British American Tobacco BangladeshMohakhali, Dhaka-1206

Ishrat Shamiem Ananta 0910007Md. Zobayer Hossain 0910053Saima Aktar Sumaiya 0910069Saif Khan Alen 0910077Samina Noor 0910136Shumaiya Ferdoush Mohona 0910147

Department of Mechanical EngineeringBangladesh University of Engineering and Technology

Industrial Training

Smoking is injurious to health

Industry at a glance

BAT is the 4th largest tobacco manufacturer in the world with a global market share of 12%

Among the 147 consumer countries of BAT only 50 countries manufacture cigarette

BATB is the oldest tobacco manufacturer in this subcontinent (103 years old)

Bangladesh is the second largest manufacturing country of BAT group

150 Million cigarettes per day, which is almost half of the total country’s demand

9 different brands of cigarettes are manufactured in BATB

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Industry at a glance (Contd…)

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Power and Energy Scenario

Limit of using up to 5 MW from DESCO 16 MW self generation capacity 5 CATERPILLAR Machines of 2000 KVA which give directly an output of

400 V All the plants are of Diesel Generator type Rock wool is used for sound insulation which attenuate noise, there are 2

mufflers to attenuate the noise Solar power generation of 11kW which requires an area of 2000 sq. ft.

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Primary Manufacturing Departments

The main raw material for producing cigarette is tobacco leaf Tobacco leaf has two main components: 1. lamina 2. stem

The primary function of PMD is to process the stem and lamina and supply it to secondary manufacturing department

After completing these processes for lamina and stem, they are mixed in the ratio of 4:1

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Primary Manufacturing Departments(Contd…)

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(4:1)

(16%)

(13%)

Secondary Manufacturing Departments (SMD)

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In SMD, filter rods from FRD & processed tobacco from PMD are combined to form a cigarette stick, wrapped in cigarette paper

From SMD, final products are dispatched SMD operations are divided into two parts

I) Making II) Packing Packer and maker makes a module. There are 22 modules in SMD

Filter Rod Manufacturing Departments (FRD) Filter rod is one of the most important and expensive part of a cigarette stick Filer rod has the following components_-acetate tow -seam glue –inner glue -plug wrap -plasticizer Filter rods are of different lengths depending on the brand of cigarette Filer rods are sent to SMD for assembling

Secondary Manufacturing Departments(Contd…)

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Tobacco pipe Hopper Pre-feeder Cutting drum Smooth roller Suction chamber Tobacco band Gum heater tape (Gum

nozzle)

First heater Cutting chamber (machine

knife) Spider finger Inlet drum Red cut drum (knife) Separating drum Filter feed drum

COMPONENTS OF A MAKER MACHINE

Secondary Manufacturing Departments(Contd…)

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PACKER MACHINE WORKING SEQUENCE

DRF and HVAC System

Total Capacity of HVAC system is 1244 Tons HVAC system cools the water, which then passes through the header and AHU to cool the

air There are primary and secondary pumps to boost the water from the chiller to the AHU The cooling tower has Fiber Reinforced Plastic (FRP) as its cover Legionella bacteria is very common in tobacco industry, so treatment plants are required

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The Pneumatic Feed Fan (PFF) consists of a motor, a blower fan and cyclone body containing filter bags inside it

The function of Dust Removal Fan (DRF) is only to remove dust and consists of similar components as PFF.

Boiler and Effluent Treatment Plant

One of the boilers is of 5 ton and another of 8 ton. Both the boilers are

fire tube boilers and have three pass.

Water is supplied to the boilers from a large feed water tank which is

filled by a deep tube well at a rate of 4000 kg per hour .

Brine solution is used as softener

The 5 ton boiler is gas driven. The 8 ton boiler is dual fuel, driven by gas

and diesel.

The boilers have no superheater or air preheater, only the 5 ton boiler

has an economizer.

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Boiler and Effluent Treatment Plant(Contd…)

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BAT Bangladesh’s CSR Activities CSR Activities :

• Afforestation

• Safe drinking water

• Solar home systems

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Assignments

Assignment-1: Digital Cataloging of Machine Parts

(under their ongoing 5S program)

Assignment-2: Time motion study of tobacco feeding

Further Recommendations

Use of Automatic Cartoning Packaging System in SMD.

Low speed modules need to be replaced.

Increase the level of workers in CTS to reduce time lag between the tobacco refill in the tipper feeder and desired tobacco level at the maker machine.

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Summary

British American Tobacco Bangladesh is an exemplary industry in the south Asia

It has enormous production of 150 Million cigarettes per day

It has a total self power generation capacity of 16000 KVA and a central HVAC system with almost 1244 Tons capacity

Efficient synchronization of man-machine-material and method

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THANK YOU

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ANY QUESTION?

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