GLT (Green Leaf
# 1-3 are related to GLT department means this department needs to remove these
problem based on the data provided and there solution are also given
The function of
distributer in the GLT department is to distribute tobacco equally on the
search conveyors (there are 5 search conveyors), but the distribution was not
the same for 5-search conveyors i.e. the 1st , 2nd and 3rd
conveyors are overloaded while lasts are sometimes completely empty, means the
last two conveyors are wasting energy.
with 2-orientations for Distributer and 5-search conveyors
distribution of tobacco among 5-search conveyors is due to the same speed (RPM)
of Doffers in the Distributer.
By varying the
speeds (RPM) of the Doffers in the Distributer would solve the problem of
non-uniformity of tobacco on the 5-search conveyors.
There are 4-doffers
in the distributer, according to the data (input tobacco per kg and their
distribution (kg) on each conveyor, speed (RPM) of each doffer will be varied
according to the data provided) calculation will be done for each one of doffer
speed (RPM) to equal the amount of tobacco on each search conveyor to save the
energy and conveyor cost (Means make the conveyor fully operational).
During the conditioning process of Tobacco leaf in
the GLT department, the leaf is passed through conditioning cylinders (CC1,
CC2) and then from the CC2 (Conditioning Cylinder # 2) the leaf is fallen down
on the conveyor, but the small amount of lamina are stuck in the outlet of CC2.
And after every 5-10 minutes a labor comes and clear the outlet area.
The sticking of tobacco at the outlet of CC2
(Conditioning Cylinder # 2) is due to the narrow plates inside the cylinder and
the direction of motion of CC2, if
we change the direction of the narrow plates inside the CC2 the problem will be
After different processes of Tobacco leaf in the GLT
department, the leaf is divided into lamina and stem portion and both are
collected differently. At the stem collection stage, according to the
2-different sizes of stem, the 2-different sizes are classified through
Vibrator and collected into the sacks. The smaller size stem is directly
collected from the vibrator into the sack while the larger sizes are collected
from an uprising conveyor. I asked one technician why not collecting the stem
directly from the vibrator like the other one while using the uprising conveyor
(which costs ½ HP Motor and Conveyor Cost), he replied that the length of sack
is larger than the distance between the vibrator and earth, which in result the
stem is not collected properly, therefore an uprising conveyor is used.
Vibrator (Shaker type)
stage#1 (small size stem collection)
Stem transferring from outflow from uprising
Vibrator to uprising conveyor into
This flaw will be removed by digging
the earth only 1-2 square ft. this will equals the two lengths (length of sack and the distance between the vibrator
and earth) or take the
vibrator upwards for 1-2ft. in the result one motor of ½ HP and conveyor will be removed for ever
means energy consumption will be decreased.
Consumption Amount for ½ HP Motor will be saved:
½ HP = 373 W = 0.373 KW
For 10hours the energy consumption will be:
KWh ……………… (1)
suppose commercial unit Price;
1 KWh = 16 Rs.
in equation (1)
= 59.68 = 60 Rs.
amount is required for 10hr to operate ½ HP motor.
1-year it will be;
= (59.68) * (2) *(30) * (12)
This amount is
wasted every year to provide electricity to the motor. Data for conveyor isn’t
given else we would calculate for the conveyor as well. If the overall cost
(maintenance, electricity etc.) of both motor and conveyor is calculated it
will be high enough, through which an extra labor is hired, if the suggestion
is applied which is feasible also.
PPD (Primary Processing Department)
Problem # 4 is related
to PPD means this department needs to remove this problem based on the data but
unfortunately the data is not provided, and only based on the literature review
and asking from an Engineer of PTC.
The main issue of the PPD was the
Reduction of waste (dust in tobacco), i.e. how to reduce the waste and increase
the yield and Quality of final Tobacco.
Falling of tobacco from the vibrator
due to non-uniformity (bundles)
The bail-Slicer for lamina cutting were
installed before the vibrator into DCC (Direct Conditioning Cylinder) but not
functional (out of order) since a long time (2-3 years), due to which a lot of
tobacco are fallen down from the vibrator due to non-uniformity (bundles).
The flaw will be removed or decreased and
there will also be less degradation in lamina by making the Bail-Slicer
functional or using the Vilkrostrips before Vibrator means at the up-rising
conveyor. The will must decrease the amount of waste (dust in tobacco and the yield will be increased. This technique is used by PTC and PMI,
told by an Engineer of the PTC.