1.0 OBJECTIVE:
1.1 The objective of this SOP is to describe the operational steps for running the Fluid Bed Equipment (FBE – 200 KGS) using the integrated PLC/HMI interface in Auto Mode, Manual Mode, Charging Mode, and Maintenance Mode.
1.2 This procedure ensures safe, consistent and compliant operation of the equipment to achieve effective drying results as per batch production requirements, Reference to PLC Manual – SEPL-12175
2.0 SCOPE:
2.1 This SOP applies to all drying operations performed in the FBE – 200 KGS installed in the Granulation area at Company and includes batch processing, alarms monitoring, documentation and interaction with PLC/HMI.
3.0 RESPONSIBILITIES:
3.1 Production Operators:
3.1.1 Responsible for operating the FBE strictly as per this SOP.
3.1.2 To report any abnormal observations immediately.
3.2 Designee Production:
3.2.1 Responsible for ensuring that operators are trained and that the procedure is followed during every batch.
3.3 Designee Quality Assurance (QA):
3.3.1 shall ensure line clearance.
3.3.2 To verify compliance.
3.3.3 To review batch-related documentation.
3.4 Engineering Dept:
3.4.1 shall ensure equipment readiness.
3.4.2 To attend breakdowns.
3.4.3 To maintain the equipment and PLC/HMI system.
4.0 DEFINATIONS:
4.1 Finger Bag: The drying chamber assembly used to fluidize granules.
4.2 Product Container: Receives the processed dried product.
4.3 Blower: Air supply unit to fluidize drying chamber.
4.4 Recipe: A stored and preconfigured set of processing parameters used for automatic batch execution.
4.5 HMI/PLC: The touch-screen control system that allows the operator to run, monitor, and adjust machine functions.
5.0 PROCEDURE:
5.1 Safety Precautions:
5.1.1 Before operating the equipment, ensure that all machine guards, safety interlocks, and emergency stop buttons are fully functional.
5.1.2 Operators must never open the drying chamber while blower is running.
5.1.3 In case of maintenance or troubleshooting, the lock-out/tag-out procedure shall be followed without exception.
5.2 Prestart Check and operation:
5.2.1 The area shall free from previous product, documents, or materials.
5.2.2 Line clearance shall perform by Machine Operator followed by designee Production and Designee QA.
5.2.3 Inspect the equipment to ensure that cleaning has been performed and documented as per the cleaning SOP.
5.2.4 Operator shall Confirm availability of all utilities such as electrical supply, compressed air, and purge air.
5.2.5 Switch ON the main power; the system will display the Welcome Screen reflecting details as described in the PLC manual.
5.2.6 Press the Login/Logout icon on the Welcome Screen followed by enter your assigned username and password to access the main operating interface.
5.2.7 Upon successful login, the HMI will display the home screen, which contains navigation options for Auto Mode / Manual Mode / Maintenance Mode / Charging Mode / Recipe / Alarms / Reports.
5.2.8 Press the RECIPE button to open the recipe management screen.
5.2.9 Select the required recipe or create/edit one based on the batch manufacturing record.
5.2.10 The operator shall use the following functions as required:
5.2.10.1 EDIT to modify an existing recipe,
5.2.10.2 LOAD to retrieve stored parameters,
5.2.10.3 SAVE to store updated parameters,
5.2.10.4 DELETE to remove obsolete recipes.
5.2.11 Ensure that all parameters such as Air inlet temp, airflow, holding time, are verified.
5.2.12 Once the recipe has been reviewed, press BATCH START to prepare the system for automatic execution.
5.3 Operation in Auto Mode:
5.3.1 Auto Mode shall be designed to execute the drying cycle automatically based on the programmed recipe.
5.3.2 Navigate to Mode Selection and press AUTO MODE to open the Auto Mode dashboard.
5.3.3 Review the displayed parameters and press START to initiate automatic sequence.
5.3.4 The finger bag sealing/unsealing, finger bag UP/DOWN movement, blower, and damper operations will run as per parameters defined in the recipe.
5.3.5 The operator shall monitor progress of the drying cycle and view mimic diagrams.
5.3.6 If the process shall be stopped for any reason, press STOP. The system shall halt the ongoing cycle safely.
5.3.7 To resume after interruption, press RESET, reload the recipe, and restart the sequence.
5.4 Operation in Manual Mode:
5.4.1 Manual Mode shall be used when the operator needs to perform functional checks, specific controlled operations, or when troubleshooting shall be required.
5.4.2 Access Manual Mode from the Mode Selection screen.
5.4.3 The operator can independently control finger bag functions (LOCK/UNLOCK, SEAL/UNSEAL, UP/DOWN, shaking ON/OFF).
5.4.4 Product Container sealing/unsealing shall be performed as required.
5.4.5 Blower motor ON/OFF, air inlet valve OPEN/CLOSE, and air outlet valve OPEN/CLOSE may be performed.
5.4.6 Temperature control functions (START/STOP, damper operation) shall be executed only when necessary.
5.4.7 Manual Mode dominates automated logic; operators shall perform it with caution.
5.5 Operation in Charging Mode:
5.5.1 Charging Mode shall be used for material loading.
5.5.2 Select Charging Mode from the Mode Selection menu.
5.5.3 The charging cycle shall be started or stopped using CHARGING START.
5.5.4 Air inlet and outlet valves shall be opened or closed as required.
5.6 Operation in Maintenance Mode:
5.6.1 Maintenance Mode shall be used only when routine maintenance or specific functional tests are required.
5.7 Alarm Management:
5.7.1 If any alarm displays prominently on the HMI, the operator shall press ACK or ACK ALL to acknowledge the alarm and then review the alarm list or alarm history to understand the cause.
5.7.2 After rectifying the issue—whether due to door interlock, overload, communication fault, or utility failure—the operator may press Alarm Clear to remove the alarm from the active screen.
5.7.3 Mode reset may be required depending on the nature of the alarm. Alarm handling must always be documented appropriately.
5.8 Shutdown Procedure:
5.8.1 Upon completion of batch processing, ensure that the equipment is transitioned to cleaning as per requirement.
5.8.2 Stop all operations from the HMI, logout from the system, and switch OFF main power supply.
6.0 REFERENCE:
6.1 PLC Manual – SEPL-12175 Fluid Bed Equipment – 200 KGS
6.2 Equipment Cleaning SOP
7.0 RECORDS:
Sr No. Title Document No.
NA NA NA
8.0 REVISION HISTORY:
Amendment Date: Update Summary Version No.
NA New SOP 01