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1 1 Introduction Ansell Lanka (Pvt) Ltd is owned by Ansell health care Limited in Redbank, America. In the protection barrier solution industry, Ansell plays a major role by producing surgical gloves, industrial gloves and condoms. Here in Sri Lanka, Ansell produces only surgical and industrial gloves which are marketed by Ansell International. 1.1 Vision We will be the most preferred manufacturer of medical and Industrial gloves, realized through a team of committed employees, for the professional & occupational healthcare markets for customer delight. 1.2 Mission Ansell behave on the own mission to be the most preferred manufacturer of medical and industrial gloves by implementing world class manufacturing practices to provide the safest working environment with consistently deliver customer value elements. 1.3 History In 1905, Sir.Eric Ansell started a balloon and condom manufacturing station in Melbourne, Australia. With time his two sons were engaged in his business. In 1925 they started a glove making factory in Richmond. They tried to produce their products by natural latex by developing various methods. However Ansell brothers had able to develop their products to a large scale and since 1960s, they were able to acquire new factories in Australia but in 1969 their factory was acquired by Dunlop Australia. Since then it has been successfully serving to the world by producing world class surgical and industrial gloves and condoms. Ansell Lanka (Pvt.) Ltd was established in export processing zone Biyagama in 1989, under the open economical policy of the Sri Lankan Government. Ansell Lanka covers an area of 25 acres and is the largest among the BOI factories. Total investment has reached to 800 billion US dollars and it is one of the strategically important plants of the Ansell International. Using experience and educated work force of 2500 employees with 12 dipping

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Ansell Lanka (Pvt) Ltd is owned by Ansell health care Limited in Redbank, America. In theprotection barrier solution industry, Ansell plays a major role by producing surgical gloves,industrial gloves and condoms. Here in Sri Lanka, Ansell produces only surgical andindustrial gloves which are marketed by Ansell International.

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Page 1: Ansell Lanka

1

1 Introduction

Ansell Lanka (Pvt) Ltd is owned by Ansell health care Limited in Redbank, America. In the

protection barrier solution industry, Ansell plays a major role by producing surgical gloves,

industrial gloves and condoms. Here in Sri Lanka, Ansell produces only surgical and

industrial gloves which are marketed by Ansell International.

1.1 VisionWe will be the most preferred manufacturer of medical and Industrial gloves, realized

through a team of committed employees, for the professional & occupational healthcare

markets for customer delight.

1.2 MissionAnsell behave on the own mission to be the most preferred manufacturer of medical and

industrial gloves by implementing world class manufacturing practices to provide the safest

working environment with consistently deliver customer value elements.

1.3 History

In 1905, Sir.Eric Ansell started a balloon and condom manufacturing station in Melbourne,

Australia. With time his two sons were engaged in his business. In 1925 they started a glove

making factory in Richmond. They tried to produce their products by natural latex by

developing various methods. However Ansell brothers had able to develop their products to a

large scale and since 1960s, they were able to acquire new factories in Australia but in 1969

their factory was acquired by Dunlop Australia. Since then it has been successfully serving to

the world by producing world class surgical and industrial gloves and condoms.

Ansell Lanka (Pvt.) Ltd was established in export processing zone Biyagama in 1989, under

the open economical policy of the Sri Lankan Government. Ansell Lanka covers an area of

25 acres and is the largest among the BOI factories. Total investment has reached to 800

billion US dollars and it is one of the strategically important plants of the Ansell

International. Using experience and educated work force of 2500 employees with 12 dipping

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machines in 25000 working area, it produces surgical and industrial gloves for the world

market. It owns an irradiation plant and a latex centrifuging plant in Paiyagala. Plant runs 24

hours around the clock in three shifts.

1.4 FunctionsAnsell Lanka produces surgical, examination and industrial gloves by Professional Health

Care and Occupational Health Care departments.

1.4.1 PHCIn this department, two types of gloves, examination gloves and surgical gloves are produced.

It consists of 8 dipping machines and 3 after processing areas.

1.4.2 OHCHere, various types of industrial gloves are dipped using 4 dipping machines and it is the

most profit making department.

1.5 Present performanceCurrently there are about 2500 employees working toward the establishment goals. Since the

plant is at its younger stage, now it is undergoing reforming its employees by recruiting new

employees and expanding the factory capacity to meet new customer demands. It has been

established new science and technology centers in both PHC AND OHC departments to

innovate new gloves and new techniques. As a solution to the present energy crisis, Ansell

has been able to establish a biomass boiler which is an example for other industries too.

1.6 Usefulness to Sri LankaAnsell serves Sri Lankans in many ways. By providing employment opportunities which pay

high salary, provide safe working environment and excellent welfare schemes, Ansell has

able to build up an excellent reputation in the Sri Lankan society.

In the welfare scheme, Ansell provides two full uniforms to every employee, claim medical

bills up to Rs. 2000 per year, free transport services for every employee, quality meal at Rs.5,

insurance for all the employee of the company, free medical service at zone medical centre by

the company, death donations and free medical checkups from a reputed hospital in

Colombo.

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1.7 StructureManagement responsibilities of Ansell Lanka consist of three separate divisions.

1.7.1 Management Team

3

1.7 StructureManagement responsibilities of Ansell Lanka consist of three separate divisions.

1.7.1 Management Team

3

1.7 StructureManagement responsibilities of Ansell Lanka consist of three separate divisions.

1.7.1 Management Team

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1.7.2 Manufacturing Team

4

1.7.2 Manufacturing Team

4

1.7.2 Manufacturing Team

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1.8 Quality Assurance DivisionAnsell Lanka has a well established, documented, implemented and maintaining quality

management system to ensure, continues improvement and to meet the company Quality

Policy Statement.

The company has adopted BS EN ISO 9001 of 2000, ISO 13485 of 2003, Medical device

directive 93/ 42/ EEC and QSR part 820 of 1997/1998, Japan Pharmaceutical affairs law

(specific to medical devices) as the basic for this quality management system.

The quality documentation consists of four levels.

The Company Quality Policy – “Comply with stated Product Quality Specifications,Comply with relevant regulatory requirements and Service the customer’srequirements whilst maintaining a cost effective manufacturing operation.”

The Company Quality Manual – describes the design and manufacture of sterilesurgeons’ latex gloves, the design and manufacture of sterile and non-sterile latexexamination gloves, the design and manufacture of industrial gloves

The documented procedures – there are Standard Operating Procedures,

encompassing drawings, electronic data information, specifications and work

instructions which describe the documentation procedures.

The records – store in a record office.

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Figure 1: Company flow chat

Qualityassurance and

regulatoryaffairs manager

Quality assuranceanalysis

QA chemist

Laboratorymanager

Senior QAauditor

QA supervisor

Senior labtechnicians

Recordoffice clerk

QA auditors

Data entryoperator

QA AuditorFRC-PHC

Labtechnicians

FRC leaders

FRCLeaders

Secretary

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1.9 Science and Technology Division – PHC

Figure 2: Science and Technology Division

Module directorS&T lanka &project liaison

director personal &professional

producttechnologies S&T

Quality controlchemist

S&T chemists

S&T seniorchemist

Senior labtechnicians

Senior labtechnicians

Senior labtechnicians

Labtechnicians

Secretary

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2 Production processesProduction processes are carried out in two main departments.

2.1 Professional health care departmentConsist of eight dipping machines in three divisions, beaded surgical, beaded synthetic and

DSG.

2.2 Beaded surgical divisionBeaded surgical division produces style 42, style 87, style 88 and under glove using two

dipping machines. Most of projects were related to the style 87 process and most of studies

were carried out on this department. Dipping times and temperatures, former temperatures,

drying time and temperatures and cure oven air circulation systems were monitored with

regard to the projects. Hot water distribution and circulation system, pneumatic system and

PID controllers are some of the features encountered with these machines. Two dipping

machines are run on a track which formers are mounted on a chain.

2.3 DSG divisionIn this division three main products are manufactured, Sensi touch, Medi grip and Gammex

in two machines. Machine 3A and 3B produces Sensi touch and Medi grip while machine 2

produces Gammex. These two machines and process steps are different from other machines.

MC 3 uses former racks which hang on a belt of alternatively moving up and down by

changing the running track orientation. In the MC 2, track moves in an ellipse and movement

of dipping tanks in up and down by hydraulic jacks which do the dipping.

After process at the DSG is also unique when comparing with other after processes.

Gammex gloves are washed in two cycles which uses reclaimed water for the first wash and

second wash by new hot water at 90C. After the first wash, waste water send through a HE

to pre heat new raw water to about 60C.

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Figure 4 plant layout

Table 1: list of contain in the figure 5

1 Exhaust 6 Filter box

2 Shutter 7 New air inlet

3 Screen 8 Screen

4 Shutter 9 Radiator

5 Shutter 10 Blower

3

6

109

1

7

8

45

2

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All Gammex gloves are then dried using a fluidized bed and then send to the chalker for re

powdering. Chalker uses magnesium carbonate powder and at the end of the cycle excess

powder which recycled again to powdering process is blow through a bed of filter clothes.

In anti microbial glove trail, PI gloves were washed using DI water in these washers. DIwater unit is consisting of sand filter bed, activated carbon bed, two anion beds and twocation beds. It has been design to reduce conductivity of raw water lower than 10 ms. It isdesign to run using gravity or using motor pumps. Since the temperature of these washingcycles is different, PLC settings of the washer had to be changed. It was done by changingthe ladder diagram by the. Also the level sensor of the side reserve of the DI water storagewas not worked due to low conductivity of the water. Hence a floating slip was used toovercome this problem.

2.4 Beaded synthetic divisionIn this section three dipping machines are in use. MC 1 produces TNT gloves which are

produced using synthetic latex and stripped using a auto stripper. It uses chlorinated post

leach tanks and it was monitored that those post leach tanks were leaking and in the annual

shutdown they were coated with fiber. Whole machine run using a cyclodrive gear system

Other two machines, MC 6 and MC 7 produce style 85, BDU, PI and PI micro gloves. PI and

BDU gloves are synthetic gloves which are compounded in a different method. For PI glove

production extreme care should be maintained.

After process area of this section consist of chlorine washers and dryers. From this section

chlorine fumes and powder dust are released. Hence they should be properly treated before

releasing to the environment. Chlorine fumes are treated using a scrubber which uses sodium

hydroxide with packing.

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Figure 5: Air cooling tower

Table 2: Contain in the Figure

1 Chlorine mixed air inlet 4 NaOH storage tank2 Scrubbing chamber 5 Circulating motor3 Cleaned air outlet 6 NaOH flow through the packings

Calcium carbonate powder is filtered using a filter unit with 68 filters. Dusty air is sucks from

a blower near the filter unit where the cleaned air passes through the filters by removing dust

in to the collection tanks. An air jet is alternatively eject into the filters in opposite direction

so that the dust on the filters are removed.

2

5

4

1 36

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Figure 6: Air cooling tower

Table 4 : list of contain in figure 6

Figure 7: air blower in the boiler

No Item Item

1 Air jet nozzles 5 Dusty air inlet

2 Air storage 6 Dust collectors

3 Cleaned air outlet 7

4 Filters 8

2

6 66

6

5

3

4 4 4

1