each column and to final exchangers.

One for feed water, one for cooling Maintenance of the distillation plant

Daily;- check for leakage of steam, air and water line and report any leakage.

-check proper function and instruments like flow meter &manometer &similar devices.

Monthl- check proper function of safety valve

-check clean less of flow meters, clean with brush are in dirty.

Every six month:-report the above inspection

-check proper function of steam trap.

-check and Laplace gas of water flow.

VOL22
RAW MATERIAL OF BETA LACTUM PRODUCTION

VOL23
Sodium citrate Sodium meta besilate
Sorbital solution 70% Salbutamol sulphate
Tartaric acid Metoclopramid hydrochloride
Trimethoprem micronized Butylated hydroxy anisole
Lso propyl alcohol Cetomacrogol 1000
Mebendazole suppension Ceto stearyl alcohol
Benzyl alcohol Hard wax
Albendazole (micro) Light liquid paraffin
Metronidazol boazoate omeprazole
Banana flavor powder Salicylic acid
Pbubutyl hydroxy ineapple flavor powder Sulphur precipitated
Strawberry flavor powder Zinc oxide
Food color raspberry real Di sodium hydrogen phosphate
Food color strawberry real Color brilliant blue
Ascorbic fine Lidocaine HCL
Dextromethorphan hbr ep 4uap27 Phenobarbitone EPV1
Butyl hydroxy tolune Grieotuvin micro
Kollidone cl-m Fluoxetine HCL
Sodium benzonate simethicone
Metronidazol boazoate ichthamol
procaine penicillin g.forifi Lactose anhydruos
Benzathine peniclline BP98 Dextrose anhydrose
Amoxicillin trihydrate compact Sorbic acid
Ampicillin trihydrate compact Ampicillin trihydrate
Empty capsule black/red s-0 Amoxicillin tryhydrate
Empty capsule black /red s-2
EHGC B/OS-2
EHGC B/0S-0
Cloxacillin sodium compacted
Empty capsule black /reds-0
Empty capsule black /reds-2
Empty capsule M/Ysize 0
Empty capsule B/0 S-0
WOOL FAT(LANOLIN ANHYDROUS)
Yellow soft (lanolin anhydrous)
White soft paraffin (petrol jel
Methyl salicylate
Alcohol 96%( ethanol)
Citric acid
Colloidal schicondioxide(aero
Ephedrine HCL
Liquid paraffin
Magnesium stearate
Maize starch
Microcrystalli cellulose PH 101
Microcrystalli cellulose PH 102
Peppermint oil
Sodium starch glycolate
sugar
Talc paraffin
Cross carmellose sodium
VOL24
Sodium chloride
Vitamin D powder
Citric acid anhydrous
Di sodium editate
 RAW MATERIACE OF B-LACTAM
A.S.A (ASPIRIN) Win coat mT-02005 white
Acacia powder (gum arabic) Win coat WT-1815 Yellow
Aluminum hydroxide Kollidone cl
Ascorbic acid(vit.c) Kollicoat R WHITE LL
Carnauba wax KOLLICONE 90F
Ceraalba(white bee wax) Kollidone 25
Chloroform trichlorometane Kollidone VA64
Chloroquine po4 HPMC K-100
Dextrose monohydrate Kollicoat MAE 100P
Lactose CERAALBA(WHITE BEE WAX)
Magnesium trisilicate Vitamine Apalmitate
Mannitol Dicloferance sodium oral
Mebendazol Chloramphenicol powder
Methyl cellulose Doxcycline HCL
Niclosamide EMPTY CAPSULE G/G SIZE2
Paracetamol Empty capsule gree/whites-2
Povidone (PVP) Empty capsule pink/blue size2
Saccharine sodium Empty capsule red /yellows2
Sodium lauryl sulfate Metronidazole
Sulphamethoxazole Tetracycline HCL
Theophylline Tinidazole
Titanium dioxide Norflaxacin
Trimethoprim Ciprofloxacin HCL
Yellow food color (tartrazine) E.H.G.Clight/pink size.2.
Erytrosine red color E.H.G.C. light g/w size.2.
Nictonomide Sodium thiosulphate
Sunset yellow BENZOIC ACID
Methylene chloride Chlorhexidine gluconate
CMCsodium Benzalkonium chloride
Propyl paraben sodium Sodium hydroxid NF
Methyl paraben sodium betracyclodextrine
Ethyl cellulose Sodium hydroxid NF
Xanthum gum Betracyclodextrine
Methocel HPMCe15 Carbomer 934p
Cimitaidine A Thiomesal
methyldapa Sodium alginate
Vitamin B1(thiamine HCL) Camphor
VITAMIN B 6(PYRODOXINE) Lilac 747
Aspartame powder Ammonium chloride
Polyethylene glycol Brown color
Food-azorxbia red Caramel flavor (powdedred caram
Food color tartarazia Diphenhydramine HCL
Yellow lake colour Giycerin (glycerol)
Hyoscine Nbutyl bromide EP4 Green color for piperazine
OPPDRY WHITE OY-C-700A Guar gum
FUROSEMIDE Mentholcrystal synthetic
IBUPROTEN bp Methylparaben
AMITRIPLTYLINE Piperazine citate
Artemether cp Poiysarbate 80
Lumefantrin
VOL25 Potassium guaiacal sulphonate
Color yellow E104ALUMIN LAKE Propylene glycol
Color blueFD&c no1lake bril proplparaben
Win coat WT-S-01204.BLUE Raspberry flavor
 2.2 PROCESS DISCRPTION OF PRODUCTION

The company is manufacture two types of drugs those are lactam and non bate lactam

1. Beta lactam:- drug that have bettering in the bond of raw material
2. Non beta lactam:-is a drug that have not bettering in the bonds of raw material
The bettering is allergic sensitive to same percent due to this reason those product cannot
manifested next each another in order to avoid contamination
General the company has 9 lines of product

2.2.1 Beta lactam line

1. Capsule line :- manufacturing capsule line has the following steps

Dispensing Blending Caps filling Inspection

Storage Packing Blistering Duduste

ring

Dispensing:- is weighting exact quantity of active and in active raw materials from the
store the in active raw materials lubricant to avoid sticking alidiont (for proper flow).
Blending:-is maxing the active and in active raw materials this is per formed in a double
cone until the mixture is uniform by rotating the Y-cone mixture.
Caps filling:-in this the empty caps raised by the pressure and inter to the segment by the
gravity pressure when separated the lower segment and segment and the powder is filled
to the lower segment cap. And reject the caps that are not opened by any error through
the pin and positive presser. Next the caps are closed by the help of pin and positive
pressure and next the powder in the segment in cleaned by negative pressure.
Inspection:- is takes place inspection machine the sated negative pressure identify the
underweight and avoid to prepared jar.
Dudastering: - is to clean the powder on outside of the capsule and to reanis the capsule
by pertain to have good for the patient.

VOL26
 Blistering: - first sheet plastic heated up to 130c in order to make mold by the size of the
capsule and increasing the temperate to 180c the mold plastic heated in order to.

-sale the plastic with the aluminum

-to write manufacturing date

-to write expire date

-write Bach number using punch and after this the sailed product is chilled by the chiller in order
to avoid fractured. When pulled by the griper and cut by the required size.

Raw material of capsule

- Talc - aluminum

- Starch - box

- Esmospring - leaflet

- Colloidal silicon dioxide - carton

- Magnesium trisilicate - glue

- Lactose - label

- Gelatin - empty capsule size 2blue or rose

- Pvc/pe/pvdc transparent 201

2. Powder syrup line:-syrup production has the following steps.

Storage Drum Sieve Double Blowing

mixer cone Bottle

Storage Packing Leveling Capping Filling

machin
e

Drum mix:- in this active one in active low materials filled in to drum and the drum
is rotated by electrical power in our to be uniform the mixture.

VOL27
 Sieve:- is a process for making throughout uniform mixture
Double lone mix:- used to mix after in active material like sugar with prepared
mixture
Blowing Bottles:- is per from in filling machine the Blower Bottles are come by the
chain and enter to the filling dies by jeniva mechanism and the powered is filled from
the hoper and bottle gets out by other jenive mechanism in to the chain.
Capping: - The filled Bottle takes cap by the help of jenive mechanism and the
coping process in per formed & get out of by Jenive into the champers.
Leveling:- in this the expire data manufacturing and Bach number are written and the
paper is level to the Bottle properly.
RAW MATERIAL OF SYRUP 125ml/bottle

Potassium guaiacum suphonate - sodium benzoate

Sugar orange oil - bottles 125ml

- Red color for ephedrine - caps

- Tartaric acid - leaflet
- alcohol - labels to bottles
3. Vial line: - First the bottles are washed in the waling station by demi water and clean in the
cleaning station by using steam. In order to avoid the deists, and small micro organisms such as
bacteria that cannot say be our naked eye. Then, the bottles are goes to filling station. In order to
fill the powder, after that it transferred to coping station to close by taking a cap. Finally, it
moves to labeling room and packed in the pecking area.
The flow sheet of the process is as shown below

Capping Lab ling Packin

Dispensing Filling station
station g
Raw water

Cleaning

Washing
Bottles

N.B: - This line is takes more safety than other lines. Because the medicines produce in this
line are takes by injection that means direct contact with our bloods. So the machine room and
the operators should be clean by demi water and steam in order to prevent contamination. Be of
this the process of this line difficult to see

2.2.2 Non beta lactam line

VOL28
1. Tablet Line:- manufactured by the following steps

Storage Preparation Mixing Basket (Drying)F Granulatio

binder Solution gronoleter BD n

Storage Packing Blisterin Coating Compretio Y-Cone

g n Mixer

Preparatio
n tanker

Pre pairing binder solution :- is uses Demi water sac rant & methyl proven
Mixing: The active and in active wet is in hoper mixer.
Basket Granulator: use to move ring type shape
Drying (FD);-Fluid bed drier in this the filtered air is heated by means of heat
Exchanger with steam and the air pass through the basket granulated low material and
the air filtered moisture is obtained.
Granulation: grinding to obtain required size.
Y-cone mixed: is cone is to mix active and inactive like aerosol and peppermint ail these
row materials are enters in to Y-come by negative pressure and then the Y-come mixer is
rotated to obtained uniform mixer.
Comprehension: is to being the powder by completion Machine the powder is lifted by
the lifted by the lift and entered in to the Lie by gravity and their compressed by the
lower and upper punch. The power on the tablet is removed by negative pressure.
Coating:- some are full smooch to avoid this problem to pass the Drug to small in
Testing without dissolving in stomach coating solution is perspired and colodialmias
make uniform solution and coated the tablet by the coating mechanize.
Raw material of tablet
- Talk - povidone - glue
- Starch - magnesium - carton
-Parstamol - leaflet

2. syrup Line

Weighting:- the active and in active raw material are weighted in weighting machine and
also the sugar is crushed in the grinder machine.

VOL29
 Syrup preparation:-in this room there are 7 tankers in the tanker 1 and tanker 2 sugar
solution would be prepared ,then the sugar solution will be transferred by sugar filter in
to tanker 3 and tanker 4 in tanker 3 and tanker 4 the active and in active raw materials
are mix to gather with sugar solution . After that it goes to tanker 5 and tanker 6 but
tanker 5 and tanker 6 are direct contact with filling machine .The remain tanker 7 is used
for suspension.

Washing area:- in this area bottles are washed to clean from any dusts. The bottles are
firstly washed by potable water and dry by compressor; secondly it washed by demi
water and then dries by compressor. After that it goes to filling machine.

Filling area:- In this area the prepared syrup solution that are collected in the tanker 5
and tanker 6 are filled in to the washed bottles that comes from washing area , finally ,it
goes to labeling area for same purpose as the dry suspension and then goes to packing
area.

Processflow diagram of syrup line

Suspension
tanker 7
Raw material

Tanker 5 Filling area

Tanker 1 Tanker 3 Labeling
and 2 and 4 and 6 area

Washing
area Bottle
3. Ointment Line:-first yellow soft paraffin and wool fat (lanolin)well melt in tanker ,after
that they will enter to fat heating and melting vessel machine in this machine butyl
butylhydroxynisale and butyl acid hydroxyl toluene are added ,after you add you will melt them
for hour , then will be transferred to preparation tanker. In this tanker until it reaches 50
we send cold water, but if it reaches 50we will add lechtamol. After that we close the cold

VOL30
water and we will mix for 2 hours, then we will sendtofilling machine, finally we will be send
packing area.
-Flow sheet of ointment line;

Melting Fat Heating Preparation Filling Packing

tanker and melting tanker machine

2.3 waste water treatment

Waste water treatment is one of the most important processes for the Ads phemecutical factory.
Waste water is treated by this manner; first water does a lot of functions in production and it
returns back to primarypound. Then to secondary pound & it goes in to the tertiary. Then to
tertiary pound & later it recycles to the secondary pound and the tertiarypound.After that by
purifying it in sand fitter it inserts in to first carbon filter if lefts in to the secondary carbon filter
& then for the fourth bound. After this remove out side as waste.

Recycle

waste water Sand

Primary Seconda Tertiary
filter
pond ry pond pond
from production

Treated waste to Fourth pond Carbon filter

green area one

Primary pound: - is physical process that non homogenizable solids and

homogeneziablethe remaining effluent.
Second ray pound: - is biological process that Remove most of the biological demount
for oxygen.
Territory pound:- is physical and biological and chemical than remove nutrients. Like
phosphorus remove in orgasmic pollutants.

VOL31
 Sandi filter:- Used to filter zed the waste water which is coming from the secondly pond
treated was the water through different type (size) of sand.
Carbon tilter:- for the same fashion / procedure/ used to filter zed the waste water which
is coming from the Sand filter through the different size of carbon.

CHPTER 3

1 MASS AND ENERGY BALANCE

From the concept or knowledge of coarse thermo dynamics (first law of thermo dynamics)
energy neither created nor destroyed but can be from one to another.

Total energy balance be comes

[Accumulation of total energy/time]= [input of total energy/time]-[out put of total

energy/time]+[energy supplied/time]

3.1, ENERGY BALANCE OF BOILLER

Accumulation =in put - out put + generation - consumption

In put out put =0

Then,in put = out put

Since the total energy is the sum of kinetic, potential and internal energy.

ET = ke + pe + u where ET = total energy

Ke = kinetic en

Pe = potential energy

U = internal energy

De/dt = du/dt +dk/dt+ dp/dt

Dk/dt =dp/dt = 0 because there is no motion and posion

Ke = 1/2mv2 (no velocity) = 0

Pe =mgh (no height) = 0

De/dt = du /dt for liquid system du/dt dh/dt

VOL32
Ther for de/ DT dh/dt dh, is total enthalphy ther for

Q ws =h + ke +pe where ws =sheft work

Ws = 0 (no moving part)

The equation will be clearly reduced to Q =. Then the energy balance in the boiler will be.

Water in=400kg/hr Tout=250andp=8bar

Tin=70 industrialsteam=4500kg/hr
Boiler Ms=4500kg/hr
Q=H

H=m(H)=m(h2-h1) then h2=hf2+x2hfg

h1=hf1+x1hfg

H=mh-mhfg

H=m (h-hfg)

1atom=1.01325bar~1bar and 1 atom=100.000pascal

Then 8 bar=0.8Mpascal

T=Tsat @ p of 8 bar=170.43(the saturation temperature is obtained from the steam table at

given pressure) if

- T <Tsatit is compressed liquid

- T>Tsat..it is super heated mixture

- T=Tsat@ p.it is saturated mixture

Then it is super heated mixture because, T>Tsat

250 >170.43=super heated

-From the table (a-6) thermodynamics we obtained the enthalpy is h=2950kj/k, and also at TOF
70 saturated water will be hfg=2335.3kj/kg there for

Q=H=mh-mhfg=m(h-hfg)

VOL33
H=4500kg/hr(2950-2335.3)kj/kg

H=4500KG/HR (614.7)KJ/KG

There for, H=2766150KJ/HR1000J/KG*1HR/36000S

H=768.375KW

3.2.The energy balance on heat exchanger

This heat exchanger is a double pipe shell and tube heat exchanger is constructed fro stain less
steel with k=15.1w/m inner tube di=1.5 do=1.9cm and an outer diameter is 3.2 cm
hi=800w/m2on the inner surface of the tube ho=1200w/m2 on the outer surface .for fouling
factor Rfi=0.0004m2/w on the tube side and Rfo=0.0001m2/won the shell side with length of
the hex is 1 meter .then find Q with the in let 15 and 85 on the tube side.

*First find R =1/Un=1/UiAi=1/UoAo=1/hiAi+Rfi/Ai+ln (do/di)/2kl+Rfo/Ao+1/Aoho

Where Ai=l=(0.015m)=0.0471m2

Ao=dol= (0.019m)*1m=0.059m2

When you inert the given value on the above equation we have let 0.o552/w means that

R=1/800*1200+0.0004/0.047+ln(1.9/1.5)/243.14*15.1*1+0.0001/0.059+1/0.059*1200

R=0.0532/w

Then Q=UAT=UiAiT=UoAoT

Let see on the inert side of the tube

Where Ui=1/RAi=1/(0.0532*0.0471)w/m2

Ui=399.1w/m2

Then Q=UiAiT= (399.1*0.0532*70) W

Q=399.1*0.0532*70) W

Q=1.486KW

3.3, Material balance of tablet (cemitidine)

VOL34
Cimitidint=32.2kg

Ethanol=105kg
Preparation Loge Basket Fluid Bed
Provident=17kg M1 M2 M3
Binder Mixer Granulator Dryer
solution

Lactose mono hydrate= 5.47kg mangzeme starch =4.65kg M4

M8 Coating M7 CompressionM5 Y-cone

Talc= 20kg
machine Mixer

M7 magnesium stearact

Methane=35kg Preparation ethanol=211kg sodium starch glycol=17.5kg

tanker

Win coat=3.68kg

General material balance

Mass of accumulation=Mass in put Mass output + Generation Mass of consumption

Since, there is no chemical reaction

Accumulation =Generation=consumption=0

So, Mass of input - Mass of output =0

Mass of input = Mass of output or, Min = Mout

A, Material balance on preparation of binder solution

Min Mout=0 then, Min = Mout

(105 Kg + 17kg) x 99.8% =M1out

122kgx0.998 =M1

M1 =121.756kg

B, Material balance on Loge Mixer

VOL35
 Min = Mout

(M1 + 5.47kg + 4.65kg + 32.2kg) x 99.4 =M2

(121.756kg + 5.4kg +4.65kg +32.2kg) x 0.994 =M2

M2 = 163.986kg x 0.994

M2 =163.330kg

C, Material Balance on Basket granulator

Min = Mout

M2 x99.8% = M3

M3 = 163.330kg x 0.998

M3 =163.003kg

D, Material Balance on Fluid Bed Dray (FBD)

Min = Mout

M3 x 99.38% =M4

M4 = 163.003kg x 0.9938

M4 = 161.993kg

G, Material balance on Y-cone mixer

Min = Mout

(M4 + 17.5kg + 17.5kg + 20kg + 5kg) x 99.8% =M5

M5 =(161.993kg + 17.5kg + 17.5kg + 20kg +5kg) x 0.998

M5 =221.993kg x 0.998

M5 =221.549kg

F, material Balance on Compression

Min = Mout

VOL36
 M5 x 99.7% =M6

M6 = 221.549kg x 0.997

M6 = 220.884kg

G, material Balance on Preparation Tanker

Min = Mout

(3.68kg + 35kg + 211kg) x 99.9% =M7

M7 = 249.68kg x 0.999

M7 = 249.43kg

H, Material Balance of coating

Min = Mout

(M6 + M7) x 99.7% =M8

M8 = (220.884kg + 249.43kg) x0.999

M8 = 469.843kg

Over all Material balance on Cemitidina tablet

Mass of accumulation = Mass in - Mass out + Mass generation + Mass of consumption

So, Min = Mout

(Feed + M7) x 99.9 =M8

M8 =(122 +249.43)kg x 0.999

M8 =371.056kg

3.4. Material balance syrup line

SUSPENTIO
N AREA 7

TANKER M1 M2
TANKER3&4
M3 TANKER FILLING
1&2 5&6 AREA
VOL37
 WESHING

BOTTLE

General material balance

Mass of Accumulation=Mass of input Mass of out + Mass of generation + Mass of conception

Or MAcc =Min - Mout + Mge + MCon

Since, there is no chemical reaction

MAcc = Mge = MCon=0

So, the equation will be

Min = Mout

1, Tanker 1&2;input , -Demi water=600kg -sugar=1275kg

Output, - M1

2, tanker 3&4; input, - dephenildramineHcl=3kg, -sodium citrate=3kg

- Ammonium chloride=37.50kg, -ethonol =6kg

- Sodium glutamate = 1.5kg - M1

Output; -M2

3, tanker 5&6; input, - M2 output, - M3

4, filling area; input - M3 output, -M4

1, Material Balance on 1&2 tanker

Min = Mout

(600kg + 1275kg) x99.8% = M1

M1 =(1875kg)x0.338

VOL38
M1 =1871.25kg

2, material Balance on tanker 3&4

Min =Mout

(M1 +37.5 +1.5 + 3 + 3 +6) kg x 99.8% =M2

M2= (1871.25 + 51.75) kg x 0.998

M2 = 1926.15kg x 0.998

M2 =1922.297kg

3, material Balance on Tanker 5&6

These tankers are used only for storage purpose.

Min = Mout

M2 x 99.9% =M3

M3 = 0.999 (1922.29) kg

M3 =1920.3754kg

4, material Balance on filling area

Min = Mout

99.8% x M3=M4

M4 =0.998 x (1920.3754) kg

M4 =1916.535kg

5, over all material balance

Min =Mout

Feed x99.8% =M4

M4 = (600 + 1275)kg x0.998

M4= (765000)kgx0.998

VOL39
M4 =763470kg

3.5 Strengths and weakness of APF

An analysis of APF reveals several positive and negative as pacts which will be helpful to asses
prospective development relatively little technical input would probably lead to further positive
results as access to the health facilities is creasing in the country.

Strengths

High production capacity for syrups tablets and capsules and relatively modern
machinery and production premises
Committed work force which needs direction incevtines training and experience
Ophthalmic ointment production is limited to APF in Ethiopia
APF has relatively modern quality control laboratory modern water treatments
systems and utilities
Most of the current working staff of technical department have been involved in
the project implementation trease of the plant hence nowadays they are easily
familiar with operation and maintenance of the plant machineries as result they
carry out their routine works effectively and with little supervision
The current utility plants can produce and supply the unities demand of the
9(nine)produMost of the plant machineries are designed of modern technology
and they are moderately automated in their operations some are high capacity
machines compared to the current available pharmaceutical machines in the
country As the same time most of the machines have adequate manuals for
operation and maintenance
Our work ship section and can manufacture different work pieces as
replacement items for damaged or worn-out machines parts moreover it is
rendering various services for other sections
Weaknesses
Lack of established working department manuals sops and system
In adequate technical competence in production ware house quality control and
technical department
In adequate internal or quantization and co-ordination of the activities of the various
section within each department and lack of co-ordination with other departments
Low salaries rigid salary scale and lack of carries structures creased employees turnout
specially professional
Lack of some equipments for production and quality control department
APF has unlicensed plant and production registration is not started
In adequate secondary packing system including corrugated cartones

VOL40
 High percentage of wastage and rejections
Inadequate distribution outlets and marketing service
Most of the plant machineries have not sufficient spare parts some do not have spare at
all as a result of this were facing with longer machine downtime when there are
technical problems such as machine break down, work out machine parts, etc

3.6 Threats and opportunities

Threats

APF has the following threats and its needs competent technical processional and
management organization
The wash rooming of new pharmaceutical factories in Ethiopia
Unavailability immediate know how to increase the product mix and production
capacity of the plant
Unavailability of current national and regional drug consumption data and poor
market forecasting system.

Opportunities

The decentralization policy will allow regions to take direct responsibility of their own
health care and drug supply system
Expanding health coverage in the country
The capability of APF to increase the product mix with little technical in put
APFwill be one of the factories which can satisfy GMP by continued training and
changing the attitude of its staff
APF has the opportunity to produce under license or so make management contract to
get management skills

3.7 Advantage and disadvantage of the technologies for production of main products

Advantage of batch production: - there are several advantage of batch production

It can reduce initial capital out lay (the cost of setting up the machines)
because assignee production line can be used to produce several
products
Batch production can be use full for small business who cannot afford to
ran continuous production lines
Batch production is also use full for factory that makes seasonal items,
products for which it is difficult to for case demand, a trial run for
production or products that have a high profit margin

VOL41
Disadvantage of batch production

Batch production also has some drow backs, there are at inefficiencies
associated with batch production as equipment most be stopped
Reconfigured and its output rested before the next batch can be
produced
Different time between batches is known as down time the time between
consecutive batches is known as cycle time cycle time variation is also
manufacturing matric

3.8 Advantage and disadvantage of alternative technologies in the APF production

Advantage of alternative technologies

Environmental benefit, low or zero carbon emission while wood is providing a

sustainable environmentally friendly and in expensive energy for heating

Disadvantage of alternative technologies

High cost:-Unfortunately the technologies that utilize alternative sources of energy remain
relatively expensive.

Low efficiency: - alternative energy technology are relatively new in offices and are not
particularly efficiency

CHAPTER 4

4 .Environmental impact

4.1 Pollution aspect: - Addis pharmaceutical factor (APF) has solid and liquid wastes
which can pose potential damage to the environment. Addition of extra material or increase in
the concentration to actual concentration creates the pollution which is direct contact with
environment.

Addis pharmaceutical factory (APF) at the moment cannot install complete liquid
waste treatment system due to finical reasons. The industrial operation produces
various types of wastes. Which might have hazardous effect over a period of time
to biological life?
In APF(Addis pharmaceutical factory) the solid wastes can be
removing[removed]using land filling &incineration methods, means that
incineration, burning solid waste or heat treatment for the solid waste simply
burring &sanitary land filling (open dumping )throw out the wastage to the green
area especially for water soluble and hazardous solid wastes. Aside far from a

VOL42
 ground water sources should be selected. The existing waste water treatment plant
which treated by. Primary. Secondary and tertiary bond uses sedimentation and
neutralization process to minimize the chemical content of the waste liquid.
The treated waste water plant which is coming from the production is treated at
the territory bond water treatment and then APF also directly uses to the green
area which can effect environmental protection.
Addis pharmaceutical factory (APF) there is also degasser in waste water
treatment (WWT) which is used to remove gases which contain odors. Test to the
environment.
APF which is removes the fuel gas (2500c) in boiler to the environment and which
can reduce the concentration of gases which is found on the atmosphere then
which can create the pollution or directly which can damage the environment.
In APF HVAC (air conditioning handling system) which can supply or exhaust air
to production and to the environment. The exhaust air to the atmosphere only uses
pre filter to purify the waste then goes to the atmosphere also create the pollution
also damage the environment.
Generally, Addis pharmaceutical factory (APF) which can cause pollution to the
environment directly or indirectly due to the lake of chemical engineer which is
highly related to the controlling of waste water treatment control unit operation,
or environmental engineer which can control at any wastes (solid, liquid , or gases
) also causes environmental protection.
Finally Addis pharmaceutically factor (APF) which contain many chemicals to
convert the raw material to the finished (final) product the waste removed also
direct contact with environment cause the pollution ( solid , liquid , etc ).

CHAPTER -5

5.Problems and challenges

5.1. Problem in the distillation plant:-first (de-mineralized water) is come from water treatment
tank which is placed after passing the whole process of filtering the water in the 250m 3 tanker.
Then the cold demi water is flow in to distillation column and the steam is come from the boiler
house with 250 temperature and 8 bar pressure. Simalitoneusly or parallel they feed in to the
column (i.e. cold demi water pass through the shell and steam through the tube).since the hot
steam and cold demi water are exchanges their temperature and makes it a heat by jacketing
system. Then the needed pure steam is produced.

VOL43
 The produced pure steam which is gained or produced from the distillation column is flow in
to the heat exchanger passing by the steam trap which is controlled the amount of the steam by
electrically system.

The distillation purpose is to distillate the pure steam in then, the cold demi water entered to
the heat exchanger. Here heat exchanger contains tube and shell it uses in order to distill water.

When the distilled water is produced, the pure steam is passed through the shell and the cold
demi water is inter to the tube and passed through. Totally the pure steam and demi water
produced a condensate water and stores at the distill tanker, after that, the cold demi water which
is condensed to the steam is clear and free but it is avoided no recycling the surrounding to the
waste water.

As I observed, in heat exchanger, the cold demi water is discharged. due to discharging of
the clean demi water ,waste water demi water from the heat exchanger have to flow either to
water treatment plant or distillation columnplant in order to use continuously in the
pharmaceutical tanker or another process.

5.2:-problems in the production process

In the production process some problems are happening. Some of them are; one since the most
they use as arow material is a powder. Since, it is a fine particle or fine particle it can simply
blow in to the workers body. The second one is contaminated with the powders itself (different
powders) because their lines are cloth each other.

Generally, from my observation and measurement in the production process

-clean air must be entered to the production area from the atmosphere conditions

-the distance of the different lines have to far away about 100 meters

-workers have to wear clean uniform in order to safe the product and their health.

challenges:-the challenges I faced is we were not asked to write our daily activities, because in
APF company there is one chemical engineering. So he has no enough time to show as these
important things worked by chemical engineer in the company.

Due to high contamination of some production lines such as vial line

we are not able to see the process completely
There was also a transportation problem

VOL44
 In the APF company there is a library, computer room, but these are
most of the time closed, so we cannot refer or use these computer,
manuals and books in order to do our task success fully.
In the production area there to enter inside the production area it needs
to fulfill the safety materials such as shoes of the company, Gabon,
glove, mask and caps, but the company is not given to us completely.

CHAPTER 6

6. Conclusion and recommendation

6.1 Conclusion

This internship helps engineering students to get based on the theoretical concept. This means we
can develop practical skills, build up self confidence, we practical knowledge from the factory
could know working characteristics and developed relationship between workers at work place
and also it helps to know working principles of each operation of each plant generally it is good
opportunity for future performance of our selves.

From my observation I conclude that in the process of the company (Addis pharmaceutical factory) is
established before 20 years ago. then the potential of the product is verify from time to time. now days
Addispharmaceutical factory(APF)has after ,effective and good quality products .due to increase the
number of employers (man power) from 900-980 employers both permanent and temporarily worked in
24 hours.

Addis pharmaceutical factory also participate in team work for the cizen philosophy of Japan toincase
the potential product of the factory.

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6.2 Recommendation

I recommended that from my observation in a distillation plant ,the pure steam produced in a column is
goes to the upper part of the distillation plant(heat exchanger) then the feeds are cooling water ,pure steam
,in this heat exchanger shell and tube the cooling water flow in the tube side and the pure steam flow in
the shell side to produce a distillate water .then in APF the cooling water feed to the heat exchanger
simply discharges .it is not recycled for any application .

As an engineer the cooling water discharges in APF will be used for any utilities to produce high steam
economy (2-3) inch pumped to the utilities (dearator, pharmaceutical, tanker, distlationcolumn,etc..)To
minimize the losses of energies .means that it also decrease their cost in a company (APF) by recycling
the discharged (cooling water). Generally, this company needed highly scholar person such as power
biologist, chemist, pharmacist, engineers this can help to develop the quality and quantity of products. In
APF factory the old machines also replaced by new machines.

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6.3 Reference:-
COLLSON VOLUME -6
Internets
Manual of the machines
Direct and indirect interview

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