1. 1
Summer Internship Report
A Study on the Production Department at
Auriga
Group of Companies.
By
Tahir saeed
DDP-FA12-BEC-073
Duration: 3rd
Aug to 31st
Aug
Department of Chemical Engineering
Submitted To
Sir Tariq Mehmood Raza
Comsats Institute of Information Technology

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Acknowledgements
‘InthenameofAllah,themostGracious,themostmerciful’
Internship remained a great experience for me as it added a lot to my knowledge.
It requires continuous hard work and zeal. I think that there are many people who
contributed a lot to this report and completion of this report would have not been
possible without the support of all these people, my respected teachers, my friends and
my well-wishers. I would like to mention that Mr. Rehan Paracha, who was
Production Manager at Auriga group of companies, has been very kind and supportive
throughout my stay at there. I would like to pay my gratitude to all my respected
teachers for their guidance and assistance in the completion of this report.
My gratitude will always remain due to the COMSATS Institute of Information
Technology and especially Auriga group of companies in increasing my
knowledge and experience by providing me such an opportunity. Both these
prestigious institutions will have a lasting impact on my life.
May Allah Bestow His Blessings on All of us.
Tahir saeed
COMSATS Institute of Information Technology, Lahore

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Table of contents
Executive Summary 4
Introduction/Background 5
Goals/Objectives 6
Granular Plant 7
Introduction 8
Raw Material 9
Explanations 10
List of Machinery 11
Emulsifier Concentrate 12
Introduction 13
Raw Material 14
Explanations 15
List of Machinery 16
Bio Organic Plant 17
Introduction 18
Raw Material 19
Explanations 20
List of Machinery 21
Wettable Powder 22
Introduction 23
Raw Material 24
Explanation and List of Machineries 25

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Executive Summary:
For almost half a century, the global agricultural system has relied heavily on the widespread
application of millions of tones and hundreds of types of synthetic chemical pesticides to
reduce crop losses. As most farmers are now treating their crops with a variety of pesticides
on a routine basis, rather than as a last resort in rare cases of heavy pest infestations, this
means that chemical inputs are applied multiple times to a crop throughout the whole
growing season. As a result of our dependence on chemical pesticides, and because of their
persistence and pervasiveness, almost every ecosystem on earth has already been negatively
impacted by these harmful chemical compounds.
How Industrial Agriculture Damages our Environment.” examines the use of synthetic
chemical pesticides in Pakistan, the widespread and severe environmental impacts they are
having - including how they are degrading some essential ecosystem services and, the
urgency of tightening the regulations that are supposed to control their use. The production,
sale and use of synthetic chemical pesticides has become a multi-billion euro industry
dominated by a small number of agro-chemical businesses. As well as Auriga group of
companies is taking part in producing pesticides, insecticides by means of planting different
types of Plants. Like Bio organic Phosphate, Wettable Powder Plant, Granulation Plant and
Emulsifying Plant.

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Introduction:
Auriga Group of companies is committed to make Pakistan self-sufficient in agriculture
because it is the largest productive sector and a bulk of our population depends upon it. With
population increasing to alarming levels, Pakistan’s agriculture needs to become more
productive and sustainable. Only agricultural innovations can help us cope with the situation.
Auriga Chemicals is the parent company. Auriga well built sales and marketing network with
a team of almost 400 dedicated agriculture graduates and 7 warehouses across Pakistan. The
company markets quality agricultural inputs at affordable prices backed by the on-farm
advisory service. This kind of marketing creates a win-win situation by guiding farmers to
manage weeds and increase yield potential. We are operating to make farming a
commercially sustainable and growing business.
Taking clue from the overwhelming success of Say-ban One Stop Shop, Auriga Group has
set up Auriga Solutions Centers on various locations to assist the farming community. From
providing agro products to free advisory services to the farmers and growers, Auriga
Solutions Centers support the agro community in growing more and reaping even more.
Auriga fertilizers is basically a research and production wing with a mandate to develop
novel combinations of micro and macro nutrients, together with growth regulators and
growth promoters, specific to different crops. We take pride in being the pioneers in this
industry and giving new trends to agribusiness industry. Our famous brands like Zarcon,
Zeneca, Galore, Grow up, Comus and Vital have become industry standards. The products
have unique combinations of micro and macro nutrients targeting different segments of the
market as per need of the specific soil and crops. Our next product from this wing is true
Potassium Humate. The test supply to the market has proven it to be a very good product and
we aim to take over 40% of the market in next couple of years

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Goals and Objectives:
The main objective of this summer internship is to gain experience in perspective chemical
Industry. Throughout the stay at industry I learn so many points.
 I learned all about working in production department of a chemical industry.
 I developed the communication skills needed to respond to the Managers and lay man
workers.
 I analyze how to tackle industrial problems regarding any issue.
 I learn to develop appropriate solution to a problem in a short period of time.
 I planned to study the methods of maintaining product quality by this firm.
 I learned to apply the principles of chemical engineering to different plants which I
have learnt in my university.
 I also learned the chemical, electrical, and mechanical part at my stay at Industry.
 I also develop solutions to environmental problems, such as pollution control by
giving them my opinions.
 I also learned the pesticides formulation by different processes at my stay at Industry.
The objective of internship will make it easier for me to find work and get off to a good
start in our career. Internships represent a cross-over point between university and career,
and will not only help us in my career, but also in planning our studies. The experience
we gain during an internship will indicate how we should structure our future studies,
particularly when it comes to deciding what aspects you should focus on. An internship
and our study focus will thus help you establish our individual career profile.

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Granular formulation and Packing Unit
What is meant by Granules?
A rock or mineral fragment larger than a sand grain and smaller than a pebble. Granules have
a diameter between 2 and 4 mm (0.08 and 0.16 in) and are often rounded.
 Granular Formation:
Granular formulations are similar to dust formulations except that granular
particles are larger and heavier. The coarse particles are made from an absorptive
material such as clay, corn cobs, or walnut shells. The active ingredient either coats
the outside of the granules or is absorbed into them. The amount of active ingredient
is relatively low, usually ranging from 1% to 15%.
Granular pesticides are most often used to apply chemicals to the soil to control
weeds, nematodes, and insects living in the soil. Granular formulations are sometimes
used in airplane or helicopter applications to minimize drift or to penetrate dense
vegetation. Granular formulations also are used to control larval mosquitoes and other
aquatic pests. Granules are used in agricultural, structural, ornamental, turf, aquatic,
right-of-way, and public health (biting insect) pest control operations.
Advantages:
 Ready to use, no mixing.
 Drift hazard is low, and particles settle quickly.
 Little hazard to applicator (no spray, little dust).
 Weight carries the formulation through foliage to target.
 Simple application equipment, such as seeders or fertilizer spreaders.
Disadvantages:
 Do not stick to foliage or other no level surfaces.
 May need to be incorporated into soil or planting medium.
 May need moisture to start pesticide action.
 May be hazardous to non-target species, especially waterfowl and other birds that
mistakenly feed on the grain like or seed like granules.

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Raw Material for the Formulation of Pesticides.
The raw material contains four products to reach formulation. These are as follow:
 Silica
 Slurry
 Car tap
 China Clay
 Silica:
Silica is important in plant and animal life. Diatoms in both fresh and salt water extract silica
from the water to use as a component of their cell walls.
Many pesticide formulations are adversely affected by moisture, humidity, the presence of
viscous liquids, and static charge. Silica is the main ingredient in formulation, approximately
for 1 batch 1.774 tons of silica is used.
 Slurry :
A thin mixture of a liquid, especially water, and any of several finely divided substances,
such as cement, plaster of Paris, or clay particles. But the slurry made for pesticides is quite
different from the above explanation. The slurry for pesticides includes Phosphoric Acid, Peg
6000 and Dye/Color. A total of 42 kg of slurry is used for 1 batch, which is a mixture of Peg
6000 car tap and color.
 Phosphoric Acid :
Phosphoric acid is a colorless, odorless, relatively strong acid which is either a sparkling
liquid or transparent solid, depending on its concentration and temperature. Phosphoric acid
is soluble in water and alcohol and is corrosive to ferrous metals, alloys, porcelain, and
granite ware. It is manufactured by the treatment of phosphate rock. Phosphoric acid is
registered as a bactericide and disinfectant. It is used to disinfect dairy farm milk handling
facilities, equipment and dairy animals, and food processing water systems. Agriculturally,
phosphoric acid is registered as an adjuvant. In the formulation of pesticides 37 kg of
Phosphoric acid is used for 1 batch.
 Peg 6000:
A compound used to modify therapeutic proteins and peptides to increase their solubility. It
is often used as a polar stationary phase for Gas Chromatography. Commonly also used in
mass spectrometry experiments. It is also used to preserve objects that have been retrieved
from the ocean. In pesticides it can be used because it can well dissolved in Phosphoric acid.

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Peg has low toxicity with systematic absorption less than .5 %. 25 kg is used for 1 batch
processing.
 Technical Information
Physical State : Solid.
Solubility : Soluble in water (500 g/l) at 20 °C.
Storage : Store at room temperature
Melting point : 60-63 °C.
 Dye/color: Dye or color is used to give color to the final product. The whole
batch consumes 1.25 kg of Dye/Color.
 Cartap :
A highly effective, broad-spectrum, low toxic and low residual insecticide, Car tap is a
systemic insecticide with stomach and contact action. Insects discontinue feeding, and die of
starvation. Car tap hydrochloride is used, at 0.4 - 1.0kg /ha for controlling chewing and
sucking insects (particularly Lepidoptera and Coleopteran), at almost all stages of
development, on many crops; including rice, tea, cotton, potatoes, cabbages. A total of 75 kg
is used for the process
 China Clay :
China clay is being used very effectively as a carrier in pesticide industries. In pesticides
formulation 37.5 kg is used for 1 batch. It can be used as a carrier for beneficial micro-
organisms such as strains of trichoderma. It can also be used as an anti-caking agent in the
production of fertilizers.
Benefits:
 It acts as excellent carrier.
 Low moisture content.
 It can be slurred in water for spray applications.
List of Machinery Which Is Utilized For the Formulation of Pesticides:

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 Conveyor Belt :
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor). A belt conveyor system is one of many types of conveyor systems. A belt
conveyor system consists of two or more pulleys (sometimes referred to as drums), with
an endless loop of carrying medium the conveyor belt that rotates about them. One or
both of the pulleys are powered, moving the belt and the material on the belt forward. The
powered pulley is called the drive pulley while the unpowered pulley is called the idler
pulley. Its Rpm is 45 to 50.
 Induction Motor :
The of the most common electrical motor used in most applications which is known as
induction motor .This motor is also called as synchronous motor because it runs at a
speed less than synchronous speed. In this, we need to define what synchronous speed is.
Synchronous speed is the speed of rotation of the magnetic field in a rotary machine and
it depends upon the frequency and number poles of the machine. An induction motor
always runs at a speed less than synchronous speed because the rotating magnetic field
which is produced in the stator will generate flux in the rotor which will make the rotor to
rotate, but due to the lagging of flux current in the rotor with flux current in the stator, the
rotor will never reach to its rotating magnetic field speed i.e. the synchronous speed. It
has different Rpms which includes 1400, 900, 2800 and 750 Rpm
 Rotary Dryer :
Rotary dryers are known as the workhorse of industrial dryers. They are able to process a
wide variety of materials, and can lend a hand in nearly any industry requiring industrial
drying solutions. Its Rpm is 6-8.
 Rotary Seive Drum :
The Rotary sieve is ok with dry compost and handles typical loads/sizes. However it
tends to clog up when used with moist compost. Some large pieces can jam and you’ll
need to stop and clear them before carrying on. Its Rpm is 11-13.
 Elevator :
An elevator is a type of vertical transport equipment that moves people or goods between
floors (levels, decks) of a building, vessel, or other structure. Elevators are generally
powered by electric motors that either drive traction cables or counterweight systems like
a hoist, or pump hydraulic fluid to raise a cylindrical piston like a jack. Its Rpm is 55-60.
 Slurry Tank:

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Where slurry is made.
 Agitator :
An agitator is device or mechanism to put something
into motion by shaking or stirring. There are three main types of agitation
machine. The washing machine agitator, which rotates back and forth; the magnetic
agitator, which contains a magnetic bar which rotates about a magnetic field; manual
agitation, such as with a stirring rod. Its Rpm is 25 to 30.
 Cyclone:
Cyclonic separation is a method of removing particulates from an air, gas or liquid
stream, without the use of filters, through vortex separation. Rotational effects
and gravity are used to separate mixtures of solids and fluids. The method can also be
used to separate fine droplets of liquid from a gaseous stream.
 Mixer :
The terms "mixing" and "blending" are often used interchangeably, but in general
blending is a much gentler process. All mixing and blending can be categorized as either
a batch or continuous process. Batch mixers are typically used when production quantities
are small, strict quality control is needed, or the blend formula changes frequently.
Continuous mixers are typically used for high production rates, combinations of multiple
process streams, or to eliminate batch to batch variations.
 Vibrator Seive Tray:
This is used to separate the final product from big particles. So that there should b no
inconvenience in packing unit.
 Hopper
 Burner
Lists of improvements in Granular formation and Packing unit:
 Environment of the surrounding area should be get better, if we install more than 5
exhausts fans in vicinity of the process area.
 After every three months, there should be kept an eye on maintenance factor of each
machine installed in the process. If not it should effect on the production and
economy of the product, and also it is dangerous for the plant operators to deal with
excess corrode machinery.

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 Conveyor belts should be moving on proper channel or they create difficulty in
transporting material.
 Cyclone should be check after it exhausts all the unnecessary fumes or dust to prevent
chocking in the lower section of the cyclone.
 The gears and chain should be greased after 1 hour, because heavy machinery cause
or eradicate friction while the gears are moving.
 Wet material should not be used in rotary sieve drum because it will choke the
different mesh no sieves, which creates resistance to flow of sand particles
 To save time and labor work, electrical buckets should be used for the transportation
of material drum sieve drum to elevator.
 Heavy load in elevators should not be used because the material starts choking in the
base of elevator, which creates difficulty for the elevator to work.
 Pressure valves should be used carefully, because not to face any inconvenience.
 Blower should be mounted on each mixer to extract the fumes and dusts for the safe
environments.
 Proper amount and time should be given to slurry for the better results.
 For mixer cleaning there should be use of some effective liquid, which saves time and
labor work.
 Motor speed should be driven at optimum speed.
 Pipes should be clean to prevent resistance to flow.
 More than two sieves required after the final dryer process, to save time and better
product.
EMULSIFYING CONCENTRATE
Emulsifier Concentrate:
These formulations usually contain a liquid active ingredient, one or more
petroleum-based solvents, and an agent that allows the formulation to be mixed with water
to form an emulsion. Each gallon of EC usually contains 25% to 75% (2 to 8 pounds) active
ingredient. EC’s are among the most versatile formulations. They are used against
agricultural, ornamental, turf, forestry, structural, food processing, livestock, and public
health pests. They are adaptable to many types of application equipment, including small
portable sprayers, hydraulic sprayers, low-volume ground sprayers, and mist blowers.
Advantages:
 Relatively easy to handle, transport, and store.
 Little agitation required and will not settle out or separate when equipment is
running.
 Will not plug screens or nozzles.

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Disadvantages:
 Solvents may cause rubber or plastic hoses, gaskets, and pump parts and surfaces
to deteriorate.
 May cause pitting or discoloration of painted finishes.
 Flammable (should be used and stored away from heat or open flame
Raw Material:
 Pyriproxyfen
 Nansa
 NE 5000
 Xylene
Pyriproxyfen:
Pyriproxyfen is a pyrine based pesticide which is found to be an effective
against a variety of artopoda. Its formula is C20H19NO3. One batch contains 1400 kg of it.
Mode of Regulator: Insect growth regulator; Suppressor of embryogenesis, inhibitor
of metamorphosis, and inhibitor of reproduction.
Nansa:
Nansa is non ionic surfactant which is a white to light yellow flakes, granules or
powder. It is soluble in water. The primary hazard is the threat to the environment. Immediate
steps should be taken to limit its spread to the environment. It is used as a synthetic detergent.
One batch contains 348 kg of it.
Xylene:
Xylene, xylol or dimethylbenzene is an aromatic hydrocarbon mixture consisting of
a benzene ring with two methyl groups at various substituted positions. The three isomers of
Xylene have the molecular formula C8H10, also represented by the semi-structural
formula C6H4 (CH3)2. Xylene is a major petrochemical produced by catalytic reforming and
also by coal carbonization in the manufacture of coke fuel. It represents about 0.5–1% of
crude oil (depending on the source), and is found in small quantities in gasoline and aircraft
fuels. Xylene is mainly produced as part of the BTX aromatics (benzene, toluene and
xylenes) extracted from the product of catalytic reforming known as "reformate". The
mixture is a slightly greasy, colorless liquid commonly encountered as a solvent. One batch
contains 10255.2 liters of it.

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List of Machinery:
Mixer:
Mixing is a unit operation that involves manipulation of a heterogeneous physical system
with the intent to make it more homogeneous. Mixing is performed to allow heat and/or mass
transfer to occur between one or more steams, components or phases. Modern industrial
processing almost always involves some form of mixing. Some classes of chemical
reactors are also mixers. With the right equipment, it is possible to mix a solid, liquid or gas
into another solid, liquid or gas.
Ball Valve:
A ball valve is a form of quarter-turn valve which uses a hollow, perforated and pivoting ball
(called a "floating ball") to control flow through it. It is open when the ball's hole is in line
with the flow and closed when it is pivoted 90-degrees by the valve handle. The handle lies
flat in alignment with the flow when open, and is perpendicular to it when closed, making for
easy visual confirmation of the valve's status.
Filters:
The filter which is used in Ec plant is cartage filter. Cartridge filters have large surface areas
enabling them to operate for long periods. Cartridge filter systems also permit better water
flow thus, placing less strain on the filter pump. These types of filters are also easiest to clean
by using a flow of high-pressure water from a hose. The filters are made of polyester or other
material that can provide a superfine filtering surface. The pleats are the key to the filter's
operation. The tight pleats, or folds, allow for a large amount of material to be used in a small
container. The more material used, the larger the surface area available to capture dirt or
debris from the water. The fabric catches and holds the impurities until the filter can be
cleaned or replaced. There 3 parts to a cartridge filter construction, end caps (made of plastic)
core structure to provide strength (most often PVC) and the pleated media (most often
polyester with a continuously graded fixed pore structure, these cartridges provide pre- and
final filtration within the same cartridge resulting in lower overall filtration and disposal cost.
Motor:
An induction or asynchronous motor is an AC electric motor in which the electric current in
the rotor needed to produce torque is obtained by electromagnetic induction from the
magnetic field of the stator winding. An induction motor therefore does not require
mechanical commutation, separate-excitation or self-excitation for all or part of the energy
transferred from stator to rotor, as in universal, DC and large synchronous motors. An
induction motor's rotor can be either wound type or squirrel-cage type. The motors in Ec
Plant are of 20 Hp. They are made up of mild steel.
Centrifugal Pump:

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Centrifugal pumps are a sub-class of dynamic ax symmetric work-absorbing turbo
machinery. Centrifugal pumps are used to transport fluids by the conversion of rotational
kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically
comes from an engine or electric motor. The fluid enters the pump impeller along or near to
the rotating axis and is accelerated by the impeller, flowing radically outward into a diffuser
or volute chamber (casing), from where it exits. The centrifugal pumps in Ec plant Hp is 30.
The pump rpm is 2900.
Agitators:
Agitator is a device to put something into motion by shaking or stirring. There are three main
types of agitation machines like the washing machine agitator, which rotates back and forth;
the magnetic agitator, which contains a magnetic bar which rotates about a magnetic field;
manual agitation, such as with a stirring rod. The mixer agitator’s rpm is 50. They are made
up of stainless steel.
Gate Valve:
A gate valve also known as a sluice valve, is a valve that opens by lifting a round or
rectangular gate/wedge out of the path of the fluid. The distinct feature of a gate valve is the
sealing surfaces between the gate and seats are planar, so gate valves are often used when a
straight-line flow of fluid and minimum restriction is desired. The gate faces can form a
wedge shape or they can be parallel. Gate valves are primarily used to permit or prevent the
flow of liquids, but typical gate valves shouldn't be used for regulating flow, unless they are
specifically designed for that purpose. Because of their ability to cut through liquids, gate
valves are often used in the petroleum industry.
List of Improvements:
 Due to low voltage most of the equipments don’t work, if some work they don’t last for
a long period of time.
 Valves should be operated well.
 Motors should be operated at desired voltage otherwise due to uneven voltage they are
useless.
 Filters should be prevented from choking otherwise they don’t work.
 Washing of the equipment should be done prior to using any other material in the
mixers.
 After every three months maintenance factor should be kept in mind.
 There should be sensor on every motor so that it trips if the voltage is low.
 The equipments used in the Industry should not across 40 dba noise.
 Agitator speed should be optimum for better mixing.

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 While taking work for pump, it is sure that it won’t cavitate.
 Pump should be self priming.
 Pump impeller width should be match with the desired fluid viscosity, to prevent pump
from choking.
 There are no gauges on Pump; there should be pressure gauges and flow meter devices
on Pumps.
 Pipes should be resistance flow.
BIO ORGANIC PHOSPHATE
What is Bio organic phosphate?
Phosphate rich organic manure is a type of fertilizer used as an alternative to
diammonium phosphate and single super phosphate. Phosphorus is required by
all plants but is limited in soil, creating a problem in agriculture. In many areas
phosphorus must be added to soil for the extensive plant growth that is desired
for crop production. Phosphorus was first added as a fertilizer in the form of
single super phosphate. SSP is non-nitrogen fertilizer containing Phosphate in
the form of mono calcium phosphate and Gypsum which is best suited for
Alkali soils to supplement Phosphate and reduce soil alkalinity.
An organophosphate (sometimes abbreviated OP) or phosphate ester is the
general name for esters of phosphoric acid. Many of the most important
biochemicals are organophosphates, including DNA and RNA as well as many
cofactors that are essential for life. Organophosphates are the basis of many insecticides,
herbicides, and nerve agents.
Advantages:
 Ready to use without mixing and are easy to apply.
 Granular product can penetrate foliage to reach the soil surface more easily than spray
droplets.
Disadvantages:
 They may present a hazard to non target species especially birds.
 They are more expensive as compared to other pest formulation products.
 They may require soil incorporation or follow up rain before coming active.
Raw Material:
 Rock Phosphate

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 Pres mud
 Molasses
 Seed Mix
 ROP
Rock Phosphate:
Phosphorite, phosphate rock or rock phosphate is a sedimentary rock which contains high
amounts of phosphate bearing minerals. The phosphate content of phosphorite is at least 15 to
20%; if it is assumed that the phosphate minerals in phosphorite are hydroxyapatite and
fluoroapatite, phosphate minerals contain roughly 18 to 5 % phosphorus by weight and if
phosphorite contains around 20% of these minerals, phosphorite is roughly 3 to 7 %
phosphorus by weight, which is a considerable enrichment over the typical sedimentary rock
content of less than 0.2%. One batch contains 730 kg on 1000 kg basis.
Pres mud:
Sugarcane press mud is the residue of the filtration of sugarcane juice. The clarification
process separates the juice into a clear juice that rises to the top and goes for manufacture,
and a mud that collects at the bottom. The mud is then filtered to separate the suspended
matter, which includes insoluble salts and fine bagasse.
Large amounts of press mud are released by the sugarcane industry and the disposal of this
by-product is a major issue. In many cases press mud is burnt in brick kilns, resulting in the
loss and wastage of millions of tones of nutrients, which ultimately degrades the
environment. A common use is for fertilizer, in both the unprocessed or processed form.
Processes used to improve its fertilizer value include composting, treatment with
microorganisms and mixing with distillery effluents. One batch contains 180 kg on 1000 kg
basis.
Molasses:
Molasses, or black treacle is a viscous by-product of the refining of sugarcane or sugar beets
into sugar. Molasses made from sugar beets differs from sugarcane molasses. Only the syrup
left from the final crystallization stage is called molasses; intermediate syrups are called high
green and low green, and these are recycled within the crystallization plant to maximize
extraction. Beet molasses is 50% sugar by dry weight, predominantly sucrose, but contains
significant amounts of glucose and fructose.

18. 18
Seed Mix:
Chemical fertilizers combine other byproducts of the petrochemical industry and other
chemicals to supply intense amounts of Nitrogen, Phosphorus, and Potassium to the soil.
They do not feed soil biology or build healthy soil. Organic fertilizers combine with seed mix
and naturally occurring materials and minerals to supply safe amounts of N, P, and K to your
crops so that they grow vigorously, but at a natural rate. Meanwhile, they feed microbial
action in the soil and contribute to a more healthy and diverse soil biology.
ROP:
Phosphate fertilizers are produced by adding acid to ground or pulverized phosphate rock. If
sulfuric acid is used, single or normal, phosphate (SSP) is produced, with a phosphorus
content of 16–21% as phosphorous pent oxide (P2O5). If phosphoric acid is used to acidulate
the phosphate rock, triple phosphate (TSP) is the result. TSP has a phosphorus content of 43–
48% as P2O5.
Two processes are used to produce TSP fertilizers: run-of-pile and granular. The run-of-pile
process is similar to the SSP process. Granular TSP uses lower-strength phosphoric acid
(40%, compared with 50% for run-of-pile). The reaction mixture, slurry, is sprayed onto
recycled fertilizer fines in a granulator. Granules grow and are then discharged to a dryer,
screened, and sent to storage.
List of Machinery
Mixer:
Mixing is a unit operation that involves manipulation of a heterogeneous physical system
with the intent to make it more homogeneous. Mixing is performed to allow heat and/or mass
transfer to occur between one or more steams, components or phases. Modern industrial
processing almost always involves some form of mixing. Some classes of chemical reactors
are also mixers. With the right equipment, it is possible to mix a solid, liquid or gas into
another solid, liquid or gas. .
Conveyer belt:
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor). A belt conveyor system is one of many types of conveyor systems. A belt
conveyor system consists of two or more pulleys (sometimes referred to as drums), with an
endless loop of carrying medium the conveyor belt that rotates about them. One or both of the
pulleys are powered, moving the belt and the material on the belt forward. The powered
pulley is called the drive pulley while the unpowered pulley is called the idler pulley. Its Rpm
is 45 to 50 Rpm

19. 19
Induction Motor:
The most common electrical motor used in most applications which is known as induction
motor .This motor is also called as synchronous motor because it runs at a speed less than
synchronous speed. An induction motor always runs at a speed less than synchronous speed
because the rotating magnetic field which is produced in the stator will generate flux in the
rotor which will make the rotor to rotate, but due to the lagging of flux current in the rotor
with flux current in the stator, the rotor will never reach to its rotating magnetic field speed
i.e. the synchronous speed. It has different Rpms which includes 1400, 900, 2800 and 750
Rpm.stator will generate flux in the rotor which will make the rotor to rotate, but due to the
lagging of flux current in the rotor with flux current in the stator, the rotor will never reach to
its rotating magnetic field speed i.e. the synchronous speed. It has different Rpms which
includes 1400, 900, 2800 and 750 Rpm.
Rotary Dryer:
Rotary dryers are known as the workhorse of industrial dryers. They are able to process a
wide variety of materials, and can lend a hand in nearly any industry requiring industrial
drying solutions. Its Rpm is 6-8.
Rotary Seive Drum:
The Rotary sieve is ok with dry compost and handles typical loads/sizes. However it tends to
clog up when used with moist compost. Some large pieces can jam and you’ll need to stop
and clear them before carrying on. Its Rpm is 11-13.
Elevator:
An elevator is a type of vertical transport equipment that moves people or goods between
floors (levels, decks) of a building, vessel, or other structure. Elevators are generally powered
by electric motors that either drive traction cables or counter weight systems like a hoist, or
pump hydraulic fluid to raise a cylindrical piston like a jack. Its Rpm is 55-60.
Agitator:
An agitator is a device or mechanism to put something into motion by shaking or stirring.
There are three main types of agitation machine. The washing machine agitator, which rotates
back and forth; the magnetic agitator, which contains a magnetic bar which rotates about a
magnetic field; manual agitation, such as with a stirring rod.
Vibrator Seive Tray:

20. 20
This is used to separate the final product from big particles. So that there should b
no inconvenience in packing unit.
Granulator:
In Bop plant granulator is machinery in which granules formulation takes place. Granulator is
a open type because aerobic process is taking place, in which bacteria needs oxygen to live, If
it is close bacteria will die.
It is suitable for hot and cold granulation and high, medium and low concentrations of mass
production of compound fertilizer. It contains further properties like;
 High balling strength.
 Good appearance.
 Corrosion resistance.
 Wear resistance.
 Low energy consumption.
 Long service life.
 Easy operation and maintenance.
List of Improvements:
 Due to low voltage most of the equipments don’t work, if some work they don’t last
for a long period of time.
 Motors should be operated at desired voltage otherwise due to uneven voltage they
are useless.
 Washing of the equipment should be done prior to using any other material in the
mixers.
 After everyone month’s maintenance factor should be kept in mind.
 There should be sensor on every motor so that it trips if the voltage is low.
 The equipments used in the Industry should not across 40 dba noise.
 Agitator speed should be optimum for better mixing.
 While taking work for pump, it is sure that it won’t cavitate.
 Pump should be self priming.
 Pump impeller width should be match with the desired fluid viscosity, to prevent
pump from choking.
 There are no gauges on Pump; there should be pressure gauges and flow meter
devices on Pumps.
 Pipes should be resistance flow.

21. 21
 Filtration of juice cane suspension should be done properly to prevent from low
quality production.
 There should be optimum load on elevators while feeding in hoppers.
 Showering of juice cane should be done timely.
 Care should be taken while removing moisture from the product.
 Burner temperature should be optimum by preventing from damaging the product.
 Paddle mixer should be washed timely for better mixing.
Wettable Powder
A wettable powder is an insecticide or other pesticide formulation consisting of the active
ingredient in a finely ground state combined with wetting agents and sometimes bulking
agents. Wettable powders are designed to be applied as a dilute suspension through liquid
spraying equipment. Wettable powders do not dissolve. When mixed with water a wettable
powder forms a suspension. That is, the particles that make up the material float throughout
the solution. The main advantages of wettable powder insecticides: initial knock-down of
targeted pests.
Advantages:
 Easy to store, transport and handle.
 Easily measured and mixed.
Disadvantages:
 Inhalation hazard to applicator while measuring and mixing the concentrated powder.
 Often clog nozzles and screens.
 Constant agitation is required to prevent from settlement of powder.
Raw Material:
 Buprofezin
 Niten
 Surf crop df-hcd
 Df-S Alpha
 SiO2
 CacO3

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Buprofezin:
Buprofezin belongs to the group of so-called insect growth regulators, in particular the chitin
synthesis inhibitors. It inhibits the biosynthesis of chitin in the target insects, and thereby
interferes with the growth of immature insects (larvae), so that they die after a few days. The
operation is mainly carried out by contact, but also through ingestion in the stomach.
Buprofezin is especially effective against Hemiptera, including (larvae), whiteflies, and
against cap-, shield and , these are difficult to control pests. It is not harmful to bees and
beneficial insects, such as wasps, which are used for biological or integrated pest
management. One batch contains 450 kg of it.
Nitenpyram:
Nitenpyram is an insecticide used in agriculture and veterinary medicine to kill external
parasites of pets. It is aneonicotinoid, a neurotoxin that blocks neural messages and binds
particularly tightly in the central nervous system of insects, causing rapid death. One batch
contains 75 kg of it.
Silicon Dioxide:
Silicon dioxide, also known as silica (from the Latin silex), is a chemical compound that is
an oxide of silicon with the chemical SiO2. It has been known since ancient times. Silica is
most commonly found in nature as quartz, as well as in various living organisms. In many
parts of the world, silica is the major constituent of sand. Silica is one of the most complex
and most abundant families of materials, existing both as several minerals and being
produced synthetically. One batch contains 20 kg of it.
Calcium Carbonate:
Calcium carbonate is a chemical compound with the formula CaCO3. It is formed by three
main elements: carbon, oxygen and calcium. It is a common substance found in rocks in all
parts of the world, and is the main component of shells of marine organisms, snails, coal
balls, pearls, and eggshells. Calcium carbonate is the active ingredient in agricultural lime,
and is commonly used medicinally as a calcium supplement or as an antacid, but excessive
consumption can be hazardous. One batch contains 106 kg of it.
List of Machinery:
Cone Mixer:
Cone mixers are used to mix or blend a wide range of materials used in different industries
including food, chemical, pharmaceutical, plastic and mineral industries. They are mainly
used to mix different materials using different types of blades to make a good quality
homogeneous mixture. Included are dry blending devices, paste mixing designs for

23. 23
high viscosity products and high shear models for emulsification, particle size reduction
and homogenization. Industrial mixers range from laboratory to production line scale.
Storage Cone:
It is used for the storage of discharge product.
Jet Mill :
Jet mill is dry ultrafine grinding equipment, integrated fluidized-bed airflow grinding and
self-diffluent classifying technology. During grinding process no temperature rise, no
pollution and low wear, especially used in the heat sensitive, low melting point and high
purity material for superfine grinding. Flammable and explosive materials can be ground with
inert gases, which can be cycle used.
Working Principle:
The pressed air via dryer raps into the grinding chamber through Laval jet, the material at the
intersection of airflow is crashed, the powdered material enters into the classifying section
together with uprising airflow, under the action of centrifugal force from classifying wheel
and draft fan, the oversized powder is repulverized and the qualified powder is collected by
the cyclone and bag filter.
Motor:
An induction or asynchronous motor is an AC electric motor in which the electric current in
the rotor needed to produce torque is obtained by electromagnetic induction from
the magnetic field of the stator winding. An induction motor therefore does not
require mechanical commutation, separate-excitation or self-excitation for all or part of the
energy transferred from stator to rotor, as in universal, DC and large synchronous motors. An
induction motor's rotor can be either wound type or squirrel-cage type.
Air Compressor:
An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of
several methods, an air compressor forces more and more air into a storage tank, increasing
the pressure. When tank pressure reaches its upper limit the air compressor shuts off. The
compressed air, then, is held in the tank until called into use. The energy contained in the
compressed air can be used for a variety of applications, utilizing the kinetic energy of the air
as it is released and the tank depressurizes. When tank pressure reaches its lower limit, the air
compressor turns on again and re-pressurizes the tank.
Blower:
A Blower is a mechanical device for moving air or other gases. The terms "blower" and
"squirrel cage fan” are frequently used as synonyms. These fans increase the speed of air

24. 24
stream with the rotating impellers. They use the kinetic energy of the impellers or the rotating
blade to increase the pressure of the air/gas stream which in turn moves them against the
resistance caused by ducts, dampers and other components. Centrifugal fans accelerate air
radially, changing the direction (typically by 90°) of the airflow. They are sturdy, quiet,
reliable, and capable of operating over a wide range of conditions.
Screw Agitators:
A screw agitator is a device to put something into motion by shaking or stirring. There are
three main types of agitation machines like the washing machine agitator, which rotates back
and forth; the magnetic agitator, which contains a magnetic bar which rotates about a
magnetic field; manual agitation, such as with a stirring rod.
Butterfly Valve:
A butterfly valve is a valve which can be used for isolating or regulating flow. The closing
mechanism takes the form of a disk. Operation is similar to that of a ball valve, which allows
for quick shut off. Butterfly valves are generally favored because they are lower in cost to
other valve designs as well as being lighter in weight, meaning less support is required. The
disc is positioned in the center of the pipe, passing through the disc is a rod connected to an
actuator on the outside of the valve. Rotating the actuator turns the disc either parallel or
perpendicular to the flow. Unlike a ball valve, the disc is always present within the flow
therefore pressure drop is always induced in the flow, regardless of valve position.
Actuator:
An actuator is a type of motor that is responsible for moving or controlling a mechanism.
It is operated by a source of energy, typically electric current, hydraulic fluid pressure or
pneumatic pressure, and converts that energy into motion.
Dust Collector:
A dust collector is a system used to enhance the quality of air released from industrial and
commercial processes by collecting dust and other impurities from air or gas. Designed to
handle high-volume dust loads, a dust collector system consists of a blower, dust filter, a
filter-cleaning system, and a dust receptacle or dust removal system. It is distinguished
from air cleaners, which use disposable filters to remove dust.
Air Filters:
A particulate air filter is a device composed of fibrous materials which removes
solid particulates such as dust, pollen, mould, and bacteria from the air. A chemical air filter
consists of an absorbent or catalyst for the removal of airborne molecular contaminants such
as volatile organic compounds or ozone. Air filters are used in applications where air quality
is important, notably in building ventilation systems and in engines.

25. 25
PLC:
A programmable logic controller, PLC, or programmable controller is a digital computer used
for automation of typically industrial electrochemical processes, such as control of machinery
on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many
machines, in many industries.
Rotary Feeders:
Rotary feeders, also known as rotary airlocks or rotary valves, are commonly used in
industrial and agricultural applications as a component in a bulk or specialty material
handling system. Rotary feeders are primarily used for discharge of bulk solid material
from hoppers/bins, receivers, and cyclones into a pressure or vacuum-driven pneumatic
conveying system. Components of a rotary feeder include a rotor shaft, housing, head plates,
and packing seals and bearings. Rotors have large vanes cast or welded on and are typically
driven electric motors.
List of Improvements:
 Due to low voltage most of the equipments don’t work, if some work they don’t last for
a long period of time.
 Actuators and pneumatic valves should be operated and care taken well otherwise dust
collectors won’t work.
 Motors should be operated at desired voltage otherwise due to uneven voltage they are
useless.
 Dust filters should be covered by their bags otherwise they don’t work properly.
 Washing of the equipment should be done prior to using any other material in the cone
blenders.
 After every three months maintenance factor should be kept in mind.
 Compressor filters should be washed at least once every 3 months.
 There should be sensor on every motor so that it trips if the voltage is low.
 Sticky material/powder should not b used because it jams the machine.
 Desired material should be introduced into the screw agitator, to prevent from choking.
 Plc should be work properly. It’s his duty to show all connections on the touch screen.
 Compressors should not b operated at low voltage.
 Desired material should be introduced into grinding section of jet mill, otherwise it will
choke.