INDUSTRIAL TRAINING REPORT

ON

STUDENTS’ INDUSTRIAL WORK EXPERIENCE SCHEME(SIWES)

HELD AT

VITABIOTIC (NIGERIA) LIMITED

BY

ALESINLADU MARIAM OMOWUMI

MATRIC NO

(161199)

SUBMITTED TO

DEPARTMENT OF CHEMICAL ENGINEERING, OGBOMOSO.

FACULTY OF ENGINEERING AND TECHNOLOGY

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE

AWARD OF BACHELOR OF TECHNOLOGY (B. TECH.) IN THE
DEPARTMENT OF CHEMICAL ENGINEERING

JANUARY, 2022
i
 CERTIFICATION

This is to certify that this industrial training report was written and presented by ALESINLADU
MARIAM OMOWUMI with MATRIC 161199 of department of Chemical Engineering, faculty
of Engineering and Technology, LAUTECH, Ogbomosho, on the completion of the industrial
training held at VITABIOTICS (Nigeria) Limited.

……………………………… ……………………….

SUPERVISOR DATE

……………………………… …………………

DATE

ii
 DEDICATION

This work is dedicated to God almighty for his unwarranted guidance in my self-chosen tangent
in the circle of life and to my late parents Mr. & Mrs. Alesinladu. I pray Almighty Allah grant
them Aljannah firdaous.

iii
 ACKNOWLEDGEMENT

I thank Almighty Allah, the uncreated creative creature who creatively creates all things, for
sparing my life up to this moment to conjure this report.

My profound gratitude goes to my uncles, Alh. Abdu Waasiu Omololu and Alh. Quzeem
Omololu for their financial, parental, religious and moral support towards my progress in life.
Also, I would like to thank the technician manager in person of Mr. Saini for giving me the
opportunity to be able to visit the maintenance department.

I am very grateful to the maintenance department staffs – Mr. Ernest, maintenance supervisor,
Mr. Jimi, Mr. Nurudeen, Mr. Moses, and others. Thank you so much for your contribution during
my stay in the department.

I would also like to acknowledge the effort of Mrs Esther Ajibade (Head, quality control) Mr.
Tunde (Head, quality assurance), Mr. Sola Arobasalu, Mr. Tunde Afonja, Mr. Taiwo, Mr. Bayo,
Mr. Dayo, Mrs. Bola, Mrs. Ibukun, Mr. Ariyo, Mr. paul, Mr. Abdul Raufand other quality
control staffs, for their contribution towards my quality control and assurance knowledge of the
pharmaceutical industry.

I will be ungrateful if I fail to recognize the efforts of production staffs- pharm. Doyin, Pharm.
Ajiboye, Pharm. Akeredolu, pharm. Ibraheem, Mr. Adeyemi, and Mr. Christopher for sacrificed
their time to take me through the production processes.This report will be incomplete without
acknowledging the mentorship of Prof. Araromi D.O andMr. Ademola Toheeb, the sisterly
advice of miss. Azeezat Omololu, my super fantastic siblings (Khadijat and Ibraheem), and my
colleague – you all have been wonderful. Thank you so much.

iv
 TABLE OF CONTENT

CERTIFICATION ii

DEDICATION iii

TABLE OF CONTENT v

LIST OF FIGURES xi

LIST OF TABLES xiv

ABSTRACT xv

CHAPTER ONE 1

INTRODUCTION 1

1.1 Background of Students’ Industrial Work Experience Scheme (S.I.W.E.S) 1

1.1.1 The industrial training fund (ITF) 2

1.1.2 Supervising agencies (NUC, NBTE and NCCE) 2

1.1.3 Employers/ Industry 2

1.1.4 The Institution 2

1.2 Aims and Objectives of Students’ Industrial Work Experience Scheme 3

1.2 Logbook 4

1.4.1 Board of directors 4

1.4.2 Departments in the organization 5

1.4.3 Mission of the company 6

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 1.4.4 Motto of Vitabiotic 6

1.4.5 The company’s products and their active pharmaceutical ingredients (API) 6

1.4.6 Production Flowchart 8

1.5 Safety Equipment 9

1.6 Personal Protective Equipment (PPE) 9

CHAPTER TWO 10

LITERATURE REVIEW 10

2.1 Pharmaceutical company using Vitabiotic as a case study 10

2.1.1 Water Treatment Plant 10

2.1.1.1 Definition of some terms in water treatment 11

2.1.1.2 Ion exchange as a method of treating water 12

2.1.2 Effluent treatment 18

2.1.2.1 Chemicals use for sewage treatment 19

2.1.2.2 Aeration treatment 19

2.1.2.3 Stages of aeration treatment 19

2.1.2.4 Chemicals removed by aeration 20

2.1.3 Boiler 21

2.1.3.1 Working principle of a boiler 21

2.1.3.2 Revomax steam generator 21

2.1.3.3 Boiler blow down and blow down time 22

2.1.4 Pumps and Compressors 22

2.1.4.1 Pumps 22

2.1.4.2 Compressor 22

2.1.4.3 Differences between pumps and compressor 23

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 2.1.4.4 Types of Compressors 23

2.1.4.5 Types of Pumps 23

2.1.5 Valves 24

2.1.5.1 ARV or ARC valves 24

2.1.5.2 Ball valves 24

2.1.5.3 Breather valves 25

2.1.5.4 Butterfly valves 25

2.1.5.5 Gate valves 25

2.1.5.6 Globe valves 26

2.1.5.7 Plug valves 26

2.2 Production in a pharmaceutical company 26

2.2.1 Compounding 26

2.2.1.1 Equipment and facilities use in compounding 27

2.2.1.2 Some of ingredients use in compounding 29

2.2.2 Liquid packaging 30

2.2.2.1 Machines use in liquid packaging 30

2.2.2.2 Materials use in liquid packaging 32

2.2.3 Granulation 32

2.2.3.1 Types of granulation process 32

2.2.3.2 Composition of a tablet 33

2.2.3.3 Equipments used in granulation 33

2.2.3.4 Some ingredients use in granulation 36

2.2.4 Compression 36

2.2.4.1Tablet compression machine 37

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 2.2.4.2 Components of a tablet press 37

2.2.4.3 Types of tablet press 37

2.2.5 Tablet packaging 38

2.2.5.1 Types of tablet packaging 38

2.2.5.2 parts of a tablet blistering machine 38

2.3 Laboratory in the operation control department 39

2.3.1 Microbiology laboratory 39

2.3.1.1 Some microbiological definition 39

2.3.1.2 Equipments used in microbiological laboratory 40

2.3.2 Chemical laboratory 44

2.3.2.1 Some definitions in chemical laboratory 44

2.3.2.2 Some of the instruments used in chemical laboratory 45

2.3.3.2 Equipment used in physical laboratory 54

CHAPTER THREE 59

ACTUAL WORKDONE (METHODOLOGY) 59

3.1.1 Treatment of Water 59

3.1.2 Regeneration process 61

3.1.2.1 Preparation of acid for cation chamber 61

3.1.2.2 Preparation of caustic soda (NaOH) for anion chamber 61

3.1.2.3 Preparation of acid for mixed bed chamber 62

3.1.2.4 Preparation of caustic for mixed bed 62

3.1.2.5 Regeneration process on cation chamber 62

3.1.2.6 Regeneration process on anion chamber 62

3.1.2.7 Regeneration process on mixed bed 63

viii
 3.2 Effluent treatment plant (ETP) 63

3.2.1 Preparation of alum solution 63

3.2.2 Preparation of lime and chlorine solution 63

3.2.3 Effluent treatment process 64

3.3 Boiler 66

3.3.1 Starting a boiler 66

3.3.2 Stopping a boiler 67

3.3.3 Blow down a boiler 67

3.4 Production Department 68

3.4.1 Compounding 68

3.4.1.1 Weighing of raw material in a dispensing room 68

3.4.1.2 Sodium CMC paste formation 68

3.4.1.3 Sugar syrup formation 68

3.4.1.4 Addition of menthol, flavor and colorant and making up 69

3.4.2 Packaging of coflin expectorant 69

3.4.3 Granulation 69

3.4.3.1 Weighing of raw material 70

3.4.3.2 Sifting of raw materials 70

3.4.3.3 Dry mixing 70

3.4.3.4 Paste formation (Binding Agent) 70

3.4.3.5 Wet mixing 70

3.4.3.6 Drying 70

3.4.3.7 Dry milling 70

3.4.3.8 Lubrication and uniformity 70

ix
 3.4.4 Compression 70

3.4.5 Tablet packaging 71

3.5 Quality control laboratory 72

3.5.1 Microbiology laboratory 72

3.5.1.1 Calibration of analytical weighing balance 72

3.5.1.2 Dry sterilization 72

3.5.1.3 Preparation of media 73

3.5.1.5 Microbial analysis of samples 73

3.5.2 Chemical laboratory 75

3.5.2.1 Chemical analysis of raw material (Paracetamol plain) 75

3.5.2.2 Chemical analysis of water samples from purified water plant 77

3.5.2.4 Dissolution rate test for Asmanol tablet 81

3.5.2.5 Preparation of reagent (0.1M NaOH) 83

3.5.3 Physical laboratory (in process) 83

3.5.3.2 Physical Analysis of Tablet (compression) 84

3.5.3.3 Physical analysis of Syrup (Coflin expectorant L51221) 85

3.6 Raw Material Warehouse 85

3.7 Packaging material warehouse 86

3.8 Finished Goods Warehouse 86

CHAPTER FOUR 87

EXPERIENCE GAINED AND CHALLENGES ENCOUNTERED 87

4.1 Experience Gained 87

4.1.1 Personal skills 87

4.1.2 Cognitive skills 87

x
 4.1.3 Intellectual skills 88

4.1.3.1 Theoretical experience 88

4.1.3.2 Practical Experience 90

4.2 Challenges Encountered 91

CHAPTER FIVE 93

CONCLUSION AND RECOMMENDATIONS 93

5.1 Conclusion 93

5.2 Recommendations 93

5.2.1 SIWES 93

5.2.2 VITABIOTIC (Nigeria) Limited 94

5.2.3 University 94

REFERENCES 95

xi
 LIST OF FIGURES

Figure Title Page

1.1 Vitabiotic production flow chart 7

1.2 Personal protective equipment (PPE) 9

1.3 Personal protective equipment (PPE) used in quality control department 9

2.1 Pressure sand filter bed and pressure sand 12

2.2 Activated carbon filter bed and activated carbon 13

2.3 Anions and cations 14

2.4 Mixed bed 14

2.5 Micron filter and ultraviolet system 15

2.6 Reverse osmosis plant 17

2.7 Sludge beds 17

xii
2.8 Pressure filtration tank and underground filtration tanks 19

2.9 Revomax steam generator 20

2.10 ARV or ARC valves 23

2.11 Ball valves 23

2.12 Breather valves 25

2.13 Butterfly valves 25

2.14 Gate valves and globe valves 25

2.15 Homogenizer 27

2.16 Fork lift 27

2.17 Suspension tank 28

xi

2.18 CMC Tank 28

2.19 Storage tank 29

2.20 Air jet bottle cleaning machine 30

2.21 Filling and capping machine 31

2.22 Automated shrink wrapping machine 31

2.23 Fluidized bed dryers 33

2.24 Rapid mixer granulator 33

2.25 Multimill machine 34

2.26 Paste kettle 34

2.27 Octagonal bender 35

2.28 Multi station press machine 37

xiii
2.29 Autoclave 39

2.30 Incubator 40

2.31 Colony counter 40

2.32 Analytical weighing balance 41

2.33 Laminar flow hood 41

2.34 Microscope 42

2.35 Centrifuge machine 43

2.36 Dissolution test machine 44

2.37 Sonicator 44

2.38 Polarimeter 45

2.39 Spectrophotometer and HPLC machines 46

2.40 Water bath and fume cupboard 46

2.41 Furnace and flask shaker 47

2.42 Oven and distillation column 48

2.43 Melting point test apparatus and glass wares dryer 48

2.44 Test tubes, measuring cylinder and beaker 49

2.45 Separating funnel 49

2.46 Hardness test apparatus 51

2.47 Disintegration test apparatus machine 51

2.48 Leak test apparatus 52

2.49 Friability test apparatus 52

2.50 Moisture content apparatus 53

xiv
2.51 Viscometer 53

3.1 Backwashing cation bed 54

3.2 Purified water treatment plant 54

3.3 Stirring of lime and chlorine solution 58

3.4 Effluent treatment plant 59

3.5 Workflow chart of liquid packaging 62

3.6 Preparation of media and analyzing of water samples 66

3.7 Conducting dissolution rate test of asmanol 72

LIST OF TABLES

1.1 Tablet and caplet 6

1.2 Syrups and suspensions 7

3.1 % dissolution test of samples during dissolution test of asmanol 72

xv
 ABSTRACT

Students’ Industrial Work Experience Scheme (SIWES) is a skill training programme which
forms part of the approved minimum academics standards in the various degree programmes
offered in Nigerian universities.The Industry Training Fund (which was itself established in 1971
by Degree 47) initiated the SIWES in 1973.

My SIWES was undertaken at Vitabiotic (Nigeria) limited. It was located at no 35, Mobolaji
Johnson Avenue, Oregun industrial estate, Ikeja, Lagos,Vitabiotic is a subsidiary of the Meyer
organics PVT, limited, one of the largest pharmaceutical products producers in India. Vitabiotic
was founded in 1975 and has evolved from a young pioneer into an established international
drugs and other pharmaceutical products.

This report contains my 6-month SIWES industrial training at Vitabiotic. It includes the
experience gained from different departments such as: Production, Maintenance, Warehouse
(raw material, packaging material and finished goods) and Quality laboratory.

xvi
 CHAPTER ONE

INTRODUCTION
1.1 Background of Students’ Industrial Work Experience Scheme (S.I.W.E.S)
The Students’ Industrial Work Experience Scheme (S.I.W.E.S) is a vital aspect of the students’
degree program whereby the students are allowed to undergo some practical training outside
their academic environment through attachment to various establishments to acquire some
practical knowledge.

It was established in 1973 by Nigeria graduates of tertiary institutions to solve the problems of
lack of adequate practical skills preparatory for employment in industries and to help the
Industrial Training Fund enabling Decree No. 47 of October 8, 1971. This aims at transforming
the nation’s economy from its total dependence on foreign expertise to a state of self-reliance,
through the training and development of Nigerians that would be competent to perform the
specialized skills required to manage essential sectors of the National Economy.

Participation in Students’ Industrial Work Experience Scheme (SIWES) has become a necessary
pre-condition for the award of diploma and degree certificate in specified discipline especially
engineering or technologically related courses in most higher learning institution in the country,
in accordance with the education policy of the government.

The Industrial Training (IT) which spans for a period of six months is undertaken by Four
Hundred level (400L) students in Ladoke Akintola University of Technology during the second
semester of the academic session. The SIWES is therefore a pre - requisite for the award of the
degree of Bachelor of technology.

This is to enable student to practically apply all the theoretical knowledge gained in the
classrooms to real life situations and to expose them to what is obtainable in industries,
companies, and establishments, thereby, catching a wider practical view of their discipline or
profession.

1
1.1.1 The industrial training fund (ITF)

Thisis solely responsible in the direct management and smooth running of the scheme. It also
supervises students undergoing training through the various ITF area offices. They examine and
sign the students’logbooks and the necessary ITF forms. Also, they supervise the payments of
allowances to students and institution-based supervisors.

1.1.2 Supervising agencies (NUC, NBTE and NCCE)

NUC - Nigerian UniversityCommission, NBTE- National Board for Technical Education and
NCCE- National Council for Colleges of Education. Their role is to select courses eligible for the
participation of SIWES, approval of master and placement lists etc.

1.1.3 Employers/ Industry

The following are the roles of employers/industry:

1. Accepting of students and deploying them to divisions relevant to their courses of study.

2. Appointing of industry-based supervisors to monitor the students.

3. Allow students to enjoy benefits such as allowance, meals, health care, transportation
which are given to staffs for the period of their attachment.

4. Check and sign their logbooks and other necessary forms and allow theinstitution- based
supervisor to visit the students.

1.1.4 The Institution

Their institution compiles and submits the master and placement list to the ITF. Their roles are:

1. Ensure that students’ placements are relevant to their courses of study

2. Prepare students for Industrial training through the organization of orientation programs

3. Appoint supervisors to students in their various places of attachment

2
 4. Beneficiaries of SIWES are undergraduate students in science, engineering, and
technology disciplines with duration of four month for polytechnic and colleges of
education and six months for universities

1.2 Aims and Objectives of Students’ Industrial Work Experience Scheme

Highlighted below are the aims and objectives of the Students’ Industrial Work Experience
Scheme program:

1. To expose the students to industry-based skills necessary for a smooth transition from
classroom to the world of work.

2. To expose the students to the methods of work not taught in school and to enhance
possible job placement for student later in the future.

3. It provides students with the opportunity of being familiarized and exposed to the use
and handling of the relevant machineries and equipment which are not commonly
found in their school system.

4. To provide students with the opportunity to apply their theoretical knowledge in

5. the outside world.

6. To impact practical method of performing professional functions to undergraduate

students of the nations’ tertiary institutions.

7. To expose the students to the type of interpersonal relationship skills expected within
the selected industry and to boost the students’ information technology morale
required for the profession.

8. To develop the skills of report writing in students and to improve the students’
interest and competence in the chosen carrier.

9. To enlighten students on how Companies can be run smoothly in correlation with

some available raw materials and manpower around such environment.

3
 10. To also make students discover the unknown potentials bestow on them when in
school in correlation with their practical knowledge.

11. And finally, to promote the technological advancement and general development of
manpower and labor force in Nigeria.

1.2 Logbook
A training logbook is designed to assist the students to keep accurate records of his/her training
during Students’ Industrial Work Experience Scheme (SIWES) and to give a brief presentation
of the projects executed by the company which include observations, comments and
recommendations to both the company and the University on ways of marrying the two
institutions together to obtain the desire result.

1.4 Brief history of Vitabiotics Nigeria limited

Vitabiotics Nigeria Ltd was established in a rented apartment in 1975 at Oduyemi street off
Anifowose Ikeja and went into production in the year 1977 as one of the pioneers in the
manufacture of pharmaceutical products in Nigeria and was later moved to 35, Mobolaji Johnson
Avenue, in Oregun Industrial Estate, Ikeja, Lagos, Nigeria in 1995. The company is engaged in
100% production, from raw materials to finished products.Vitabiotics Nigeria Ltd is a brainchild
of Omega Meyer Limited, New jersey which is composed of world-renowned scientists like Dr.
K.T. Lalvani,Prof. A.B. Beckett and Dr. Meyer. Vitabiotics has resources of international
research and development that complement her operations in Nigeria. New products formulation
is a continuous process. It has established its own comprehensive engineering tool room facility
in Dopemu for repairing the won out spare parts and offers this same service to other
services.The company engages in manufacturing and marketing of different form of oral drugs.
The oral dosage drugs include solids (caplet,tablet) and liquid oral (syrups and suspensions).The
company is engaged in manufacturing of pharmaceutical products licensed by the Pharmacy
council of Nigeria (PCN) and National Agency for Food and Drugs Administration and Control
(NAFDAC).

4
1.4.1 Board of directors

1. Managing Director: Mr. Ramesh

2. Chief Pharmacist: Mr. Otiko

3. Quality Operation Manager: Mrs. Aladejana

4. Production Manager: Mr. Adeleke

5. Chief Accountant: Mr. Odeniyi

6. Sales Manager: Mr. Shina Akinyoade

7. Operation Manager: Mr. Patil

8. Technical Manager: Mr. Saini

1.4.2 Departments in the organization

2. Administrative Department

3. Manufacturing Plants

4. Raw material Stores

5. Quality Operations

6. Maintenance

1. Administrative department

This department is in control of all the administrative works in the company and comprises of
four sections
1. Auditing Section
2. Sales Section
3. Marketing section
4. Account section

5
2. Manufacturing plants
The department is where production of all pharmaceutical’s products Start and Ends. It
comprises of various section such as:
1. Raw Materials

2. Production halls

3. Packaging materials stores

4. Finished Goods Stores

3. Quality operations:
This department oversees all the activities and tasks needed to maintain desire level of excellent
in the product of all Pharmaceutical Products. It is comprising of two sections:
1. Quality Control

2. Quality Assurance

4. Maintenance department:
This is the engineering Department comprises of Chemical, Mechanical and Electrical section.
They deal with maintenance and servicing or repair of any faulty machine and equipment and
treatment of water for pharmaceutical production and that of sewage to prevent environmental
pollution.

1.4.3 Mission of the company

“Improving the health and well –being of people across the globe”

1.4.4 Motto of Vitabiotic

“Science of healthy living”

1.4.5 The company’s products and their active pharmaceutical ingredients (API)

Table 1.1:Tablet and caplet

Tablet and caplet API
6
 Vitamin B Complex 1. Vitamin B1
2. Vitamin B2
3. Vitamin B6 HCL
4. Nicotinamide
Metrozol Metronidazole
Pentax Extra Caplets 1. Paracetamol
2. Caffeine
3. Ibuprofen
Folic Acid B12 1. Folic Acid
2. Vitamin B12
Salbutamol Salbutamol Sulphate
Combiworom Pyrantel Pamoate
Cotrox 1. Sulphamethoxazole
2. Trimethoprim

Table 1.2 Syrups and suspensions

7
 API
Syrup and suspension

Coflin Linctus 1. Ammonium Chloride

2. Sodium Citrate

3. Ephedrine HCl

4. Chlopheniramine Maleate

Coflin Expectorant 1. Diphemhydramine HCl

2. Ammonium Chloride

3. Sodium Citrate

Maxiquine Syrup 1. Chloroquine Phosphate

2. Promethazine HCl

3. Paracetamol

Calcimax 1.calcium carbonate

1.4.6 Production Flowchart

RAW MATERIALS
QUARANTINE
Q. C SAMPLING &
ANALYSIS
DISPENSING
QUARANTINE

GRANULATION AND
Q. C SAMPLING & COMPOUNDING
ANALYSIS
QUARANTINE Q. C SAMPLING &
ANALYSIS
COMPRESSIO QUARANTINE
N &
Q. C SAMPLING
ANALYSIS
QUARANTINE
8
PACKAGING

FINISHED GOODS
 QUARANTINE

SALES

Figure 1.1: Vitabiotic production flow chart

1.5 Safety Equipment

Safety can be described as the condition of being protected from or unlikely to cause danger,
risk, or injury. It can be defined as the elimination or control of recognized hazard. Safety is
accident prevention.

1.6 Personal Protective Equipment (PPE)

Personal protective equipment (as shown in Figure 1.2) refers to wearable equipment that
protects the wearer's body from injuries, illness, and a variety of heat-borne, fire-borne,
electrical, physical, chemical-borne, and airborne particulate matter.Personal protective
equipment includes protective clothing, goggles, industrial footwear, boots, face masks, hard
hats, ear plugs, respirators, gloves, safety harnesses, and helmets. Personal protective equipment
also finds application across various industries including construction & manufacturing, oil and
gas, chemicals, healthcare, food industry, pharmaceuticals, transportation, and others. Personal
protective equipment uses in maintenance department of Vitabiotic include:

i. Goggles for eye protection.

ii. Helmet for head protection.

iii. Ear plugs for ear protection.

iv. Face mask for face protection.

v. Rubber gloves for hand protection.

9
vi. Safety boots for foot protection.

vii. Overalls for body protection.

Figure 1.2 Personal Protective Equipment (PPE) used in Quality Control Department

10
 CHAPTER TWO

LITERATURE REVIEW

2.1 Pharmaceutical company using Vitabiotic as a case study

In the pharmaceutical company, there are various departments in Vitabiotic (as listed in chapter
one). Words encountered in each department will be briefly discussed

2.1.1 WaterTreatment Plant

Water treatment plant is the design plant that shows how water is being treated to make it useful
forproduction. Water Treatment is the process that improves the quality of water to make it
appropriate for aspecific end-use. The end- use may be drinking water,industrial water
supply,water recreation irrigation river flow maintenance or many other uses.

2.1.1.1 Definition of some terms in water treatment

Coagulation is a process used to neutralize charges and forma gelatinous mass to trap particles
thus forming a mass large enough to settle or be trapped in the filter, it involves adding iron or
aluminum salts.

Flocculation is the separation of a solution, commonly the removal of sediment from a fluid.
The difference between coagulation and flocculation is that coagulation is achemical process
while flocculation is a physical process.

Sedimentation is a physical water treatment process using gravity to remove the suspended
solids from water.

Filtrationis the process of removing particles or suspended impurities in water through a filter.

PH and Conductivity

PH means potential of hydrogen and it is effectively a measure of the concentration of hydrogen

ions i.e. protons in a substance. Conductivity is a measure of the ability of water to pass an
electrical current because dissolved salts and other inorganic chemicals conduct electrical
current. Conductivity is important in ion exchange water treatment because it provides a measure
11
of what dissolved in water a higher conductivity value indicates that there are more chemicals
dissolved in the water.

Regeneration

Regeneration is a process that takes ion exchange resin beads that are exhausted and removes
ions that have been picked up during the in- service cycle so the resin can continue to be used.
Regeneration of an ion exchange resin bed involves multiple processes including;

1. Back wash

2. Chemical injection

3. Slow rinse

4. Fastrinse

Backwash is done by running water backward through the bottom of the bed

Chemical injection is the addition of regenerate chemical such as hydrochloric acid, caustic to
the bed

Injection of an acid

Acid is injected into the cation and mixed bed during regeneration, it is introduced in an up flow
regenerant header. It lowers the PH value of the water to around 7, to eliminate the soda taste and
improve the effectiveness

Injection of caustic soda

Caustic soda is injected into the anion and mixed bed during regeneration. It is introduced in a
down flow regenerant header. It raises the PH value of the water to a level that minimizes the
corrosion by increasing it soda taste.

Regeneration interval

12
 Regeneration is done where there is an excessive rise in conductivity, and this shows that there
are dissolved chemicals in the water.

Back washing is the way of cleaning a drinking water system which is a means of reversing the
flow and increasing the velocity at which water pass through the filter.

Rising is done after backwashing to allow water to flow back down through the sand to flush out
any remaining dirt and debris from the filter and piping. Rising is important after backwashing
because the backwash lifts and flushes the sand, the rinse reseats the sand into original position
for optimum filtration.

2.1.1.2 Ion exchange as a method of treating water

Ion exchange is a water treatment method where one or more undesirable ionic contaminants are
removed from water by exchange with another non objectionable or less objectionable ionic
substance. It involves removal of calcium, magnesium, and certain other metal cations in the
hard water.

Ion exchange resin or polymer is a resin that acts as a medium for ion exchange. It is an insoluble
matrix normally in the form of small micro beads, usually white or yellowish. It is of two types
which are the cations and anion.

Stages of ion exchange

 Pressure sand filter

Sand filtration is used for the removal of suspended matter as well as floating and sinkable
particles. The water flows vertically through a fine bed of sand or gravel,particles are removedby
way of absorption or physical encapsulation.

In a pressure sand filter, water is gone throughmultilayer of filter media comprising reviewed
sand,rocks, and rock layers.The contaminants in the water are caught in the media and the sifted
water goes into the release manifold at the base of the tanks.

13
 Figure 2.1: Pressure Sand Filter Bed and Pressure sand

 Activated carbon filter

Activated carbon filter removes certainorganics such as unwanted taste and odours and
micropollutants from water and gases.

Activated carbon filter work by adsorping,in which pollutants in the fluid to be treated
are trapped inside the pore structure of a carbon substrate . the substrate is made of many carbon
granules each of which is itself highly porous. As a result, the substrat has a large surface area
within which contaminants can be trapped.

14
Figure 2.2: Activated Carbon Filter Bed and Activated Carbon

 Cations

cations resins are positive charged resin which attract positive ions such as calcium,
magnesium, cations release hydrogen ions or other positive charges.Cation resin
formular : R-H

R-H + M+ = R-M + H+

 Anionsresins are negative charged resin which attract negatives ions (cations) such as
arsenic, nitrate, bicarbonate (HCO), carbonate (co), sulphate (SO), hydroxide (OH) and
replace them with chloride.

Anion exchange resin formular –NR4+OH- + HCL = -NR4+CL- + H2O

15
 Figure 2.3: Anions and Cations

Mixedbedion exchange resins are mainly used in water purification for polishing process water
to achieve demineralized water quality. As the name states consists of strong acid cation
exchange and strong base anion exchange

During the cycle, water enters the unit through the inlet distributor at the top of the vessel and is
evenly distributed across the resin bed. As the water flows through the resin bed, its ionic
contaminants are exchanged for H and OH ions on the resin beds thus removes the ionic
contaminants from the water. The treated water then passes through the false bottom under drain
strainers to the outlet piping at the bottom of the unit.

16
 Figure 2.4 Mixed Bed

 Micron filter

Micron filter are filters which filter the water to designated micron rating for example 5-micron

filter. 5 micron-filters are the most popular and it is installed in an upward stream of ion
exchange columns (mixed bed) to remove particles and downstream to remove the resin that
could pass through under drains and clog a pure water system.

Figure 2.5: Micron filter and Ultraviolet System

 Ultraviolentsystem

Ultraviolent disinfects water containing bacteria and viruses and can be effective against
protozoa like Giardia lamblia cysts or Cryptosporidium oocysts. It penetrates harmful pathogens
in the water and destroys them by attacking their genetic core (DNA).

2.1.1.3 Reverse osmosis water treatment

Reverse osmosis is a water purification process that uses a semi-permeable membrane

(synthetic lining) to filter out unwanted molecules and large particles such as contaminants and
sediments like chlorine, salt, and dirt from drinking water. It gets water clean down to a
17
molecular level, leaving only pure water behind. The fresh water produced is called the
permeate. The concentrated water left over is called the waste or brine.

Semi permeable membrane has small pores that block contaminants but allow water molecules
to flow through. In osmosis, water becomes more concentrated as it passes through the
membrane to obtain equilibrium on both sides. Reverse osmosis, however, blocks contaminants
from entering the less concentrated side of the membrane.

How does a reverse osmosis system work?

A reverse osmosis system removes sediment and chlorine from water with a pre-filter before it
forces water through a semi permeable membrane to remove dissolved solids. After water exists
theRO membrane, it passes through a post-filter to polish the drinking water before it enters a
dedicated faucet. Reverse osmosis systems have various stages depending on their number of
pre-filters and post-filters. A reverse osmosis system removes dissolved solids like arsenic and
fluoride through the RO membrane. An RO system also includes sediment and carbon filtration
for a broad spectrum of reduction. The carbon filters in an RO system remove chlorine and bad
taste and odors, and the sediment filter removes dirt and debris.

Stages of RO systems

The RO membrane is the focal point of a reverse osmosis system, but an RO system also
includes other types of filtrations. RO systems are made up of 3, 4 or 5 stages of filtration. The
filter is called either pre-filters or post-filters depending on whether water passes through them
before or after it passes through the membrane.

Each type of system contains one or more of the following filters:

1. Sediment filter: reduces particles like dirt, dust, and rust.

2. Carbon filter: Reduces volatile organic compounds (VOC s), chlorine, and other
contaminants that give water a bad taste or odor.
3. Semi-permeable membrane: Removes up to 98% of total dissolved solids (TDS)

After filtration, water flows to the storage tank. Where it is held until needed. A reverse osmosis
system continues to filter water until the storage tank is full and thenshuts off.
18
1. Ultraviolet: this kills the microns present in the water
2. Dosage injector: this pumped the dosage like chlorine into the water.

Figure 2.6: Reverse osmosis Plant

2.1.2 Effluent treatment

Effluent treatment is also known as sewage treatment and it is a type of waste treatment which
aims to remove contaminants from sewage to produce an effluent that is suitable to dischargeto
the surrounding environment or intended re use application,thereby preventing water pollution
from the raw sewage discharge.

Sludge is the residue that accumulates a sewage treatment plants. It can also be refered to as
solid, semisolid or slurry residual material that is produced as a bye-product of wastewater
treatment processes.

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Figure 2.6 Sludge beds

2.1.2.1 Chemicals use for sewage treatment

1. Chlorine is a powerful oxidant that will kill or inactivate most pathogenic organism that are
harmful to bacteria,viruses, and othermicrobes in water andto prevent the spread of water
borne diseases such as cholera.
2. Limeis used to increase the alkalinity of the wastewater. Lime controls the PH,
neutralization of acidic wastewater. When alum and ferric chloride are used to coagulate
suspended matter,lime is added to counteract the low PH induced by these acidic salts and to
provide the necessary alkalinity for efficient nitrogen removal.
3. Alum sulfate is most widely used in municipal drinking water and wastewater treatment, it
removesturbid, suspended solids,total organic carbon (TOC) and biochemical oxygen
demand (BOD). Alum is a coagulant and it comprised of positively charged (AL) molecule
that when added to the water and mixed accomplish this charge neutralization.

2.1.2.2 Aeration treatment

Aeration treatment is the treatment using aeration tank, aerating brings water air in close
contact to remove dissolved gases such as carbondioixide and oxidizes in the effluent. It brings
water and air in contact by exposing drops or thin sheets of water to the air or by introducing
small bubbles of air and by letting them rise through the water. The scrubbing process cause by

20
the turbulence of aeration physically removed dissolved gases from the solution and allows them
to escape into the surrounding.

2.1.2.3 Stages of aeration treatment

Thestages of aeration treatment involve;

1. Waste holding tank: this is used to stored wastewater from the factory
2. Aeration tank: this is a large rectangular tank in which the wastewater is put into which air is
pumped for the treatment of effluent by a blower.
3. Air blower: this supply air into the waste in the tank to mix the waste and chemicals
together.
4. Dosage tank: this is used for preparation and storage of chemicals used in the treatment.
5. Sludge bed: is the most widely used method for sludge dewatering. Sludge drying involves
natural ways of drying by mechanical ways of removing water content
6. Filtration bed: this is used to store the filtrate from the sludge bed
7. Pressure filter: this filters the filtrate and removes all suspended particles.

21
Figure 2.8: Pressure Filtration Tank and Underground Filtration Tanks

2.1.2.4 Chemicals removed by aeration

1. Volatile organic chemicals such as benzene
2. Ammonia
3. Chlorine
4. Carbondioxide
5. Hydrogen sulfide
6. Methane
7. Iron and manganese

2.1.3 Boiler

A boiler also known as a steam boiler is a type of heat exchange system where water is heated to
its’ boiling point via combustion of a fuel blown through a tube submerged in water. The heat
produced in this system is then rejected into the system as steam. This steam flows through pipe
systems to the equipment that is being heated, whether it be hot water coils in air handling units,
or other water heating equipment.The steam boiler for use in various processes or heating
applications such as cooking, water heating, or boiler-based power generation. It is essential part
of thermal power plants.

Diesel oil boiler has a widely usage,it can be use in pharmaceutical industry, chemical
industry,light,textile,building materials,farming,food, and beverages.

2.1.3.1 Working principle of a boiler

A steam boiler operates through a combustion reaction between fuel and air, which ignites a
flame into tubes that submerged in water. The heat from this combustion is then transferred from
the tube to the water in which the tubes are submerged. The water is then evaporated into steam.
The steam is then taken into piping to be used in the specific heating application.

After the heat from the steam is taken and transferred into the process needing heat, the steam
condenses back into water as condensate. This can be collected and returned to the boiler to be

22
used through a condensate return line. This saves the amount of needed make-up water, as well
as needed chemicals since the condensate has evaporated away dissolved solids.

2.1.3.2 Revomax steam generator

Revomaxis a versatile, fully automatic, instant steam generating range of boilers designed for
safe and reliable operations. Easy to install and commission, these time-tested boilers require
very little maintenance. It features a specially designed furnace and combustion system to burn
difficult heavy oils and it flexibility between light and heavy oil help respond to fluctuating fuel
prices.

Figure 2.9: Revomax Steam Generator

2.1.3.3 Boiler blow down and blow down time

Blow down is the removal of water from a boiler. Its purpose is to control boiler water
parameters within prescribed limits to minimize scale, corrosion, carryover, and other specific
problem.

Blow down time gives an indication of the extent to which the coil tubes are scaled up
and should be measured when boiler is hot i.e., has run for at least 20-30 minutes.

23
2.1.4 Pumps and Compressors

2.1.4.1 Pumps
Moving fluids plays a major role in the process of a plant. Liquid can only move onits
own power, and then only from top to bottom or from a high pressure to a lower pressure system.
This means that energy to the liquid must be added, to moving the liquid from a low to a higher
level. To add the required energy to liquids, pumps are used. There are many different definitions
of the name PUMP, but this is best described as:“A machine used for the purpose of transferring
quantities of fluids and or gases from oneplace to another”.

2.1.4.2 Compressor
Compressor is a device for increasing the pressure of a gas by mechanically decreasing its
volume. It is the most frequently compressed gas but natural gas, oxygen, nitrogen, and other
industrially important gases are also compressed. The three general types of compressors are
positive displacement, centrifugal, and axial.

2.1.4.3 Differences between pumps and compressor

Moving hydraulic fluid through a system requires either a pump or compressor. Both achieve
this goal, but through different operating methods. Pumps can move liquids or gases.
Compressors typically only move gas due to its natural ability to be compressed. Pumps and
compressors both have very high pressure rises.

2.1.4.4 Types of Compressors

There are different types of compressors that move air into a chamber. Most compressors are
positive-displacement compressors in which, by forcing air into the chamber, volume
isdecreased to compress the air. Reciprocating or piston-type air compressors pump air by
using pistons and one-way valves to guide air into the cylinder.

2.1.4.5 Types of Pumps

Two basic types classify pumps: Positive displacement pumps and Centrifugal pumps.

a. Positive displacement pumps: move fluid by moving a fixed amount of it and forcing
thefixed amount into a discharge pipe. They can produce the same flow at a given speed
24
regardless of the discharge pressure making them constant flow machines. Positive displacement
pumps can be classified as reciprocating pumps (piston, plunger, and diaphragm), power pumps,
steam pumps, and rotary pumps (gear, lobe, screw, and vane, regenerative or peripheral, and
progressive cavity).

b. Reciprocating pumps: consist of a cylinder with a plunger in which the retract strokecauses
suction valves to open drawing fluid into the cylinder. The forward stroke push the liquid into
the discharge valve.

i. Diaphragm pumps: pressurize the hydraulic oil via the plunger, which flexes the diaphragm
in the pumping cylinder. Typically, diaphragm pumps are for hazardous and toxic fluids,
especially during chemical injection

ii. Centrifugal pump: converts input power to kinetic energy by accelerating liquid in
animpeller. Centrifugal pumps are constant head machines. A volute pump is the most common
centrifugal pump. Here, the fluid enters the pump through the eye of the impeller rotating athigh
speed. As the fluid accelerates radially outward from the pump chasing, a vacuum is created at
the impeller’s eye. This vacuum creates more suction and draws in more fluid into the pump. The
maximum head is determined by the outside diameter of the pump impeller and the rotating shaft
speed.

2.1.5 Valves

Valves are essential parts of any piping system used to control the flow and pressure of
contents, whether that is oil, gas, liquid, or vapors. Here is our list of 10 of the most used oil and
gas valves in the industry and the reasons for their existence, with details. These are some valves
but used in IFS:

2.1.5.1 ARV or ARC valves

Acronyms for 'Automatic Recirculation Valve' and 'AutomaticRecirculation Control'
these valves are multi-functional but have the primary purpose of ensuring that a pre-determined
minimum flow is assured through centrifugal pump always.

25
Figure 2.10: ARV or ARC valves Figure 2.11: Ball valves

2.1.5.2 Ball valves

A ball valve is a quarter-turn rotational motion valve that used a ball-shaped disk to control a
flow. If the valve is opened, the holes in the ball stay in line with the body inlet allowing
contents to pass. The combination of materials means the ball valve can operate at temperatures
as low as -200 deg C and as high as 500 deg C. Mainly used for air, gases and liquids, ball valves
are quick to turn on and off and have a tight sealing with low torque.

2.1.5.3 Breather valves

It is also known as vacuum relief valves as a special type of relief valve designed for tank
protection. The valves prevent the build-up of excessive pressure or vacuum which can
unbalance the system or damage the storage vessel. Pressure and vacuum protection levels are
usually controlled with weighted pallets and can be combined to meet the required settings.

2.1.5.4 Butterfly valves

Quarter-turn rotational motion valves, the butterfly valves are used to stop, start and regulate
flow. Easy and fast to open, the valve usually comes equipped with a gearbox where the hand
wheel by gear is connected to the stem. This simplifies the operation of the valve, but at the
expense of speed. These valves must also be installed a minimum of 6 pipe diameters away from
other line elements. As well as being lightweight, and quick to use, the butterfly valves are
available in large sizes and can cope with low-pressure drop and high-pressure recovery.

26
Figure 2.12: Breather valves Figure 2.13: Butterfly valve

2.1.5.5 Gate valves

Gate valves are primarily designed to start or stop a flow when a straight-line flow of fluid and
minimum flow restriction is needed. In service, these valves are pretty much kept either fully
open, or fully closed. When turned open, the disc of the gate is completely removed allowing
contents to pass. Although this gives the valve good shut-off properties and isbidirectional, they
cannot be quickly opened or closed and sensitive to vibration when open.

Figure 2.14: Gate valves& Globe valves

2.1.5.6 Globe valves

Typically used for cooling water systems, transporting fuel oil and turbine lube oil systems, a
globe valve is a linear motion valve used to stop, start, and regulate flow. Conventionally used
for isolation and throttling services, the globe has become the world's most common types of
valves. With a good shut off ability, available in tee, wye, and angle patterns and easy to
machine the valve seats - it’seasy to see why they are so popular.
27
 2.1.5.7 Plug valves
A plug valve uses a tapered or cylindrical plug to stopor start a flow. In open position, the plug-
passage is in one line with the inlet and outlet ports. If the plug is rotated from the open position,
the solid part of the plug blocks the port and stops the flow. These are quick to turn off, smaller
in size compared to most valves and have minimal resistance flow.

2.2 Production in a pharmaceutical company

Pharmaceutical manufacturing is the process of industrial-scale synthesis of
pharmaceutical drugs as part of the pharmaceutical industry. The process of drug manufacturing
can be broken down into series of unit operations, such as;

2.2.1 Compounding

Pharmaceutical compounding is the practice and the science of preparing personalized

medications for patients. The compounding department produces liquid pharmaceutical
preparations such as syrup, suspension, and tonic.

2.2.1.1 Equipment and facilities use in compounding

There are several equipment and machinery utilized to ensure seamless workflow in the
compounding department.

- Homogenizer: Homogenization is the process of reducing pharmaceutical product particle sizes

under high pressures, sheer, turbulences, acceleration, and impact, to make them more stable and
clinically effective. Homogenizer is use in reducing the particle sizes due to proper mixing of
slurries during transfer of products to compounding tank

28
 Figure 2.15: Homogenizer

- Forklift: This is a type of vehicle categorized as a power industrial truck used to lift and move
various materials over short distances. Forklift use pressurized fluid to generate movement. It is
used to carry/transport heavy ingredients from in house store to site production, examples of
ingredient transported includes: Sucrose, sugar, sorbitol Etc.

Figure 2.16: Fork Lift

- Suspension Tank (10, 000) : This is a vessel that is use for compounding of suspensions which is
a coarse dispersion of insoluble solid particles in a liquid medium. Examples of suspensions
produce in Vitabiotic includes; Kidiprofen suspension (Ibuprofen), calcimax suspensions.

29
 Figure 2.17: Suspension Tanks

- CMC Tank (4, 000L): Carboxymethy cellulose (CMC) tank is use for production of paste which
is use for thickening by increasing the viscosity of the products. Sodium CMC, and Xanthan gum
were missed in the tank.

Figure 2.18: CMC Tank

- Syrup compounding tank: This is used for mixing of sugar solution and paste to form syrups and
tonic e.g. Ferovital, Dr. Meyer pentax syrup etc

30
- Storage Tank: This tank is use for the storage of products produced about to be transfer to the
packaging section.

Figure 2.19: Storage Tank

- Pump and hose:pump Used to transfer liquid medicaments to the packaging section

2.2.1.2 Some of ingredients use in compounding

 Zinc sulphate (ZnSO4): This is a naturally occurring mineral of molar mass 161.47g/mol, density
3.54g/cm3. It is important for growth and for the development of body tissues. It is use to treat
zinc deficiency, diarrhea in children, ulcers, wound healing, acne and skin infections.

 Sodium carboxymethy cellulose (NaCMC): this is a sodium salt derivative of cellulose used as
additive agent, thickening agent, emulsifier. It is primarily used in compounding to increase the
viscosity and as a stabilizer.

 Paracetamol plain: This is a common pain killer. It is used to treat aches and pain. It can also be
used to reduce a high temperature. It is use for treatment of headache, muscle aches, arthritis,
backache, toothache, colds, and fever. It is the active ingredient of Dr. Meyer pentax syrup,
pentax extral caplet, pentax plus caplet and paragesic paracetamol tablet.

 Xanthan gum: It is used as a suspending agent, an emulsion stabilizer, and a foam enhancer in
semi-solid and liquld.
31
 Calcium carbonate: This is use as an antacid to relieve heartburn, acid indigestion and upset
stomach.

 Sucrose: This is used for sweetness. It is often used in medications to impart a more pleasant
taste to often unpalatable chemicals. Sucrose is commonly known as sugar.

 Propylene glycol (CH8O2): This is commonly used in drug solubilzer, it is used as a non-polar
solvent. It was used in dissolving paracetamol plain in production of pentax syrup.

 Tween 80 (polysorbate 80): this is used as an emulsifier in pharmaceutical product.

 Nipasol (methyparaben) and nipagin(propylparaben): C8H8O3 and C1OH12O3 wereused as a

preservative in the food, cosmetic and pharmaceutical industries.

2.2.2 Liquid packaging

Liquid packaging is the final stage of liquid production in the compounding department.

2.2.2.1 Machines use in liquid packaging

- Air jet machine : This is a machine use for cleaning of the bottles used in production (PET)
which can either be 60Ml or 100Ml. The machine work on the principle of back pressure of
bottle which will be fed by the unscramble to reach separator assembly, which transfer the bottle
on conveyor belt and pushes bottles to the cleaning section one after the other. It applies
compressed air through jets and also applies vacuum to suck out the particles inside the bottle for
effective cleaning.

32
 Figure 2.20: Air jet Bottle cleaning Machine

- Filling & Capping machine – Filling machine is used to fill syrups into the bottles. It works when
the pressure is high. The liquid flows into the bottles based on its own weight when the amount
of pressure of the liquid reservoir is equal to the amount of air present in the bottle. Bottle filling
machine consist of thread nozzles 1-12, it has inner tank, each thread nozzles has springs, it has
two key one is to open and other is for locking. Capping machines consist of cap feeder that
supplies the machine with the caps.

Figure 2.21: Filling and Capping Machine

- Labeling machine: This machine attaches the label and information like batch no, manufacturing
and expiry date which were written on a sterile. It has gum feeder that supply the gum to the
labels.

- Automated shrink wrapping machine: this is the machine in which the packed bottles are
packaged into nylon of bottles with. It closes open ends of the shrink film, and heat source
applies heat to the material to shrink it down to the product. It make use of compressed air in
cooling the nylon after heating.

33
Figure 2.22: Automated Shrink-Wrapping Machine

2.2.2.2 Materials use in liquid packaging

Materials used include:

1. Cap
2. Inner and outer label
3. Inner and outer carton
4. leaflet
5. Polyvinylchloride
6. Gum acacia
7. Sterile
8. bottle

2.2.3 Granulation

Granulation is the process of forming granules from a powdery or solid substance producing
granular materials. It involves agglomeration of fine particles into larger granules, typically of
size range between 0.2 mm and 4.0 mm depending on their subsequent use.

2.2.3.1 Types of granulation process

Granulation process is of two types:

1. Wet Granulation

2. Dry Granulation
34
 DRY GRANULATION:

The dry granulation process is used to form granules without a binding solution because the
ingredients may be sensitive to moisture and heat.

WET GRANULATION:

In wet Granulation, granules are formed by the addition of a binding solution onto the
powder. The binding solution contains a solvent or carrier material which must be volatile so that
it can be removed by drying and depending on the intended application.

In Vitabiotics, tablets made are stable to moisture and heat and are formulated through the wet
Granulation method.

2.2.3.2 Composition of a tablet

In addition to the active ingredient (s), a tablet basically contains;

5. Diluents: These are mixture of substances added to a tablet to increase the bulk in order to make
the tablet a practical size for compression e.g. corn starch bulk, dibasic calcium phosphate.

6. Binder: This is a substance added to a tablet to impart a cohesiveness to the tablet formulation
which insures the remaining intact after compression. Common binders used in Vitabiotic
include; Polyvinylpyrrolidone K-30 (PVPK 30), gelatin and gum acacia.

7. Disintegrator: this is a substance or a mixture of substance added to a tablet to facilitate its break
up after administration.

8. Lubricant: this is a substance(s) added to a tablet to improve the flow ability and to prevent
adhesion of the tablet material to the surface of sies and punches of a compression machine e.g.
magnesium stearate and corn starch lubricant.

2.2.3.3 Equipments used in granulation

1. Fluidized bed dryer (FBD)

The fluidized bed dryer (FBD) is used to reduce the moisture content of pharmaceutical
granules. The equipment works on the principle of fluidization of the feed material. In
fluidization process, hot air is introduced at high pressure through a perforated bed on moist solid
particles. The wet solids are lifted from the bottom and suspended in a stream of air (fluidized
35
state) heat transfer is accomplish by direct contact between the wet solids and hot gases, the
vaporized liquid is carried away by the drying gases

2.23: Fluidized bed dryer (FBD)

2. Rapid mixing granulator (RMG)

In rapid mixing Granulator, the formation of granules occurs by rising, whirling and
tumbling motion of the material. RMG mixing is done by adding all ingredients into the RMG by
rotation of impeller and chopper at high speed. During the addition of binder solution to the
powder, the impeller and chopper are operated at low speed. After the formation of wet mass, the
impeller and chopper are operated at high speed to form the granules of the required size.

Figure 2.24: Rapid Mixer Granulator (RMG)

3. Milling machine

The main objective in milling is to reduce particles size to a specific acceptable range while
minimizing the generation of fine dusty particles. Particles size distribution (PSD) is essential to
36
flow, compression, ejection, friability, disintegration, dissolution, downtime, changeovers,
yields, product quality attributes and most importantly, tablets weights.

Figure 2.25: Multimill Machine

4. Paste kettle

The paste kettle is designed to meet missing needs of wider range of products under valid
operating conditions in chemicals, foods, cosmetics and pharmaceutical industry. The basic
principle utilized in the design of this kettle is the jacket for passing steam in order to melt down
the product to make paste. This kettle has a unique tilting arrangement for discharging the
product.

Figure 2.26: Paste Kettle

5) Octagonal blender

37
Octagonal blender, due to its Octagonal shape is designed to process larger volume of material.
Power consumption is also less, blending takes place at low speed during operation. It is well
balanced even in higher capacities it is very useful for pharmaceutical industries where gentle
blending of dry granules of powder is to be done. It is also a speed blender and has removable
type baffles mounted on a rectangular shell.

Figure 2.27: Octagonal Blender

2.2.3.4 Some ingredients use in granulation

Ingredients use in granulation process includes:

1. Gum acacia: This is also known as gum Arabic is used in pharmaceutical industry as an
emulsifier, stabilizing agent, suspending agent, tablet binder and viscosity-increasing agent.
2. Ibruprofen: This is a nonsteroidalanti-inflammatory drug (NSAID). It works by reducing
hormones that cause inflammation and pain in the body.
3. Caffeine: this is use in combination with painkiller e.g. paracetamol for treating headache
(pentax)
4. PVPK30: polyvinylpyrrolidone k-30 polymer is amorphous polymer, soluble in H 2O,
organic solvents, and PH stable. It is used as a binder in pharmaceutical tablets.
5. Talcum: this is an anti-clumping agent that is used to prevent certain ingredients from
sticking to the machinery that produces the tablet
6. Nipasol (methyparaben) and nipagin (propylparaben): C 8H8O3 and C1OH12O3wereused as a
preservative in the food, cosmetic and pharmaceutical industries.

38
 2.2.4 Compression

Compression involves bringing together the upper and lower punches under pressure within the
die to form the tablet. As the punches enter the compression stage, the upper and lower punches
move between two large wheels called pressure rolls.

2.2.4.1Tablet compressionmachine
This is also called tablet press, it is a mechanical device that compresses powder into tablets of
uniform size and weight.

2.2.4.2 Components of a tablet press

1. Hopper: this is connected to the feed shoe and it is where the granules mixtures are poured into
prior to compression.

2. Upper punches: these are on the upper section of the rotary system and they move vertically, in
and out of the die bore.

3. Lower punches: these are on the lower section of the rotary system of the tablet press and during
the processes, the lower punches remain within the die bore throughout the entire cycle.

4. Die: this is where the powder is compressed into desire tablets of definite thickness and size. The
die cavity determines ;

I. The diameter of the tablet

ii. The size of the tablet

iii. To some extent the thickness of the tablet.

5. Cam truck: this guides the position or movement of the punches.

6. Tablet adjuster: this is used to adjust the volume of the powder to be compressed and so
determines the weight of the tablet.

7. Ejection adjuster: this facilitates the ejection of the tablet from the cavity after compression.

39
2.2.4.3 Types of tablet press
a. Single punch tablet machine: This is also known as eccentric press or single station press is
the simplest machine for tablet manufacturing. This machine uses a single set of station tooling
i.e. a die and a pair of upper and lower punches.

b. Multi-station press: this is a mechanical device that unlike the single punch tablet press has
several tooling stations which rotates to compress granules mixture into tablet of uniform size,
shape, and uniform weight.

Figure 2.28: Multi Station Press Machine

2.2.5 Tablet packaging

Packaging is the science, art and technology of enclosing or protecting products. Tablet
packaging is the process of packing tablets after compression.

2.2.5.1 Types of tablet packaging

(a) Blister packaging: blister packaging is a type of pre-formed plastic packaging used for small
consumer goods. Blister packaging machine is a special machine that is used as unit-dose
packaging for tablets, capsules, etc. most blister machines use polyvinylchloride (PVC) to form
the packaging. The forming film is heated and softened by the flat heating device. The softened

40
film is blown into a blister by using compressed gas within the flat forming devices and therefore
the filling device fills the package into the blister.

(b) Stripping packaging: the strip packing of the pharmaceutical products like capsules and
tablets between two sheets of aluminum foils,cellophane,polyethylene, or any other type of heat-
sealing material.

2.2.5.2parts of a tablet blistering machine

1. hopper
2. vibrator
3. infeeed motor roller
4. forming mod
5. channel
6. web
7. sealer mod
8. pusher
9. cutter

2.3 Laboratory in the operation control department

There are micro laboratory,physical laboratory and chemical laboratort as explained in chapter
one.

2.3.1 Microbiology laboratory

Micro laboratory is the most sensitive of all the laboratory and it requires personal safety &
hygiene to be put in use. The major function of a microbiologist in this company is to sample and
perform microbial analysis on everything involved in production starting from the RAW
MATERIALS, MANUFACTURING VESSELS RINSE, PHARMACEUTICAL PRODUCTS
i.e the Drug ( at different stages-granules & tablet) to the PACKAGING MATERIALS. All this
is to ensure that the Drugs conforms to the microbial specifications for safety, efficacy and
absence of pathogens. They also carry out ENVIRONMENTAL MONITORING of within and
outside production areas to ensure safety and this is done mostly by the POUR PLATE
METHOD.
41
 2.3.1.1 Some microbiological definition
(a) Agar: this is a jelly-like commonly used in the laboratory to help feed and grows bacteria and
other microorganisms. Examples of agar used are:

i. Tryptone soya agar(TSA): this is used for the growth of total aerobic microbes count (TAMC)

ii. Saboured dextrose agar (SDA): this is used for growth of total yeast and mould (TYMC)

iii. Macconkey agar: this is used to grow negative bacteria.

iv. R2 agar: this is used for the enumeration and cultivation of bacteria from potable water. It
supports the growth of escherichiacoli, enterrococcus, pseudomonas spp, streptococcus spp, and
staphyloccus spp. This is to ascertain the pathogenicity of the Drug. However staphylococus is
not a know pathogen but it is a PATHOGEN in pharmaceutical companies because the presence
indicates that the product has come in contact with human body (as staphylococus is commonly
found on human skin) which can serve as threat to the product (Drug).

(b) Broth: this a clear liquld made from meat, vegetable used to culture bacteria and other
microorganism in the culture. The main difference between agar and broth is that agar is a
solidifying agent (solid) while broth is liquld form. Examples of broth are;

i. Tryptone soya broth (TSB): this is used in microbiology laboratory as a culture broth to grow
aerobic bacteria.

ii. Macconkey broth: this is used for cultivating negative, lactose fermenting bacilli and as
presumption test for E-coli.

(c)Media: this is a growth medium used to grow bacterial. It is formed by dissolving the broth
and agar in a distilled water.

(d) Ringer salt: this is used for the preparation of suspension of samples and other biological
matter in dilution techniques for enumeration.

(e) Sterilization: this is the killing or removal of microorganism

(f) Disinfection: this is the reducing the number of microorganism to a level that cannot cause
infections.

42
2.3.1.2 Equipments used in microbiological laboratory
1. Autoclave: This machine is used to decontaminate certain biological waste and sterilize
media, instruments and laboratory ware. It operates at high temperature and pressure in order to
kill microorganisms and spores. This works on the principle of moist heat sterilization, where in
saturated steam is generated under pressure in order to kill microorganism such as bacteria and
viruses.

Figure 2.29: Autoclave

Ii)Incubator: This equipment provide a controlled contaminant free environment for safe
reliable work with cell and tissue cultures by regulating conditions such as temperature, humidity
and C02. It is used for the growth and storage of BACTERIAL CULTURES.

43
Figure 2.30: Incubator

iii) Colony counter: This equipment is used to estimate a liquid culture’s density of micro
organisms by counting individual colonies on an agar plate, side, mini gel or pettish dish.

Figure 2.31: Colony Counter

iv) Analytical weighing balance: This is the most precise instrument that it used to determine
the weight or mass of growth media that is used for microbial analysis. It has higher readability,
measuring to the nearest 0.0000g i.e. t the nearest four decimal place.

44
Figure 2.32: Analytical Weighing Balance

v) Laminar air flow hood: This hood/cabinet is used for all contamination sensitive processes
like microbial analysis of pharmaceutical raw materials, intermediate and finised products. Drug
preparation techniques are also performed inside the cabinet to ensure a particulate-free
environment during the operations.

45
Figure 2.33: Laminar Flow Hood

vi) Microscope: This is absolutely essential to the Microbiology Laboratory as most micro
organisms cannot be seen without the aid of this instrument. It is use to observe micro-organisms
in pharmaceutical products.

46
Figure 2.34: Microscope

2.3.2 Chemical laboratory

Chemical laboratory is use for analysis of all the products at each stages of production in
order to check or ascertain that the active pharmaceutical ingredients (API) of each raw material
used in the production of the Drug conforms to the standard pharmaceutical specification. They
sample and analyze Raw material and also to check if it conforms with specifications.

2.3.2.1 Some definitions in chemical laboratory

Standard solution: this is a solution containing a precisely known concentration of an element
or a substance.

Mobile phase: this is a solvent that moves through the paper, carrying different substances with
it.

Stationary phase: this is contained on the paper and does not move through it.

Distilled water: this is water that has been boiled into vapor and condensed into liquid in a
separate container. Impurities in the original water that do not boil below or near the boiling
point of water remain in the original container.

47
Purified water: this is water that has been mechanically filtered or processed to remove
Impurities and make it suitable for use.

Potable water: this is also known as drinking water,it is water that is safe to drink or use for
food preparation.

Diluting solution: this is the solution added to a solution to decrease it concentration.

Reagents: these are substances or compounds that are added to a system in order to bring about
chemical reaction or are added to see if a reaction occurs.

Spectrophotometry: This is a standard and inexpensive technique to measure light absorption or

the amount of chemicals in a solution.

Dissolution: this is the process in which a substance forms a solution. Dissolution testing
measures the extent and rate of solution formation from a dosage form, such as tablet, capsule,
ointment,etc.

2.3.2.2 Some of the instruments used in chemical laboratory

1. Centrifuge machine: This is a device that uses centrifugal force to separate various
components of a fluid. This is achieved by spinning the fluid at high speed within the container,
thereby separating fluids of different densities (e.g. cream from milk) or liquids from solids. This
is used to separate colloidal particles from their solutions during chemical analysis.

48
 Figure 2.35: Centrifuge Machine

2. Dissolution test machine: This is an instrument for the determination of active drug
ingredient in any pharmaceutical formulation as per USP,BP and IP. This is a pivotal analytical
testing machine used for detecting physical changes in an active pharmaceutical ingredient (API)
of drug. Dissolution standardized apparatus include;

 Basket

 Paddle

 Reciprocating cylinder

 Flow-through cell

49
Figure2.36: Dissolution Test Machine

4. Sonicator: This is used to dissolve particles in a solution using sound energy.

Figure 2.37: Sonicator

5. Polarimeter: This instrument is used for purity control and determination of concentration of
substances according to the requirement of the European and American Pharmacopeia by
measurement of both specific and optical rotation.

44
50
 Fig
ure2.38: Polarimeter

6. High Performance Liquid Chromatography Machine (HPLC):This is a highly improved

form of chromatography. This is used for liquid chromatography that is used to analyze finished
drug products and their ingredients quantitatively and qualitatively during and after the
manufacturing process. There are five major components of HPLC;

 Pump: This is to propel a liquid (mobile phase) through the chromatography at a specific flow
rate, expressed in ml/min. Normal flow rates inHPLC are 1-2 ml/min.

 The injector: This serves to introduce the liquid sample into the flow stream of the mobile phase.

 The column: This is considered as the heart of the chromatography. The column’s stationary
phase separates the sample components using various physical and chemical parameters

 The detector: This is detects the compositions of the sample

7. Spectrophotometer: this is use to measure how much a substance absorbs light as a beam of
light passes through solution. This can also use to measure the amount of a knew chemical
substance.
51
Figure 2.39: Spectrophotometer and HPLC Machine

8.Fume cupboard: Fume cupboard is used for heating and preparation of strong and toxic
chemicals e.g. ammonium chloride, conc. Tetraoxosulphate acid.

9. Water bath: This is used to heat solutions for better test results.

52
Figure 2.40: Water bath and Fume Cupboard

10. Flask shaker: this is used for mixing of solutions by converting electrical energy to
mechanical energy.

11. Furnace: this is use for heating after the burning of sample with 2ml of sulphuric acid to
change to ash during loss on ignition test

Figure 2.41: Furnace and Flask Shaker

53
12. Melting point apparatus: this is used to test the melting point of the raw materials. It
consists of thermometer that measures the temperature, the coil that supplies heat to boil the
silicon oil that it contained.

13. Oven: this is used to heat at a certain temperature and pressure

14. Distillation column: this is used to produce distilled water. It contain the inlet in which
water enters and the vapor unit which contained the steam produced in the column and the
condenser which cool it and comes out as a distilled water and the waste is collected through the
distillate part as waste water.

54
Figure 2.42: Oven and Distillation Column

15. Crucible and desiccators: crucible is a ceramic material used for melting or testing
chemicals,It is use for conducting high temperature chemical reactions and analyses. Desiccators
are sealable enclosure containing desiccants used for preserving moisture-sensitive items such as
cobalt chloride paper from humidity.

14. Glass ware dryer: this is use to dry and store the glass wares for use.

55
 Figure 2.43: Melting Point Test Apparatus and Glass Wares Dryer

2.3.2.3 Glass wares used in chemical laboratory

 Test tubes: this is use for performing test analyses.

 Measuring cylinder: this is used for measuring of liquid substances.

 Beakers: these are used for measurement of chemicals, water and other liquids substances used
and weighing of substances.

Figure 2.44: Test Tubes, Measuring Cylinder and Beaker

 Volumetric flasks: this is a piece of laboratory apparatus calibrated to contain a precise volume
at a certain temperature. These are used for dilution and preparation of standard.

 Conical flask: this is the most commonly used laboratory equipment that is used to hold and
measure chemical liquid samples.

 Separating funnel: this is used in liquid-liquid extractions to separate the components of a

mixture into two immiscible solvent phases of different densities.

56
 Figure 2.45: Seperating Funnel in a restort Stand and Volumetric Flasks

 Burette: this is used in quantitative chemical analysis to measure the volume of a liquid or gas.

 Pipette: this is used to measure out or transfer small quantities of liquid.

2.3.3 Physical laboratory

The function of an in-process inspector is to monitor each production process & Stages; and to
analyze the physical parameters of each stages in order to ensure that it conforms with standard
pharmaceutical specifications.

2.3.3.1 Physical parameters of a drug

Friability: this is when a tablet has the tendency to chip, crumble or break during transportation.
Friability test is important because it tells how much mechanical stress tablets are able to
withstand during their manufacturing, distribution and handling by the customer.

Moisture content: this affects the physical, chemical and microbiological properties of a
pharmaceutical finished dosage forms. Moisture content test is done on drugs because it affects
overall flow properties and consistency of blended powders.

Bulk density: this is the ratio of a tablets mass to its bulk volume measurement with graduated
cylinder. It is used in determining the amount of powder that can fit in a space such as hopper on
a tablet press.

57
Tablet hardness: this is done to determine the breaking point and structural integrity of a tablet
and find how it changes under condition.

Tablet disintegration: this is the mechanical break up of a compressed tablet into small granules
upon digestion.

Specific gravity: this is a means of obtaining information about the concentration of solutions of
various materials such as drugs.

Viscosity: this is the property of a given liquid that describes its resistance to flow. Liquids with
a high viscosity flow more slowly than low-viscosity liquids. Cough syrup should flow slowly
through the digestive tract to coat the surface of the throat and not flow off.

2.3.3.2Equipment used in physical laboratory

1. Hardness tester: This machine is used to test for the structural integrity of a tablet to
determine the BREAKING POINT and also to find out how it changes “under conditions of
storage transportation, packaging and handling before usage’

58
Figure 2.46: Hardness Test Apparatus

2. Disintegration test apparatus: It is used to test how a drug pellet form will disintegrate in
solution i.e. the in vitro breakdown of powered compounds For quality control purpose.

Figure 2.47: Disintegration Test Apparatus Machine

3.Leak test apparatus: This machine is used to check the sealing integrity of Blister packs, strip
packs sachet & pouch packs etc. it is also used for checking leaks from capped bottles,induction
sealed containers.

59
Figure 2.48: Leak Test Apparatus

4. Friability test machine: This is used to test the durability of tablet after transit or when
exposed to external pressure. It is used to measure the difference between the weight of the
sample before and after the process in order to check the physical strength of uncoated tablet.

Figure 2.49: Friability Test Apparatus

5. Moisture content tester: This is used to measure the percentage of water in drugs, in order to
prevent excess moisture from affecting the physical, chemical and microbiological properties of
the drug.

60
Figure 2.50: Moisture Content Apparatus

6. Viscometer: this is use to measure the viscosity of a syrup

Figure 2.51: Viscometer

61
 CHAPTER THREE

ACTUAL WORKDONE (METHODOLOGY)

During the period of my industrial training, I was attached to the following departments;

1. purified water treatment plant

2. Effluent treatment plant (ETP)

3. Production department

4. Quality operation laboratory

5. Raw material warehouse

6. Packaging material warehouse

7. Finished goods warehouse

3.1. Purified water plant

During my stay in purified water treatment, I was able to treat water and do the regeneration
process.

3.1.1 Treatment of Water

I on the pumping machines, each of 1.5 horsepower to pump the raw water from the borehole
into the two underground tank A (11,600litres) and B (9500litres). The water was then pumped
in an upward direction into the overhead tank with a pumping machine of 5.5 horsepower in
capacity. I on the control panel and then later pump1 which is 1.5 horsepower capacity which
pumped the water downwardly from the overhead tank to the pressure sand bed. I regulated the
pressure of water flow at the purified water treatment plant to 2.5bar at 25 oc. The water flew
through the plant as thus;

62
Sand bed: At the pressure sand filter bed, I turned the knob to backwash to backwash the bed for
15minutes and after which I turned the knob to rinse to rinse the bed until clean water comes out
from the filter which took about 20mins and finally, the knob was changed to filter to allow
water to flow to the carbon filter bed.

Activated carbon filter bed: at the carbon bed, backwashing and rinsing was done as that of sad
bed and water was then passed to the cation resin chamber.

Cation: I turned the knob to backwash for 20mins and later to service to allow water to flow to
anion resins.

Figure 3.1: Backwashing Cation Bed

Anion: backwashing was done for 20mins, and the knob was then turned to service which
allowed water to flow the mixed bed.

Mixed bed: backwashing was done for 25mins, and the knob was then turned to service which
allowed water to flow to the micron filter.

Micron filter: i opened the valve so that water can flowed to the ultraviolet

63
Ultraviolet: I opened the valve so that water can flow through it and finally to the loop system
for distribution and storage.

Figure 3.2: Purified water treatment plant

3.1.2 Regeneration process

Regeneration was done when there was increase in conductivity of the water as thus;

1. preparation of acid for cation chamber

2. preparation of caustic soda (NaOH) for anion chamber

3. preparation of acid for mixed bed chamber

4. preparation of caustic soda (NaOH) for mixed bed

5. regeneration process

3.1.2.1 Preparation of acid for cation chamber

120litres of purified water was measured into the regeneration tank 1 and 10litres of
concentrated hydrochloric acid was added and stirred with a plastic rod until HCL was fully
dissolved in the water.

64
3.1.2.2 Preparation of caustic soda (NaOH) for anion chamber
187litres of purified water was measured into the regeneration tank 2 and 22kg of N aOH was
added and was then stirred with a plastic rod until it was completely dissolved.

3.1.2.3 Preparation of acid for mixed bed chamber

3litres of purified water was measured into the regeneration tank 3 and 2litres of concentrated
hydrochloric acid was added and stirred with a plastic rod until HCL was fully dissolved in the
water.

3.1.2.4 Preparation of caustic for mixed bed

3litres of purified water was measured into the regeneration tank 4 and 3kg of N aOH was added
and was then stirred with a plastic rod until it was completely dissolved.

3.1.2.5 Regeneration process on cation chamber

The regeneration was done as thus;

1. then acid ejector power water valve was opened to power up flow of water

2. The acid ejector suction valve was slightly opened to gradually sucked the diluted acid In the
tank for 10mins and acid rinse outlet valve was simultaneously opened to discharge acid
from the tank.

3. The acid ejector power water valve was adjusted halfway to maintained specific flow for
after which the acid ejector suction valve was locked.

4. A sample was taken from the rinse outlet valve and was tested for free mineral acidity
(F.M.A) in the laboratory and when the result was satisfactory, the rinsing was stopped.

5. The main valve was opened so that water can flow to the anion chamber.

3.1.2.6 Regeneration process on anion chamber

1. then caustic ejector power water valve was opened to power up flow of water

65
2. The caustic ejector suction valve was opened to gradually suck the caustic soda in the tank
for 10mins and caustic rinse outlet valve was simultaneously opened to discharge caustic
solution from the tank.

3. The caustic ejector power water valve was adjusted to maintained specific flow for after
which the caustic ejector suction valve was locked.

4. A sample was taken from the rinse outlet valve and was tested for free mineral basicity
(F.M.B) in the laboratory and when the result was satisfactory, the rinsing was stopped.

5. The main valve was opened so that water can flow to the mixed chamber

3.1.2.7 Regeneration process on mixed bed

Acid injection was done as that of cation chamber and caustic injection was done as the anion
chamber then;

1. The purified water treatment plant pumping machine was switched off from the main

2. The service outlet valve was locked, and wash outlet was opened.

3. The compressed air valve was opened, and air drain valve was opened to drain out for
10mins.

4. The air valve was locked, and the air released valve was opened to removed trapped air

5. The main inlet was opened

6. Conductivity and PH indicator was switched on to check the conductivity and PH of the
water

7. The water samples were taken for laboratory test.

3.2 Effluent treatment plant (ETP)

In ETP, I was involved in the treatment of 8000litres of effluent which involves; preparation of
alum solution, preparation of lime and chlorine solution and treating processes.

66
3.2.1 Preparation of alum solution

10kg of alum was added to 100litres of water and then mixed until the alum was fully dissolved
in the water to give alum solution.

3.2.2 Preparation of lime and chlorine solution

9kg of lime and 5kg of calcium hydrochloride was mixed with 100litres of water and the mixture
was stirred until there was evenly mixed of those compounds.

67
Figure 3.3: Stirring Chlorine and Lime solution

3.2.3 Effluent treatment process

The process involves:

1. I checked if all valves were closed

2. The effluent was pumped from theholding tank into the aeration tank by turned on holding
tank (l) switch. the switch was turned off when 8000litres have been collected

3. The air blower switch was turned on for vigorous agitation of the effluent collected

68
4. The prepared chemicals were added and was allowed to mix for 30mins before turned off the
blower

5. the treated effluent was allowed to settle for 2hrs

6. The switch(pump to sludge bed) was turned on to pump the sewage to the sludge bed. The
effluent few evenly on the bed and the sludge remains on the bed and the clear water
percolated into the filtration tank

7. The switch transfer (a) was then turned on to pump the treated effluent from filtration tank
into the pressure filter tank.

8. After collection of the sample for laboratory test and the result was satisfied, the treated
effluent was disposed into the public drain.

Figure 3.4:Effluent Treatment Plant

69
3.3 Boiler
Activities carried out in boiler section are:

1. Starting a boiler

2. Stopping a boiler

3. Blowing down a boiler

3.3.1 Starting a boiler

The following are operating procedure I took in starting a boiler:

1. The valve on water supply line was opened

2. I observed control lamp was observed to be on

3. The main steam valve was closed, and the auxiliary valve was opened

4. The fill switch was on to fill up the coil

5. The unit was fired when water started coming out of the auxiliary steam valve by put the
FIRE switch on.

6. After the pressure of the steam that came out increased, the main steam valve was opened to
send in the steam and the auxiliary steam valve was closed.

3.3.2 Stopping a boiler

The following are operating procedure I took in stopping a boiler:

1. The steam stop valve was fully closed

2. The FIRE switch was off

3. Blow down of the boiler was done

4. The FILL switch was on to filled up the coil with water for the next operation

5. The electric main switch was put off

70
6. Dripped oil, water was cleaned off from the unit

7. The outlet valve of soft water tank and fuel oil service tank was closed

3.3.3 Blow down a boiler

The following are operating procedure of blowing down a boiler:

1. The main steam valve was closed

2. The FILL-O-FIRE switch on the control panel was put in off position

3. The blow down valve was fully opened

4. The blow down time was observed by measured the time the steam pressure dropped from
10kg/cm2 to 2kg/cm2

5. The blow down valve was closed

6. The coil was cooled by filled the new water

3.4 Production Department

I was able to monitor the production process of some drugs in various production section

3.4.1 Compounding

In compounding department, I was able to participate in the production of coflin expectorant

syrup which involves.

3.4.1.1 Weighing of raw material in a dispensing room

The raw material used in the production was weighed according to the batch
manufacturing record (BMR). the materials include Dipheneramine HCL, ammonium chloride,
citric acid monohydrate, sodium citrate, menthol, sodium CMC, Raspberry flavor, allura
colorant, sucrose, and sorbitol.

71
3.4.1.2 Sodium CMC paste formation
3500litres of water was boiled in a steam jacketed. 1000litres of hot water from steam jacketed
tank was transferred into 1500litres CMC tank and sodium CMC was added. The mixture was
then stirred until there is no lump and gel was formed. it was then transferred into compounding
tank of 10000litres capacity.

3.4.1.3 Sugar syrup formation

2500litres that remains in the steam jacketed tank was used to made sugar syrup as thus.

1. addition of nipasol then nipagen

2. Addition of water-soluble active ingredients like Dipheneramine HCL, ammonium chloride,

citric acid monohydrate, sodium citrate was added and stirred well.

3. Addition of sucrose

4. Addition of sorbitol 70%

5. Transferring of sugar syrup into compounding tank

3.4.1.4 Addition of menthol, flavor and colorant and making up

Menthol, flavor, and colorant were added at the second day. After this it was then made up to
volume by adding purified water. The syrup was then transferred by the uses of pump to the
storage tank.

3.4.2 Packaging of coflin expectorant

After certification from the operations department, the liquid preparation was pumped from the
Compounding room to the liquid packaging hall (Line 1- 4). Before it was pumped, the rinse
sample of the packaging storage tank was taken and certified by the quality operations
department. Then the product was transferred and then pumped from the storage tank to the
filling and capping machine reservoir bit by bit. This machine was accurately set to the
appropriate volume. The packaging commenced from the first roller to the air jet machine and
then to the filling and capping region which was automated. Then it passed on to the next roller
where the bottles were passed to the labeling machine and then were put in cartons with dosage
72
cups and leaflet. The cartons are then wrapped with the aid of the shrink-wrapping machine. The
packs were then put in cartons while some bottles were collected by QC (Upper and Lower
Samples) for analysis. After which the result was satisfied, the product was transferred into the
finished goods warehouse and ready for sale.

1ST Roller Air Jet 61Filling & 2nd Roller

Machine capping

Outer Shrink Inner Labeling

cartonning wrapping Cartonning/Packi
and labeling ng

Figure 3.5: Workflow Chart of Liquid Packaging

3.4.3 Granulation

In granulation department, I was able to participate in the production of drugs like pentax plus
caplet, paragesic, co-trox tablet and metrozol 200mg.Granulation of any tablet involves;

3.4.3.1 Weighing of raw material

The raw material used in the production was weighed according to the batch manufacturing
record (BMR). The materials includes; the API, binders, disintegrators and lubricants.

3.4.3.2 Sifting of raw materials

Sifting was done to ensured particle uniformity and conformity.

3.4.3.3 Dry mixing

This was done in rapid mass granulator (RMG) and it involved mixing of active pharmaceutical
ingredients for 30mins

3.4.3.4 Paste formation (Binding Agent)

20litres of purified water was boiled in the paste kettle using the steam from the boiler. Nipagen
and Nipasol were added and stirred. the corn starch paste was dissolved in 5litres of purified

73
water and binder like gum acacia was added to the mixture. the mixture was then turned into the
kettle and stirred until a boiled jelly was formed

3.4.3.5 Wet mixing

The paste was turned into the active ingredients in the RMG and 5litres of boiled water was
added. The mixture was mixed very well until desired texture was achieved.

3.4.3.6 Drying
The mixture was placed in the jacket of fluidized bed drier. The finger bang was attached to
prevent dusting and the mixture was dried until fine powders were obtained.

3.4.3.7 Dry milling

The powders were milled by the uses of mutilmill machine.

3.4.3.8 Lubrication and uniformity

This is done in a octagonal blender by adding all the sublot and lubricants such as corn starch
lubricant, magnesium stearate to the mixture and mixed for 15minutes.

3.4.4 Compression

The tablet compression procedure that was used is divided into four distinct stages. These are
named as filling, metering, compression and ejection. Those four steps are explained below.

1. Filling: This procedure of the tablet compression machine involved the transporting of the
granules into position for tablet compression. The ultimate product was then blended into the
homogeneous blend. Then the mixture flew to the compression tool punch die cavity (There are
two fillers A & B present on a machine) the punch-die cavity was made of upper punches, die
and lower punches.

2. Metering: The metering procedure for the tablet compression procedure involved removal of
excess granules from the compression machine. At this stage, the required weight (volume) of
granules to be compressed into tablets was controlled by the height of the lower punch in the die
and the height of the lower punch was controlled by the metering can. The lower punch was
raised to the required level in the die to get the required weight of granules in the punch-die
cavity. The excess granules were scraped from the surface of the die tablet.
74
3. Compression: During the compression stage, the top and bottom punch (tablet holding) came
together by pressure within the die to form the tablet. As the punches entered into the
compression stage, the top and bottom punches moved between two large wheels called
compression rolls. These compression rolls pushed the punches towards the die to form the
product.

4. Ejection: The ejection procedure for the tablet compression process involved removal of the
tablet from the lower punch-die station. In this stage, the upper punch retracted from the die
cavity and rise above the turret table. Then the lower punch rosein the die, which in turn pushed
the tablet upward to the top surface of the die table and out of the die cavity then out the surface
of the die table and out of the die cavity. Then by a scrapper, tablets were collected in the
container.

3.4.5 Tablet packaging

The blistering machine was used for packaging of tablet like paragesic, co-trox tablet, metrozol.
Things to do before operating the machineinclude.

1. the product was cross checked if it were approved by the QA

2. The parts of the product wereidentified

3. the machine was washed with 70% ethanol and 30% water

4. the forming and sealing mod, cutter and gear were checked if are for the product and if not,
they were changed

5. The forming temperature controller and vibrator controller were adjusted. The tablet moved
from the hopper to vibrator, to the infeed motor roller which felt the tablets into the channel
from which it moved on a conveyor into the sealing mod that sealed it. The sealed tablet
moved to pusher which pushed it to the cutter that cut it into desired number.

75
3.5 Quality control laboratory

3.5.1 Microbiology laboratory

During my stay in microbiology, I was able to do the following activities.

1. Calibration of analytical weighing balance

2. dry sterilization

3. preparation of media

4. wet sterilization of media

5. microbial analysis

6. incubation

7. counting of microorganisms using colony counter

3.5.1.1 Calibration of analytical weighing balance

This was done by using the standard weight such as 2g, 5g, 10g, 20g, 50g and 100g to
test for the accuracy of the weighing balance. This is done every day before the weighing
balance can be use.

3.5.1.2 Dry sterilization

Dry sterilization of spatula, petrish dishes, sample bottles and pipete was done by the use of oven
till the temperature reach 1600C.

3.5.1.3 Preparation of media

Media for the growth of microorganism were prepared according to the number of samples to be
analyzed. When there were water samples from the purified water plant, TSA, SDA, MAC,
ringer salt solution and R2A were prepared. For drug or raw material samples, TSA, SDA, TSB,
and ringer salt solution were prepared.

For SDA, 65g was to dissolved in 1000ml of water

For TSA, 40g was to dissolved in 1000ml of water

76
 For MAC agar, 52.5g was dissolved in 1000ml of water

For MAC broth, 40g was dissolved in 1000ml

For R2A, 18.2g was dissolved in 1000ml

For TSB, 30g was dissolved in 1000ml

250× 65
For example if 250ml of SDA is needed, then = =16.25g
1000

16.25g was added dissolved in 250ml of water

3.5.1.4 Wet Sterilization of media

Sterilization of prepared media was done in the autoclave to kill microorganism such as bacteria
and viruses in the media. This was done until temperature reached 1210C for 15mins.

3.5.1.5 Microbial analysis of samples

After wet sterilization, the media was allowed to solidified then after took to the laminar
flow hood for the analysis.

a. Microbial analysis of water samples

For samples 1-3, serial dilution was used as thus;

 10ml of sample 1-3 each were dilutedwith 90ml of ringer salt solution and shake well.

 1ml of the solution was pipette into 4petrish dishes labeled TSA, SDA, MAC and R2A each.

 The mixture in the petrish dishes were allowed to solidified which after took to different
incubator where they were incubated for 3days.

SDA were kept in an incubator at 23 0C, TSA, SDA andR2A were kept in incubator at 36 0C while
MAC Agars were kept in incubator at 44.70C.

For samples 4-14 and 30

1ml of each samples were pipette into petrish dishes labeled TSA, SDA, MAC and R 2A and 4ml
of the media were added respectively.

b. Microbial Analysis of drugs and raw materials

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 Serial dilution was done as that of water sample but were tested only with TSA and SDA

 Using TSB as thus

 40ml TSB were pipette into test tubes and sterilized

 4ml of the samples were added into 40ml TSB in the test tube

 The mixtures were allowed to solidify before incubating. The cloudy of the mixture after
incubation show the presence of pathogen.

Figure 3.6 Preparation of Media andAnalyzing Of water samples

3.5.2 Chemical laboratory

In chemical laboratory, activities done were;

 Chemical analysis of raw material

 chemical analysis of water samples from purified water plant

 Chemical analysis of drugs

 Dissolution rate test

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 Reagent preparation

3.5.2.1 Chemical analysis of raw material (Paracetamol plain)

Raw materials were analyzed before they were used in the production. Raw materials
such as sulfamethoxazole, paracetamol plain e.t.c. were analyzed by me in the lab. For
paracetamol plain the following analyzes were carried out;

a. Description

Paracetamol plain is a white crystalline powder

b. Solubility test

When paracetamol plain was poured in water, alcohol, methylene chloride, it was soluble
in water, freely soluble in alcohol, very slightly soluble in methylene chloride.

c. Melting point test

Sample was placed in capillary tubes and inserted in a melting point testing apparatus
contain silicon oil and a coil supplying the heat. It melted at 1700C.

d. Loss on drying test

An empty dried crucible was weighed and 1.0001g of paracetamol plain was weighed
into the crucible and the crucible was re-weighed again. The crucible was put in an oven at
1000C.

The weight of empty dried crucible (before drying) = 40.1307g

Weight of the crucible + sample (before drying) =41.1308g

Wt of crucible + sample (after drying) = 41.1282g

Loss on drying = 41.1308 – 41.1282 =0.0026g

loss on drying 0..0026

%Loss on drying = × 100% = × 100% =0.26% (spec. not more than 0.5%)
initial weight 1.0001

e. Sulphated ash

An empty dried crucible was weighed and 1.0003g of paracetamol plain was weighed
into the crucible and the crucible was re-weighed again. The crucible was put on a burner and

79
 2ml of sulphuric acid was added to burn it and then later put in a furnace till second day.
Crucible was then brought out and put in desiccators to cool it. the weight of the crucible was
taken again.

The weight of empty dried crucible (before ignition) = 41.3826g

Weight of the crucible + sample (before ignition) =42.3820g

Wt of crucible + sample (after ignition) = 41.3830g

Loss on ignition = 42.3820- 41.3830 =0.0004g

loss on drying 0..0004

% Loss on drying = × 100% = × 100% =0.04% (spec. not more than 0.1%)
initial weight 1.0003

f. Specific absorbance

This was done as thus;

 0.1g of sample was put in 100ml of methanol

 1ml of the solution was pipette into volumetric flask and 0.5ml of 0.1 HCL was added

 It was then diluted with methanol

 The solution was protected from bright light

 The spectopotometric was operated at 249.0nm to measure the absorbance as 0.882Abs.

Theoretical concentration (TC) was calculated as;

wtofsample amountpipette
TC = × × 100%
volumeofvolumetricflask volumeofvolumetricflask

0.1× 1× 100 w
= %
100× 100 v

absorbance 0.882
Specific absorbance = = = 882 (spec. 860- 980)
TC 0.001

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3.5.2.2 Chemical analysis of water samples from purified water plant
Several tests were done on water samples, tests performed by me are;

a. PH test

100ml of samples were put in a 250ml beakers and PH apparatus was used to read the PH of the
water

b. Conductivity test

100ml of samples were put in a 250ml beakers and conductivity apparatus was used to read the
conductivity of the water

c. Acidity test

10ml of each samples were pipette into the test tubes and was boiled and cooled. 0.05ml of
methyl red solution was added. Methyl red was red in PH under 4.4 which is acidic, yellow in
PH over 6.2 (base) and orange in between.

d. Alkalinity test

10ml of the samples were pipette into the test tubes and 0.01ml of bromothymol blue solution
was added.Bromothymol blue was yellow in acidic, blue in basic and green in basic.

e. Calcium and magnesium test

10ml of samples were put in test tubes and 2ml of ammonium chloride buffer PH 10 was added
and 50mg of mordant black ii triturate was added. Then after 0.01ml of 0.01M ethylenediamine
tetra acetic acid (EDTA).

f. Chloride test

10ml of the samples were put into test tubes and 1ml of 2M nitric acid and 0.2ml of 0.1M silver
nitrate was added.

g.Sulphate test

10ml of samples put in test tubes and 0.1ml of 2M HCl was added. 0.1ml of BaCl 2 was added
and shakes well.

h. Oxidable substances

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 10ml of water samples were put in test tubes and 1ml of 1M sulphuric acid was added .0.01ml of
0.02M potassium permangamate solution was added and the mixture was boiled for five minutes.

3.5.2.3 Chemical analysis of drug samples

There are two principles used in chemical analysis of drug.the principles are;

 High liquid performance chromatography (HPLC): this principle is based on peak area of the
test in comparison to the peak area of the standard of the solution. Some of the drug analyzed by
this principle are vitamin b-complex , cot-rox tablet, pentax plus caplet, metrosone200mg tablet
e.t.c. The principle involved preparation of mobile phase, standard solution and assay base on the
SOP of each products.

 Spectophotometric principle: this principle is based on the absorbance of the test in comparison
to the absorbance of the standard of the solution. Some of the drugs analyzed by this principle
are paragesic tablet and chlorpheniramine (CPM)tablet.

a. Chemical analysis of petax plus caplet using HPLC principle

Each caplet contained;

Paracetamol – 500mg

Caffeine - 25mg

The principle involved;

 Preparation of mobile phase

600ml of distilled water was mixed with 400ml of methanol in 1000ml volumetric flask. The
mixture was allowed to equilibrate to room temperature and was then poured into the labeled
reagent bottle.

 Preparation of standard solution

Standard solution was prepared according to SOP as thus;

 0.250g of paracetamol and 0.012g of caffeine were weighed into 100ml volumetric flask

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 70ml of methanol was added and the mixture was shake mechanically with the use of flask
shaker for 15mins.

 the mixture was made to volume with methanol

 10ml of the mixture was centrifuge for 2mins.

 2ml of the solution was diluted with the mobile phase

 Preparation of assay

Equivalent wt =0.250g label claimed = 0.5g average wt = 0.5955g

Assay or test solution was prepared as;

 20pentax caplets were collected and grinded in a mortal until desired texture was achieved

compression∨equivalent weight × average weight 0.250 ×0.5955

 weight = = = 0.2978g was
labelled claim 0.5
weighed into 100ml volumetric flask

 70ml of methanol was added and shake mechanically for 15mins

 The volume was made up with methanol

 10ml of the mixture was centrifuge for 2mins

 2.5ml of the solution was pipette into 50ml flask and was diluted with mobile phase

 HPLC was operated to get the peak area of test and samples

Calculations of Paracetamol -500mg/caplet

Peak area of standard 1 = 1577.58923 Peak area of test = 1592.56921

Peak area of standard 2 = 1579.80176 wt of standard =0.250g

Peak area of standard 3 = 1582.96179 wt of sample =0.2978g

Peak area of standard Av. = 1580.11759 compression weight =0.5955g

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 peak area of the test weigth of sample
% yield = × × dilution of sample×
peak areaof the standard volume of volumetric flask
volume of flask comression wt purity standard
× dilution of standard × × × 100%
weight of standard label claimed 100

1592.5692 0.25 2 100 50 595.50 99.36

% yield of paracetamol = × × × × × × × 100%
1580.11759 100 50 0.2970 2 500 100

= 100.09% (spec. 95% -105%)

% yield × label claimed 100.09× 500

Potency = = = 500.45mg/caplet
100 100

Calculation of caffeine- 25mg/caplet

Peak area of standard 1 = 256.73572 Peak area of test = 253.57315

Peak area of standard 2 =257.72357 wt of standard =0.250g

Peak area of standard 3 = 257.21344 wt of sample =0.2978g

Peak area of standard Av. = 257.22424 compression weight =0.5955g

253.57315 0.012 2 100 50 595.50 99.50

% yield of caffeine = × × × × × × × 100%
257.22424 100 50 0.2970 2 25 100

= 98.04% (spec. 95% -105% B.P)

% yield × label claimed 98.04 ×25

Potency = = = 24.51mg/caplet
100 100

b. Chemical analysis of Paragesic tablet using Spectrophotometric

Each tablet contains paracetamol – 500mg

This principle involves preparation of mobile phase and sample.

 Preparation of mobile phase

600ml of distilled water was mixed with 400ml of methanol in 1000ml volumetric flask and
mixture was allowed to equilibrate to room temperature. The solution was turned into the well
labeled reagent bottle.

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 Preparation of sample

Sample was prepared as thus;

 20tablets were collected and grinded to desired texture

compression∨equivalent weight × average weight 0.5891× 0.15

 weight = = = 0.1767g was
l abelled claim 0.5
weighed into 200ml volumetric flask

 50ml of distilled water and 50ml of 0.1M N aOH were added and shaked mechanically for
15minutes

 distilled water was added to made it up to volume

 the solution was filtered and 10ml of the clear filtrate was pipette into 100ml volumetric flask

 10ml of 0.1M NaOH was added and was madeup to volume with distilled water

 Spectrophotometer was operated at 257nm

Calculations

Absorbance = 0.536 weight of sample used =0.1767g A’= 715

w %
TC = 0.00075% E’ = 715
v

Absorbance of sample 0.536

% yield = ×100%= × 100 % =99.95%
E ’ % ×TC 715× 0.00075

% yield × label claimed 99.95 ×500

Potency = = = 499.75mg/tab
100 100

3.5.2.4 Dissolution rate test for Asmanol tablet

Medium: 900ml of water at 370C

Time: 30mins

Apparatus: 100revolutions per mins (basket)

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 Diluents: distilled water

Preparation of test using Dissolution test apparatus

 900ml of distilled H2O at 370C was put into the dissolution flask

 6tablets were introduced into six baskets and the baskets were attached to the dissolution test
apparatus

 the machine started the analyzes

 After the test, 10ml of the solution was pipette into six centrifuge tubes each and were
centrifuged for 10mins

 HPLC was operated

Calculations

peak areatest weight of standard volume used

% yield = × ×dilution × × 100%
peak area standard 100 claim

peak area of standard 1 = 1.2324e4 peak area of standard 2 = 1.37339e4

peak area of standard 3 = 1.23503e4

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peak areatest 100 6 900 peak areatest

% yield = × × × × 100% = × 90%
peak area standard 100 100 60 peak area standard

Table 3.1: % dissolution yield test of samples during dissolution test of Asmanol tablet

Sample Peak area test % dissolution yield

A 1.13478e4 79.77

B 1.13826e4 80.02

C 1.24153e4 87.27

D 1.35985e4 95.59

E 1.25304e4 88.08

F 1.35976e4 95.57

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Figure 3.7: Conducting Dissolution Rate Test of Asmanol Tablet

3.5.2.5 Preparation of reagent (0.1M NaOH)

Molar mass of NaOH =23+16+1 =40g/mol

mass of substance
From mole = mole = 0.1
mola mass

Mass of NaOH= 40×0.1 =4g

4g of NaOH pellet was dissolved in 1000ml of distilled water

3.5.3 Physical laboratory (in process)

Activities carried out by me in physical laboratory are;

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3.5.3.1 Physical analysis on co-trox granules (granulation)

a. Determination of MoistureContent

3.2g of granules were put in moisture content apparatus and was allowed to determine the
moisture content as 1.20 (spec. 1-3)

b. Determination of bulk density

100g of granules were weighed and poured in measuring cylinder.

Weight of granules (WO)= 100g volume of granules (VO) = 76ml

100 g
Bulk density = = 1.32g/ml
76

3.5.3.2 Physical Analysis of Tablet (compression)

a. Friability test

10tablets were weighed and then put into basket of friability test apparatus. the final weight was
weighed.

Weight of 10 tablets before test (initial) =11.8659g

Weight after test (Final test) = 11.8353g

initial−final
Friability = × 100%
11.8659

11.8659−11.8353
= × 100% = 0.76%
11.8659

b. weight variation

Weight variation = weight of 10 tablets ÷ 10=¿ 11.8659÷ 10 = 1.1866g

c. Hardness test

10tablets were collected and hardness machine was used to measured the hardness of each tablet.

A = 10.8Kpa/cm2, 7.7, 10.8, 8, 11.3, 6.8, 9.2, 8.2, 9.5 and 9.9

10.8+7.7+10.8+8+ 11.3+6.8+ 9.2+8.2+9.5+ 9.9

Average Hardness = = 92.2Kpa/cm2
10

88
but 1000Kpa = 1Kgf

92.2÷ 1000 = 0.0922Kgf/cm2

d. Disintegration test

600ml of water at 350C was put in a beaker of the apparatus and 6tablets were put in the
disintegration test hanger and time for each tablet were recorded

t1 =4min 38mins,t2 =4mins 40secs, t3= 4mins 48secs, t4 =5mins 18secs, t5 =5mins 30secs, t6
=5mins 4sec

Average time =5mins 06secs

3.5.3.3 Physical analysis of Syrup (Coflin expectorant L51221)

a. description

It is a clear reddish – pink liquid with raspberry and vanilla flavor

b. PH – 5.32 (spec. 4.5 – 6.0)

b. Calculation of weight per ml

weight of syrup
Weight per ml =
volume of specific gravity

Weight of empty specific gravity bottle = 25.2766g

Weight of bottle with water = 75.8123g weight of water = 75.8123 -25.2766 = 50.5357g

Weight of 1ml of water (constant) = 0.999602g weight of syrup = 61.7723g

50.5357
Volume of specific bottle = = 50.73764ml
0.99602

61.7723
Weight per ml = = 1.2175g/ml
50.73764

c. Calculation of Viscosity

Viscometer constant = 4.535mm2s-2 time = 4.53secs

Viscosity = time ×viscometer constant

= 4.535× 4.53 = 20.5436mm2s-1

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3.6 Raw Material Warehouse
Works done in raw material warehouse are:

1. Introducing to standard operating procedure of receiving, storing, and dispensing of raw

material

2. Receiving of 20bags of pracetamol plain

3. checking the physical appearance of the raw material received

4. carrying the raw material into quarantine section where samples were taken by QC for
analysis

5. Stocking of raw material in the store

6. Dispensing of raw material used for orheptal blood syrup

3.7 Packaging material warehouse

Works done in packaging material warehouse are.

1. Introducing to standard operating procedure of receiving, storing, and dispensing of

packaging material

2. Receiving of 5bags of inner label and inner carton of asmanol tablet

3. checking the physical appearance of the materials received

4. carrying the packaging material into quarantine section where samples were taken by QC for
analysis

5. Stocking of packaging material in the store

6. Dispensing of packaging materials used for ferovital blood syrup

90
3.8 Finished Goods Warehouse
In finished goods warehouse, the finished goods were kept until there is buyer. Activities done
by me in finished good warehouse includes.

1. Introducing to standard operating procedure of receiving, storing, and selling of finished

goods

2. Receiving of metrozol 200mg tablet of batch no T31221

3. Storing of product received

CHAPTER FOUR

EXPERIENCE GAINED AND CHALLENGES ENCOUNTERED

4.1 Experience Gained
My experience gained was from the 3 different types of personal skills: Social, Cognitive, and
Intellectual skills.

4.1.1 Personal skills

The following are the personal skills I gained during my internship:

1. Communication

2. Interpersonal

3. Collaboration

4. Adaptability

4.1.2 Cognitive skills

These are the cognitive skills I gained:

1. Critical Thinking.
91
2. Research and Analysis.

3. Initiative.

4. Time Management.

4.1.3 Intellectual skills

The following are grouped under intellectual skills which are: Theoretical and practical
experiences.

4.1.3.1 Theoretical experience

The following are my theoretical experiences at the office, divided into the following
departments:

a. Purified water treatment plant

The following are my theoretical experiences at the purified water treatment plant:

1. Pressure sand filter

2. Activated carbon filter

3. Backwashing and rinsing

4. Ion exchange water treatment

5. Resins, types of resins and how they were used in water treatment

6. Working principle of a mixed bed

7. Regeneration process

8. Micron filter and ultraviolet light system

b. Effluent treatment plant

The following are the theories learnt in ETP

1. Sludge and sludge bed

92
2. Aeration effluent treatment

3. Types of aerators

4. Chemicals removed by aeration

c. Production

1. Ingredients use in production such as zinc sulphate, sodium carboxymethy cellulose,

pararcetamol, sucrose, magnesium stearate, propeleneglycol, calcium carbonate, tween 80,
sorbitol, etc.

2. Binders such as talcum, gelatin, xanthangum etc.

3. Disintegrator such as corn starch bulk

4. Lubricant such as, magnesium stearate, corn starch lubricant

5. Compression machine and its components

6. Blistering machine and its components

d. Quality operation laboratory

The following are the theories learnt in the laboratory:

1. Agar and examples of agar such as TSA, SDA and macconky agar

2. Broth and examples like; TSB, macconky broth and cetrimide broth

3. Autoclave, incubator, and colony counter

4. Mobile phase and stationary phase

5. Reagents like BaCl,CaCO3etc.

6. Standard, test, and diluting solution

7. High liquid performance chromatographic principle

93
8. Spectrophotometric principle

9. % Yield and potency of drugs

10. Active pharmaceutical ingredient(s) of drugs

11. Indicators, examples of indicator and tests they are used for

12. Water R

13. Specific gravity, weight per ml, viscosity, and description of some syrup

14. Friability, hardness, and disintegration of tablet

e. Warehouse

The following are the theories learnt in the raw material, packaging and finished goods
warehouses:

1. Stocking

2. Types of packaging material which are primary that have direct contact with the product.
such as inner label, caps and inner cartoon and secondary packaging material that don’t have
direct contact with the product such as outer carton.

3. Standard operating procedure for receiving, storing, and dispensing of raw material

4.1.3.2 Practical Experience

The following are the practical experiences learnt during my internship:

a. Purified water treatment plant

1. Backwashing, rinsing, and filtering of sand and activated carbon beds

2. Regeneration of anion, cation, and mixed bed

3. Preparation of HCL and caustic soda solution

4. Chemical injection

94
b. Effluent treatment plant

1. Preparation of chemical for effluent treatment

2. Treating of 8000litres of effluent

3. disposing of sludge

c. Boiler and Compressor

1. Starting and stopping of a boiler

2. Blow down of a boiler

3. Sending of steams into granulation and compounding department

d. Production

1. Production process of coflin expectorant

2. Production process of metrozol 200mg, co-trox tablet and pentax plus caplet

3. Packaging process of syrups

4. Blisterring process of paragesic and co-trox tablet

e. Quality control laboratory

1. Media preparation

2. Microbial analysis of drugs, raw materials, and water samples

3. Chemical analysis of drug samples

4. Dissolution rate test

5. Melting point and solubility test

6. Production of water R and distilled water

7. Viscosity test

95
8. Weight per ml test

9. Friability test

10. Disintegration test

11. Hardness test

4.2 Challenges Encountered

The following are the challenges I encountered:

1. Obtaining of industry placement is quite difficult due to congestion and bureaucracy in most
organizations, and the lack of formidable existing industry partnerships between the
university and key industry players.

2. Lack of dexterities or flexibility in responsibilities given to interns.

3. Access to executives/authorities is nearly impossible.

4. Emphasis on errands being the major phase of learning rather than the standard phase of
learning.

5. Problematic situations that warrant high tasking knowledge capacity were not coming forth.

6. Being only engineering student

96
 CHAPTER FIVE

CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion
My four months field experience was practically intensive and enlightening as I was exposed to
the practical aspect of many theories. I appreciate been given the opportunity to learn better and I
also commend the teams in charge of this experience. I benefited a lot in the field attachment in a
way I managed to apply the theoretical knowledge from the university into practice through the
many activities/tasks/assignments I was instructed to do. I got different ideas from the different
people (employees) at the Organization and through interacting with other interns and this
contributed a lot on the knowledge and experience.

Finally, my internship was fun and therefore I would encourage that the school continues to give
students this opportunity to do their academic requirement of internship from this organization.
At the conclusion of this program, certain ideas, and myth i heard about the pharmaceutical

97
industry was debunked. I found it to be an interesting branch of pharmacy practice that is almost
always exciting with bundles of knowledge to uncover every step of the way, and the potential
adaptability to change and development

5.2 Recommendations

5.2.1 SIWES

1. SIWES has always been a platform for the formation of competent and productive technical
manpower for the economy

2. The establishment of a national commission of student industrial training or a national board

for cooperative education should be proposed to oversee the implementation of SIWES at
the national level.

3. The federal government should make adequate provision in the annual budget for proper
funding of SIWES. A view of the potential of the scheme to enhance the quality of the pool
of technical skills available to the economy

4. The stipulation that employers should accept students for SIWES should be strengthened.

5. The ITF should ensure that the back log in payment of student allowance is cleared urgently
to remove the negative image being created for SIWES

6. Tertiary institutions need to put more efforts in securing quality places of industrial

5.2.2 VITABIOTIC (Nigeria) Limited

1. Job enlargement: The management should see to it that they carry out job enlargement and
enrichment such that it mitigates the conflict amongst employees for roles and tasks. This
will ensure good industrial relations between the supervisors and subordinates at the
organization.

2. There should be more opportunities for students to do internship in the organization.

98
3. Serious supervision to the workers and students: The organization should increase and
ensure more supervision over the employees to work effectively and also eliminate workers
who relax, work lazily and perform actively after seeing their supervisors.

4. I would like to suggest for Human Resource to provide a meeting with student weekly or
monthly to ensure the welfare of the students are not ignored. It is important for ensuring the
health, welfare, and fitness of students in the company.

5. Graduate Trainee Programme.

5.2.3 University

1. Constant supervision of students: I recommend the university to carry out constant

supervision and monitoring of students during the internship training to encourage them to
perform the duties fully and accurately. This will also put a close link between the academic
supervisors and the field supervisors to foster appropriate assessment of what interns are
doing in the field.

2. Secure Internship placements for students: The University should help students to secure
internship positions according to their respective programs undertaken at the University
through giving students recommendations to ease their training periods and avoid the ache
gotten by students in search of internship placements.

99
 REFERENCES

 Industrial training fund-federal Republic of Nigeria. www.caniriv .com/ITF NIG/SIWES.PHP

 Shanmugam, s. (2015). Granulation techniques and technologies: recent progress. Bio impects, 5
(1):55-63

 Parikh M. (2016). Handbook of pharmaceutical Granulation technology 3 rd edition. USA:

Informa Healthcare.

 “Pumps and compressor”.Available at http://www.machinedesign.com/whats-difference-

between/what-s-difference-between-pump-and-compressor and

 https://www.britannica.com/technology/compressorRetrieved on 02-12-2021.

100
 “Differences between pumps and compressor”, “Types of compressors” and “Types of
pumps”. Available at http://www.machinedesign.com/whats-difference-between/what-s-
difference-between-pump-and-compressor. Retrieved on 02-12-2021.

101