What are industrial buildings?

Any building structure used to store raw materials or for manufacturing

products of the industry is known as an industrial building. Industrial buildings
may be categorized as normal type industrial buildings and special type
industrial buildings. Normal types of industrial building are shed type buildings
with simple roof structures on open frames. These buildings are used for
workshop, warehouses etc. Special types of industrial buildings are steel mill
buildings used for manufacture of heavy machines, production of power etc. The
function of the industrial building dictates the degree of sophistication.
Aim
This seminar aims to plan the framework for industrial building for facilitating
the performance of industrial processes in terms of safety, environmental
quality and selection of envelope and structural system.

Objective
• To identify and select the typologies of industrial buildings.
• To understand codes and standards of India relevant for design of
industrial buildings and to identify the gaps.
• To identify the peculiarities of industrial buildings in facilitating the
performance of process.
• To create a framework for industrial building systems incorporating the
latest innovations and practices pertaining to issues of safety,
environmental quality and selection of envelope and structural system.

Typologies of industrial buildings

Various types of industrial buildings according to their
• Pharmaceutical industry
• Textile industry
• Paint industry
• Aerospace industry
• Food factory
• Automotive industry
• Leather industry
• Chemical industry
Safe practice for layout of an industrial plant as per codes
• Plant layout is concerned with the spatial arrangement of processing
equipment, storage vessels, workplace and warehouse.
• Good layout will ensure that the plant functions correctly, safely and
efficiently
• Plant layout will be based on factors like:
- Type and quantity of products to be produced
- Possible future expansion
- Operational convenience and accessibility
- Type of process and product control
- Type of building and building code requirements
- Guidelines related to health and safety
- Waste-disposable problems
- Space available and space requirement
- Auxiliary equipment
- Roads and railroad
• Zoning/Division criteria should be considered at the planning stage.
• HAZOP and risk assessment should be undertaken. With this analysis, the
best possible layout will emerge with major emphasis on safety.
• The site layout must accommodate the systems for handling the liquid
effluents, gaseous emissions, solid wastes, storm water and fire water.
• Storages and explosive storages should be segregated and laid out of plant
with fire-resistant construction to minimize fire and explosion hazards.
• Administration buildings should be near the main entrance.
• A minimum of two escape routes should be provided for any workspace,
with no workplace should be more than 12-45 m.
• Escape routes should be at least 0.7 m and preferably 1.2 m wide to allow
the passage of 40 persons per minute.
• Plants over 18 m high should be provided with dry riser mains and those
over 60 m high or of high risk should be equipped with wet riser mains.
• Roadways alongside the godowns should not be less than 5 m wide for
maneuvering of fire engines and the gates of the compound shall be at 4.5m
wide.
• Single storey storage buildings should be divided by separating walls into
compartments not exceeding 750 sq.m in floor area for fire safety.
• In no case should a storage building exceed 15 m in height. Buildings used
for storage of hazardous should be preferably of single storeyed structure.
• Separating walls should be provided between:
- A storage godown and a packing godown,
- A storage godown and a process building,
- A storage godown and boiler house or where naked flames are used,
- A non-hazardous storage godown and a hazardous or extra-hazardous
storage godown
• The minimum distance between any two facing godowns should be 12m.
• The passageways or aisles should be of sufficient width for the removal or
transfer of material and in general shall have a minimum width of 2·0 m and
2.5m where mechanical handling appliances are used.
• In any case, the maximum height of stacks should not exceed 12 m.
• All godowns should have an illumination of at least 50 lux.
• Clearly audible fire alarm shall be provided in all areas of the factory.
• All factories irrespective of their size and risk shall make suitable provision
for water supplies for fire fighting.
• The minimum requirement for a medium size factory of size about 1000 sq.
m. will be 1 800 l/min.

Functional Requirements (lighting and ventilation)

Good lighting enables workers in factory buildings to carry out their visual tasks
easily, quickly and without fatigue and to move about in work areas safely. It
also helps in cutting down wastage and rejects, in utilising floor space efficiently
and in boosting morale and thus in improving the overall performance of the
factory. The Factories Act provides that sufficient and suitable lighting either
natural or artificial or both shall be provided and maintained in every part of the
factory where workers are working or passing. Therefore, while speaking of
good lighting, we are talking of lighting to be not only sufficient, that is, the
quantity of illumination required at the workplaces and approaches, but also
suitable, that is the quality of lighting, and this brings in concepts like glare,
uniformity of distribution, brightness contrast, direction of lighting, and colour
and colour rendering. These concepts will be discus- sed later. First of all, we will
consider what is meant by the lighting to be sufficient, that is, the quantity of
light.
• Skylight for industrial buildings:-
Saw-tooth ( north-light ) fenestration
-Having glass area 20 per cent of floor area.
-Level of illumination varying between 9 and 6 percent daylight factor.
Monitor roof fenestration
-Having glass area 30 per cent of floor area.
-Level of illumination varying between 7 and 6 percent daylight factor.
Double-pitch inclined roof fenestration
-Having glass area 20 per cent of floor area.
-Level of illumination varying between 12 and 10 percent daylight factor.
• Ventilation rates of 30 to 60 m3/h per m2 of work area have been found to
give good results in many plants.
• Ventilation in buildings can be natural ventilation or mechanical ventilation
or both.
• Natural ventilation in a building is caused by cross and roofed ventilation.
• Mechanical ventilation in a building is caused by:
-Exhaust ventilation
-Positive ventilation
-Air-conditioning

Pharmaceutical industries -Background information

Pharmaceutical companies deal in generic or brand medications and medical
devices. Drug production is a specialized area. Drugs are chemical based and
chemicals too are sensitive to changes in weather conditions and radiation.
Pharmaceutical industry design therefore demands specialized knowledge, a
good understanding of how the industry is run and how best to ensure the
production of efficacious and quality products for the consumer.
Lighting, temperature, humidity and ventilation are of prime importance
throughout production, ultimately to ensure the quality of the product. The
main mode of contamination is through dust particles airborne or by contact.
Recent advancement in dust control systems used in plants includes the use of
extractors, air showers and airlocks to arrest dust particles at the source.
Pharmaceutical industries –Quality control
• Quality Control department should even have a different air supply from
production areas. Different types of chemicals are employed in this
department in their daily investigations.
• Provision should be made for the proper and the safe storage of waste
materials awaiting disposal. Toxic substances and flammable materials should
be stored in suitably designed, separate, enclosed.
• A good design for personnel should be such that workers enter the plant into
a changing area for their change routine guided by the design of the area so
that they enter actual production environment having successfully gone
through all the required change routine.
• Use of elbow pads on doors, dust extractors, airlocks and air showers are
effective in controlling contamination by personnel.
• Finishes to the interior, as much as possible should eliminate or minimize dust
collection and therefore contamination
• Temperature, humidity and ventilation should be appropriate and also
controlled and checked periodically. With latest technology these parameters
and others as lighting levels and security, can all be managed effectively under
an automated program known as Building Management Systems (BMS).
• Building Management System (BMS) is a computer software program,
usually configured in a hierarchical manner, to control, monitor and manage
all the equipment installed in the building.
• The advantages of Building Management Systems are numerous and include
the following:
- Reduction in clerical staff and management costs
 - Reduced risk of human error and increased reliability
- Provision of checks on work done
- Possible instant updating - Easy adaptation to alterations to building
- Incorporation of various management and administrative functions
Guidelines for pharmaceutical industry
Good Manufacturing Practices (GMP, also referred to as 'cGMP' or 'current
Good Manufacturing Practice') is the aspect of quality assurance that ensures
that medicinal products are consistently produced and controlled to the quality
standards appropriate to their intended use and as required by the product
specification. More than 100 countries have incorporated the WHO GMP
provisions into their national medicines laws, and many more countries have
adopted its provisions and approach in defining their own national GMP
requirements. The WHO GMP continues to be used as a basis for the WHO
Certification Scheme and prequalification of vaccines for procurement by UN
agencies. Schedule M is a part of Drug and Cosmetic act 1940. It is GMP for
pharmaceuticals that should be followed by pharmaceutical manufacturing
units in India.
Comparison of Guidelines of Indian GMP with WHO GMP
Comparing WHO GMP requirements with the schedule M, later has
incorporated additional requirements as per the Indian experience & legal
status and thus found to be more stringent than the WHO GMP Guidelines.

• On comparison of regulations of Indian GMP , Schedule M and WHO

good manufacturing practices for pharmaceutical products, it is noticed
 that all the principal requirements of WHO GMP text are taken and
incorporated into Indian GMP.
• However the Indian GMP requires updating of the GMP requirements as per
changing trends in GMP Globally. The chapters viz.
-Quality policy
-Quality Risk management
-Concepts of Hazards of Critical and Control Point (HACCP), etc. are to be
incorporated in the forthcoming amendments.
 CURRENT INNOVATIONS IN INDUSTRIES

The First Industrial Revolution started in the late 1700s. Factories went from
using hand tools and basic machines to rudimentary turbines powered by water
and steam.
While the First Industrial Revolution fueled the growth of industry and
transportation infrastructure, the Second Industrial Revolution witnessed the
expansion of electricity, petroleum and steel industries to satiate increases in
consumption.
The Third Industrial Revolution, also known as the Digital Revolution, started in
the late 1960s, when factories went from the use of mechanical and analog
electronic technology to digital electronics. Before the invention of the
Programmable Logic Controller (PLC), the manufacturing of automobiles was
predominately composed of relays, cam timers, drum sequencers and dedicated
closed-loop controllers.

THE FOURTH INDUSTRIAL REVOLUTION

Today, we are in the midst of the Fourth Industrial Revolution or Industry 4.0,
and just like the previous industrial revolutions, it is the result of the collision of
multiple new technologies. These include sensors and connectivity, integration
of cyber-physical systems, streaming and big data analytics tools, which are
beginning to transform manufacturing once again. This revolution will bring
incredible productivity gains, exponential in nature, in the manufacturing sector
just as the last three revolutions did.
• Industry 4.0 is a blend of advanced analytics, big data, robotics & automation,
artificial intelligence, internet of things (IoT) and process digitization across
the business value chain.
• Components of Industry 4.0 are:
-Internet of things (IoT)
-Robotics and automation
-Artificial intelligence
-Building Management Systems(BMS)

Internet of Things (IoT) in manufacturing

IoT or Internet of Things is a phrase coined to define a system of interrelated
physical devices embedded with sensors and network connectivity that enable
them to collect, process and exchange data. Machine-to-machine (M2M)
communication already existed, IoT goes beyond it by offering advanced
connectivity covering a variety of domains, protocols and applications.
Practically every industry that requires devices to collect data and transmit over
a network along with remote controlling can benefit by adopting IoT.
Industrial Internet of Things (IIOT) has now been coined to refer to the industrial
subset of IoT. The IoT devices enable rapid manufacturing, dynamic response to
demand fluctuations, and real time optimisation of supply chain networks and
manufacturing production.
Uses and benefits of Industrial Internet of Things (IIoT)
• Digital/connected factory:
IoT enabled machinery can transmit operational information to the partners like
original equipment manufacturers and to field engineers. This will enable
operation managers and factory head to remotely manage the factor units and
take advantage of process automation and optimization.
• Facility management
The use of IoT sensors in manufacturing equipment enables condition-based
maintenance alerts. There are many critical machine tools are designed to
function within certain temperature and vibration ranges.
• Production flow monitoring
IoT in manufacturing can enable the monitoring of production lines starting from
the refining process down to the packaging of final products. This complete
monitoring of process in near real time provides scope to recommend
adjustments in operations for better management of operational cost.
• Inventory management
IoT applications permit the monitoring of events across a supply chain. Using
these systems, the inventory is tracked and traced globally on line-item level and
the users are notified of any significant deviations from the plans.
• Plant safety and security
IoT combined big data analysis can improve the overall workers safety and
security in the plant. By monitoring the key performance Indicators (KPIs) of
health and safety, like the numbers of injuries an illeness rates, near misses, short
and long term absences, vehicles incidents and property damage or loss during
daily operations.
• Quality control
IoT sensors collect aggregate product data and other third party syndicated data
from various stages of a product cycle. This data relates to the composition of
raw materials used, temperature and working environment, wastes, the impact
of transportation etc. on the final products.
• Packaging Optimization
By using IoT sensors in products and/ or packaging, manufacturers can gain
insights into the usage patterns and handling of product from multiple
customers. Smart tracking mechanism can also trace product deterioration
during transit and impact of weather, road and other environment variables on
the product.
• Logistics and supply Chain Optimization
The Industrial IoT (IIoT) can provide access to real time supply chain information
by tracking materials, equipment, and products as they move through the supply
chain.