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 Octagonal Blender (OB – 1000 LTR) using the integrated PLC/HMI system.
1.2 The SOP outlines the correct method to operate the equipment in Auto Blending, Manual Blending, Charging Mode, and Discharge Mode ensuring that each batch is processed consistently and safely, as referenced in PLC Manual – SEPL-12177.
2.0 SCOPE:
2.1 This SOP applies to all manufacturing operations involving OB-1000 installed in the blending area of the company, covering batch production, charging operations, discharge operations, troubleshooting and interaction with the PLC/HMI interface.
3.0 RESPONSIBILITIES:
3.1 Production Operators:
3.1.1 Responsible for operating the OB 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 Octagonal Blender: A rotating blending chamber used for uniform mixing of dry powders.
4.2 Homing: Positioning of blender to home reference point through PLC.
4.3 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 reach inside the blender while rotation is active.
5.1.3 Lock-out/tag-out procedure shall be followed during maintenance.
5.2 Prestart Check and operation:
5.2.1 The area shall be free from previous product, documents, or materials.
5.2.2 Line clearance shall be performed by Machine Operator followed by Designee Production and then Designee QA.
5.2.3 Inspect the blender to ensure that cleaning has been performed and documented as per the cleaning SOP.
5.2.4 Confirm availability of required utilities.
5.2.5 Switch ON the main power; the Welcome Screen shall be displayed.
5.2.6 Press the Login/Logout icon followed by entering assigned username and password.
5.2.7 Upon successful login, the home screen shall display mode selection, recipes, 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 as per BMR.
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 blending time and required IPQC sampling stages, 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 Blending mode executes the blending operation automatically based on the stored recipe parameters.
5.3.2 Navigate to Mode Selection and press AUTO BLENDING.
5.3.3 Review parameters and press START to initiate the cycle.
5.3.4 INCH and HOMING functions shall be available during Auto Mode as required.
5.3.5 Sampling may be performed through the SAMPLING function.
5.3.6 Press STOP to halt the process safely if required.
5.3.7 To resume after interruption, press RESET.
5.4 Operation in Manual Mode:
5.4.1 Manual Blending mode shall be used for controlled blender movement and troubleshooting.
5.4.2 Select MANUAL BLENDING from Mode Selection.
5.4.3 The operator shall use START, STOP, INCH, and HOMING functions as required.
5.4.4 RESET shall be used to clear sequence before restarting.
5.4.5 Manual operation overrides automatic sequence and shall be performed cautiously.
5.5 Operation in Discharge Mode:
5.5.1 Discharge Mode shall be used after completion of blending to transfer blended material.
5.5.2 Select DISCHARGE MODE from Mode Selection.
5.5.3 Discharge valve shall be operated using VALVE OPEN and VALVE CLOSE functions.
5.5.4 Valve operation shall be gradual to prevent material bridging.
5.6 Operation in Charging Mode:
5.6.1 Charging Mode shall be used for loading materials into the blender.
5.6.2 Select CHARGING MODE from Mode Selection.
5.6.3 CHARGING START shall begin charging and CHARGING STOP shall terminate charging.
5.6.4 HOMING may be used to position the blender for safe loading.
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 After completion of batch operations, ensure cleaning as per Cleaning SOP.
5.8.2 Stop all operations from the HMI and Logout from the system.
5.8.3 Switch OFF the main power supply.
6.0 REFERENCE:
6.1 PLC Manual – SEPL-12177, Octagonal Blender – 1000 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