1.0 OBJECTIVE:
1.1 The objective of this SOP is to describe, in a clear and comprehensive manner, the step-by-step operation of the Rapid Mixer Granulator (RMG – 500 L) using the integrated PLC/HMI system.
1.2 The SOP outlines the correct method to operate the equipment in Auto Mode, Manual Mode, Discharge Mode, and Wash Mode, ensuring that each batch is processed consistently, safely, and in accordance with the parameters defined in the respective recipes, as referenced in the PLC Manual – SEPL-12173.
2.0 SCOPE:
2.1 This SOP applies to all manufacturing operations involving the RMG-500 L installed in the granulation area of the company, covering routine batch processing, cleaning operations, troubleshooting activities, and any interaction with the PLC/HMI interface.
3.0 RESPONSIBILITIES:
3.1 Production Operators:
3.1.1 Responsible for operating the RMG 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 Impeller: The main mixing blade responsible for blending powders and forming a homogeneous wet mass.
4.2 Chopper: A high-speed cutter that assists in breaking lumps and achieving the desired granule size.
4.3 Recipe: A stored and preconfigured set of processing parameters used for automatic batch execution.
4.4 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 attempt to open the bowl lid during equipment operation, and the impeller or chopper must not be run when the discharge valve is open unless specified for the process.
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 mode selection, recipe management, alarms, audit activity, reports, and settings.
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 impeller speed, chopper speed, binder addition timing, and granulation sequences 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 is designed to execute the entire granulation 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 batch parameters for accuracy and press START to initiate the automated sequence
5.3.4 The impeller, and chopper will operate according to the defined timing, speed, and binder addition logic embedded in the recipe.
5.3.5 The operator shall move across multiple screens using the Next arrows to monitor real-time progress of impeller/chopper speeds, binder addition status, processing times, and mimic diagrams, all of which are described in the PLC Manual.
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 an interruption, press RESET, reload the recipe, and restart the sequence.
5.3.8 Auto Mode shall always be preferred for batch production as it ensures consistency, accuracy, and compliance with pre-approved parameters.
5.4 Operation in Manual Mode:
5.4.1 Manual Mode shall be used when the operator needs to perform functional checks, perform 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 start or stop the impeller and chopper using the dedicated buttons displayed on the HMI.
5.4.4 By pressing the Next button, the second page of Manual Mode becomes available, through which the purging valve can be opened or closed as needed.
5.4.5 Manual Mode dominates the automated logic; operators shall perform it with caution and perform these actions only when explicitly required.
5.5 Operation in Discharge Mode:
5.5.1 Once granulation completes, use Discharge Mode to empty the bowl safely and efficiently.
5.5.2 Select Discharge Mode from the Mode Selection menu.
5.5.3 The discharge valve shall be opened or closed using OPEN and CLOSE controls.
5.5.4 The purging valve shall also be activated to prevent material buildup.
5.5.5 By pressing the Next button, operators may access controls for intermittent impeller and chopper operation to facilitate uniform discharge of wet granules.
5.5.6 The impeller ON/OFF timing shall be configured using the SET function.
5.5.7 The Wet Mill can be started or stopped as per downstream processing requirements.
5.6 Operation in Wash Mode:
5.6.1 Wash Mode shall be intended for equipment cleaning and maintenance activities.
5.6.2 Enter Wash Mode from the Mode Selection screen.
5.6.3 The operator shall open or close the discharge valve, raise or lower the impeller, and enable or disable purge air to assist in cleaning.
5.6.4 On the next screen, the impeller, chopper, and wet mill may be run to support effective cleaning.
5.6.5 These steps shall be executed as per the cleaning SOP to avoid equipment damage and ensure safety.
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 and discharge, ensure that the equipment is thoroughly cleaned or transitioned into Wash Mode as per requirement.
5.8.2 Once cleaning or further processing has been completed, stop all operations from the HMI, log out from the system,
5.8.3 Finally switch OFF the main power supply.
6.0 REFERENCE:
6.1 PLC Manual – SEPL-12173, Rapid Mixer Granulator – 500 Ltr (Saan Engineers)
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