A presentation on the quality control

measures of Birla White Cement

Presented By:

Mehadi Nawaz (2K91/M/26)

Ajay Prabhu (2K91/M/32)

Shabir Hussain (2K91/M/47)

Tutul Samanta (2K91/M/60)

U.Prabir Jaiswal (2K91/M/61)

Ashutosh Sharma (2K91/M/67)

Birla White Cement

BIRLA WHITE is brought to you by Grasim Industries Limited, a unit of the Aditya Birla Group

Established in the year 1988

Initial production capacity was 80 thousand tonnes

It is India's largest white cement producer.

Production capacity of over 550 thousand tonnes annually.

Quality certifications

Birla White is certified with ISO 9001 QMS system

ISO-14001 Certification – May 1998 OHSAS 18001 SA 8000. Its CEM I and CEM II grade of white cement are

CE Certified confirming its suitability for export to European markets.

Quality control

The Quality Control works in three stages namely

1. Input quality control - Involves the checking of quality parameters in the raw materials

2. In-Process quality control - Involves the checking of the outputs from various stages during the process.

3. Output quality control - Involves the testing of the white cement after final grinding and during packing

Process of Cement ProductionThe process of Cement production can be divided into the following stages:• Crushing• Homogenization• Proportioning• Grinding• Preheating and Burning• Quenching and Drying• Milling• Packing

Quality measures for Raw materials

Computerized mine planning and deposit evaluation to enable optimum use of raw material

Selective mining of Limestone is done manually to avoid impurities.

Online X-ray fluorescence spectrometer for raw material control and raw mix design.

Better aided instrumentation and process measurements using X-ray analysis, gas analyzers, temperature and pressure measuring devices, etc.

Quality measures taken for

Other quality measures taken

Vertical Roller Mills and Roller Presses, sourced from Pfeiffer and Koppern respectively, are used for cement grinding to ensure quality.

Manufacturing process is entirely automated and controlled by systems from ABB and Leeds & Northrup, USA.

XRF controlled QC systems are used to ensure superior quality.

continued

• First to introduce sealed valve bags for wall care putty, using Roto Seal Packer with Ultrasonic System to curb adulteration.

• Centralized kiln control system in conjunction with expert control systems for process and operation control.

• Continuous monitoring of quality in production by plants as well as by the certifying agency, namely, Bureau of Indian Standards (BIS) under compulsory Certification Scheme.

Quality method of cement storage

• All windows & doors are closed and weather & Moisture must not affect to the cement.

• Distance of stacking bags should be 1 feet from wall & 2 feet from ceiling.

• In one stacking put only max. 15 cement bags.

• Use of cement bags FIFO system.

• Put the cement bags on wooden-plates & than cover by the plastics-sheets.

Quality measures for safety

The regular safety inspection is done.Awareness and training programmes are being

conducted. A safety booklet in Hindi was published for

workers.Various competitions like slogan, poster,

declamation etc. were organised with regards to safety.

Safety week and safety day are celebrated.

Quality measures for Environment

External environment audits were conducted.Environmental monitoring were implemented to

maintain the ecological balance in and around the plant & mining premises.

The statutory requirements were duly compiled.Water management studies of the district were

carried out.Mass environmental awareness programmes are

being conducted

Awards and achievements

• IQRS Level –5 rating from DNV – May 2000• RGNQ Award Commendation Certificate – 2000• Chairman’s Silver Award for Mfg. Excellence 2002• CII EXIM Bank Award 2006• National Industrial excellence Award• Golden Peacock Occupation Health and safety Award-

2007• Indian Manufacturing Excellence Award -2007.