This internship report summarizes Mahmud Murtofa Salekin's 1-month internship at Aero Pharma from April 22nd to May 21st, 2014. The report provides background on Aero Pharma, describes Mahmud's observations of the company's store, manufacturing, packaging, and quality control departments, and includes 6 chapters with his findings, recommendations, and conclusion.

1. 9/7/2013
V.G. VAZE COLLEGE
INTERNSHIP
REPORT
ON
AERO PHARMA
Prepared By:
Mahmud Murtofa Salekin
Roll – 926
Internship Period: 22nd April – 21st May, 2014.
Post Graduate Diploma in Perfumery & Cosmetics Management
Prepared For:
Mrs. Anuya Joshi
Department of PGDPCM
Date of Submission: August 25, 2014

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LETTER OF TRANSMITTAL
August 24, 2014
Mrs. Anuya Joshi
Post Graduate Diploma in Perfumery & Cosmetics Management
V.G. Vaze College.
Dear Madam;
This is to inform you that I have completed the internship report titled Aero Pharma
which has been prepared as a requirement for the completion of the PGDPCM
Program.
While working on the report, I have tried to follow each and every guideline that you
had advised. It has been a very enlightening experience to work in this new venture
and I have thoroughly enjoyed my internship period Aero Pharma. The authority of
Aero Pharma has also extended their cooperation whenever required.
Sincerely Yours,
Mahmud Murtofa Salekin
Roll - 926

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Acknowledgment
I would first like to thank my faculty advisor, Dr. Renuka & Mrs. Anuya Joshi of
PGDPCM department of V.G. Vaze College, for guiding me throughout the course of
my internship program. Next I would like to thank Mr. B.S. Bobade, factory manager
for guiding me during my internship attachment with Aero Pharma.
This study required voluminous primary information which I could not have collected
properly in time without the help of my mentor/Supervisor Mr. Sachin, and all the
persons in manufacturing and color cosmetics, and Store department also deserves my
heartfelt thanks for their cooperation in helping me understand, participate, and
perhaps preparing my report.
Lastly, I would like to thank Mr. Alok, director of Aero Pharma to give the
opportunity to work in Silvassa. Besides that, thanks to my colleague Mr. Anuj Mishra
and Vipul Dharviya for continuous support during internship. Without their sustained
support such an exhaustive study would not have been possible.

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TABLE OF CONTENTS
No. CONTENTS Page No.
1.0 CHAPTER 1
1.1 Introduction of the Report 10
1.2 Objective of the Report 10
1.3 Methodology 10
1.4 Limitations 11
2.0 CHAPTER 2 12-14
2.1 Back Ground of the Organization 12
2.2 Beliefs & Policies 13
2.3 Business Models 14
2.4 Core Products 14
Chapter 3
3.0 A Glimpse of operation of Aero Pharma
3.1 Store Department 15
3.2 Manufacture & Packaging Department 16-18
3.3 QC Analysis Department 19 -21
Chapter 4
4.0 General Finding 22
CHAPTER 5
5.0 Recommendation 22

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Chapter 6
6.0 Conclusion 23

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CHAPTER 1
1.1 Introduction of the Report
I have worked under the two departments i.e, manufacture & packaging, store of Aero
Pharma from 22nd
April – 21st
May, 2014 . My internship program is an educational
requirement of PGDPCM Program under an assigned faculty of PGDPCM
department, V.G. Vaze College, which is a professional degree. PGDPCM students
have to do an internship program as a practical orientation to the workplace where
he/she can amalgamate the traditional hypothetical knowledge with practical work
experience.
1.2 Objectives of the Report
Broad Objective
� To utilize the experiences gathered during the internship
� To observe the activities and formulation process.
Specific Objectives
� To demonstrate different aspects of the organization.
� The operation and function of Aero Pharma.
� To present my observation of different and new raw materials
� To draw a comparative picture between the difference of Working in Lab &
Working in manufacture unit.
1.3 Methodology
The data needed to prepare this report has been collected from both primary and
secondary sources.

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Primary Data Source: Primary data has been collected through unstructured personal
interviews and discussions with officials from Aero Pharmas all Department.
Secondary Data Source: The secondary data have been collected through Aero
Pharmas official website.
1.4 Limitations
 While doing the internship program, I faced some obstacles. These are given
below:-
 Internship report is one kind of research work. Research work requires
enormous time and effort. But the time provide for Internship is not enough.
 As my working division is manufacture dept, it’s prohibited to disclose some
information. This affects the quality of the report.
 Lack of experience of this type project is one of the main constraints of the
study

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Chapter-2
2.1 Back Ground of the Organization
Aero Pharma Group of companies was promoted by Ravi Kamat and incorporated in
the year 1983. It started operations at Rabale, Navi Mumbai in 1995 and still has its
Head Office at Rabale.
Over the last 21 years, it has grown to become a multi-locational, multi-product
independent contract manufacturer for some of the most recognized names in India in
cosmetics and personal products, like Hindustan Lever Ltd, Aviance (Direct
Marketing subsidiary of HLL), Avon, Oriflame, Revlon, JK Helene Curtis (Park
Avenue), Gillette, Medicare, Marico, E. Merck, Godrej Sara Lee etc.
Today, Aero Pharma Group is one of the Largest Cosmetics and Toiletries Contract
Manufacturing Group in India, with manufacturing spread across two entities and
three locations (Aero Pharma P Ltd at Rabale and Murbad, and Aero Pharma
(Silvassa) at Silvassa). Both these entities are collectively referred to herein as Aero
Pharma. The total built-up area of these factories is 75,000 sq ft (5,000 at Rabale,
30,000 at Murbad and 40,000 at Silvassa). The plot size at Murbad can take a total
construction of 120000 sq. ft. (11500 sq. mtr.)
Aero Pharma is probably the only company in the country that offers to its customers
a wide range of products like Lipsticks, Foundations, Compact Powders, Eye Make up
products, Skin Care Creams, Hair Care Creams, Lotions, Shampoos, Aerosols like
Foams, Deodorants, Natural Sprays, Splash on etc. All these are packed in an array of
packaging choices like bottles, jars, tubes, sachets etc. Currently, at all three plants put
together, more than 1000 SKUs are manufactured every year, using more than 3,500
different items of stock.
Today, Aero Pharma is been chosen as the major contract manufacturer by Marico

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Ltd. to cater their export orders of Hair Creams and Hair Oils.
Its competence lies in the ability to handle high complexities even for relatively low
volumes, at competitive rates, while maintaining the highest quality standards. Aero
Pharma follows stringent quality procedures and adheres to GMP norms. Small
wonder then, that any major MNC manufacturer entering India invariably shortlists
Aero Pharma for consideration as a prime manufacturer and vendor.
2.2 Beliefs & Policies:
Aero Pharma strongly believes that the work environment should be conducive to the
workmen, the surroundings and the local regulations.
Aero Pharma has in place policies that guide each and every employee to work safely
in an environment friendly manner and keep the interests and safety of the consumer
in mind. Besides having inhouse Safety and GMP Manager, its plants are regularly
audited for Plant and Workers’ Safety, Consumer Safety etc and have consistently
scored well. This is apart from the statutory audits carried out by the respective local
government audit teams.
Aero pharma belief in the following policies:
• Respect for human life.
• Commitment to prevent all accidents as all
risks & accidents are preventable.
• Need to provide machinery & technology with
proven safety standers.
Health and
Safety Policy
• Follow standards of environmental safety.
• Maintain environmental management systems
• Assess environmental impact
Environment
Policy
• Define and set standards
• Record and monitor methodically every stage
of operation.
• Take corrective actions if any quality issue
arises of product at any stage.
Quality and
Consumer Safety
Policy

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2.3 Business Model
2.4 Core Products:
Contract
Manufacturer
Company Consumers
Marketing
Distributors
Consumers
Face care Lip care Eye Care
Skin care Hair care Body Care

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CHAPTER 3
A GLIMPSE OF OPERATION OF AERO PHARMA
The above departments are the major departments of Aero Pharma. Besides that, the
Accounts department also which plays a very big role in paying the suppliers, staffs and
collect money from the distributors.
3.1 Store Department:
Packaging materials and Raw materials are kept in the store. There are two stores for
packaging and raw materials. Besides, that there is another store also for keeping the perfume
in a specified temperature. To register in the material register book and to dispatch the
materials the store department follow FIFO (First-in First Out) METHOD. The store
process the materials in the following manner:
Main
Departments
Store
Manufacture
& Package
Quality
Diagram of major departments

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3.2 Manufacture and Packaging
Department:
Manufacture and packaging department works in hand to hand. HUL(Hindustan
Unilever Limited) provide the list of products before 13 weeks to manufacture
department. According to the requirements, the department manufacture the products
and in the manufacturing process they follow the HUL’s given formula. While
working the department monitor the following parameters:
PM/ RM
Enter
Issue vehicle
checklist
Record in the
material
register book
Send to QC
Accept/
Reject/ Hold
If accept:
Record in the
stock book
If reject:
Return
If hold: Wait
for clearance
No. Stage Cause What to check
1. Receipt of materials Manufacture Damage Boxes/ Bags
2. Oil Phase filtration Manufacture Condition of filter bag
3. Particle Size Manufacture Particle size on
Hegmann Guage
4. Filtration of Solid Body/ Bulk Manufacture Condition of S.S. Sieve
5. Bottle washing Manufacture Ensure proper packing
after washing
6. Filling M/c End of Line Strainer Manufacture Condition of Strainer

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No Stage Cause What to check
1. Receipt of materials Microbes Check Wet boxes/ Bags
2. Check of incoming material Micro Check Micro Checking
3. Pasteurization of water Micro Check Chart record for
temperature
4. Sanitization of equipments for batch
manufacture
Micro Check Contract time of
sanitizers
5. Addition of Preservative to Batch Micro Check Quantity &
Sequence
6. Sanitization of storage kettle Micro Check Contract time of
sanitizers
7. Sanitization of filling M/c Micro Check Contract time of
sanitizers
8. Sanitization of Moulds & Molding
kettle
Micro Check Cleanliness
9. Autoclaved dries Micro Check Check tag on
material
While manufacturing the products the department maintains the following procedures:
Receive Raw
Materials
Cleaning of S.S.
Sieve
Receive the
formula
Put the raw
materials
according
formulla
Complete
production
Send to QC If Accept: Send for
packaging
If hold/reject:
Wait for clearance

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Process of Lipstick:
1. Preparation of the lipstick base and preserve the lipstick base for 1 day.
2. Send the Base sample to QC for checking following parameters:
 Melting point
 Soften point
 Break point
 Transaction trial test
3. Next day, check the stability test and color shade match of the base.
4. Heat the base to 70 – 80 degree Celsius.
5. Weigh and add the other raw materials like waxes, preservative, anti oxidants
etc and mix well using stirrer.
6. Allow the wax blends and other materials melt completely at 75 degree
Celsius.
7. After 1 to 2 hours, collect 20 gram sample for QC Analysis to test Peroxide
Value.
8. If the QC approves, then weigh and add the required color muds and pearl (If
any) and stirr for 25 – 30 minutes to avoid aeration.
9. Once the shade is deaerated add perfume at 35 to 40 degree Celsius under
moderate stirring for 5 to 10 minutes.
10.Draw out a sample mould (10 Salves) and send to QC for analysis and
microbiology test.
11. Analysis Parameters:
 Pay off
 Appearance
 Odor
12.Microbiology test parameters:
 TVC – Total variable count
 YTM – Yield of material

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Packaging Department:
After receiving the product from manufacture department packaging department start
package the products and send to the
dispatch department. In packaging
Aero Pharma maintains CQRS
method which is internationally
accepted method and follow it only
for the consumers good.
Permissible Error:
HUL accepts 10 % error from Aero Pharma while packaging and
HUL will also pay for the errors. If the errors are beyond 10% then
HUL is not compel to pay. The error chart is given below:
3.3 QC Analysis Department:
After test the product the QC sticks 3 labels to the products:
 Red label – Fail/ Reject

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 Green Label – Pass / Accept
Yellow - Hold
Although I did not get the opportunity to work in QC. But I am discussing the basic
activities of QC Department. For maximum products the QC conduct the following
tests:
1. Viscosity
2. pH
3. Water % check
4. Bulk density check
5. Appearance
6. Odor
7. Color
8. Melting point
9. Microbial test
10.Acid Value/ SAP Value/ Peroxide Value/ Ash Value
Demineralize Water Analysis test criteria:
Water is one of the major ingredients in cosmetic industry. Without proper water
cosmetics can be damage for microbes. So, the following tests are taken by QC:
No Tests Standard result
1. Appearance / Color Clear, colorless, liquid
2. Odor Odorless
3. Conductivity Max 5 us/cm
4. pH 5 - 7
5. Water hardness Max 0.5 degree FH
6. Solids Max 10mg/kg
7. Sulfates Pass the test
8. Chloride Pass the test

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9. Arsenic Max 2mg/Ltr
10. Heavy Metals (as Pb) Max 15mg/kg
Quality Incident Pyramid

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CHAPTER 4
5.0 General Finding
This internship helped me a lot to know about the recent scenario of the
cosmetic industry of India. I have got knowledge about Aero Pharma as well as
their clients like HUL and the manufacture, store, packaging and quality
process. By researching about company, I have got to know about the
formulation, packaging, microbes testing etc. It helped me to find out the Pros
& Cons of different company products. By researching, i have got to know
about the challenges that company faces during the period & also learnt what
steps took to mitigate the challenges.
Chapter 5
RECOMMENDATION
After going through the above project work Aero Pharma we found, Aeropharma is
trying to grab all the opportunities to be successful in India Cosmetic Market as
contactor. But considering the present scenario, I would like to draw their attention
over some of the following facts.
 Lack of Human Resources in the company.
 Workers are not properly motivated for the salary structure
 Store people should more concern about the hazardous material.
 Should make a different store only for hazardous materials.

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Chapter 6
CONCLUSION
Aero pharma is one of the leading cosmetics contractor company in India. I was
always interested to know about the manufacturing, quality etc of the company. So it
was a great opportunity for me to work at Aero Pharma as an intern. After 1 month
of my Internship, I have got to know many facts about manufacturing &
formulation, technical process which were like a hidden treasure for me In this
report, I tried to describe the all departments functions of Aero Pharma.

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Picture Gallery
Hegmann Guage: Used
to measure Particle
Size i.e, Kajal
Lipstick Base
Lipstick Blending Waxes
& Colors
Lipstick Mold
Triple pressed Rolling
Machine : use for make
small particle of Kajal
Kajal Packaging
Machine