Omnipack Industrial

Corporation

MAINTENANCE
HIPOLITO MAÑALAC III
Maintenance Supervisor
Calibration Officer
Pollution Control Officer
Safety Officer
Good Manufacturing Practice (GMP) Head Coordinator
1. MAINTENANCE
- Types of Maintenance
a . Preventive Maintenance
b . Predictive Maintenance
c . Troubleshooting
2. UTILITIES
- Boiler
- Chillers
- Compressors
- Cooling Towers
- Generator Sets
- Fire Pump
- Transformer
3. CALIBRATION
4. CIVIL WORKS
- Building Maintenance
5. Pollution Control Officer
- DENR
> Permit To Operate ( PTO )
>> Compliance on PTO conditions
> Self Monitoring Report
> Compliance Monitoring Report
- LLDA
> Discharge Permit ( DP )
>> Compliance on DP conditions
> Self Monitoring Report
 - Sludge Management plan
- Hazardous Waste Management Plan
- Solid Waste Management Plan
- Waste Water Monitoring
6. Safety
- Potable Water Monitoring
- Annual Accident Monitoring
- Annual Work Environment Monitoring ( WEM )
- Basic Safety Rules
> Training and Orientation
>> New Employee Orientation
>> Refresher Course for employees
>> Visitors Safety Orientation
7. Good Manufacturing Practice ( GMP )
- Monitoring
> Production
> Perimeter
8. Fire Brigade
9. Pest Control
- Rodents Control
- Birds Control
- Insects Control
Maintenance
• Preventive Maintenance ( PM )
- The care and servicing by personnel for the purpose of maintaining
equipment and facilities in satisfactory operating condition by
providing for systematic inspection, detection, and correction of
incipient failures either before they occur or before they develop
into major defects.

- Maintenance, including tests, measurements, adjustments, and

parts replacement, performed specifically to prevent faults from
occuring.

> Primary goal of maintenance is to avoid or mitigate the

consequences of failure of equipment. This may be by preventing
the failure before it actually occurs which planned
maintenance and condition based maintenance help to achieve. It is
designed to preserve and restore equipment reliability by replacing
worn components before they actually fail.
> Preventive maintenance activities include partial or complete
overhauls at specified periods, oil changes, lubrication and so on.
Maintenance
• Predictive maintenance ( PM )
- Technique help determine the condition of in-service equipment in
order to predict when maintenance should be performed. This offers
cost savings over routine or time-based preventive maintenance,
because tasks are performed only when warranted.

- The main value of Predicted Maintenance is to allow convenient

scheduling of corrective maintenance, and to prevent unexpected
equipment failures.

> The key is “ the right information in the right time “. By knowing
which equipment needs maintenance work can be better planned (
spare parts, people etc. ) and what would have been “ unplanned
stops “ are transformed to shorter and fewer “ planned stops “, thus
increasing machine availability.
> Other advantages include increased equipment lifetime,
increased plant safety, fewer accidents with negative impact on
environment, and optimized spare parts handling.
Maintenance
• Troubleshooting
- A form of problem solving, often applied to repair failed machine(s).
It is a logical, systematic search for the source of a problem so that it
can be solved, and so the product or process can be made operational
again.

> Troubleshooting is needed to develop and maintain complex

systems where the symptoms of a problem can have many possible
causes.
> Troubleshooting requires identification of the malfunction(s) or
symptoms within a system.
> Experience is commonly used to generate possible causes of the
symptoms. Determining the most lokely causes is a process of
elimination – eliminating potential causes of a problem.

>> Troubleshooting requires confirmation that the solution

restores the machine to its working state.
UTILITIES

• Boilers
• Chillers
• Compressors
• Cooling Tower
• Generator Sets
• Fire Pump
• Transformer
BOILERS
- Use for the production of steam
> Steam pressure requirement ( 4 to 6 bars )
> Preventive Maintenance
1. Descaling of water chamber – every six ( 6 ) months ( c/o Ambient )
2. Desooting of tubes / pipes - every three ( 3 ) months ( c/o Maintenance )

Importance of Steam to production

- Use in heating and drying of Printing Machines and Dry Extrusion Lamination
( DEL ) machine
Types of Boiler

1. Water Tube 2. Fire Tube

> Water passes on tubes during operation > Fire passes on tubes during operation
> Higher maintenance > Lower / easy maintenance
> Ideal for high steam requirement > Ideal for low steam requirement

Boiler Name Capacity ( Bhp ) Type

Chuan li 130 Water Tube
Mech Mar 232 Fire Tube
Lin Charng 232 Fire Tube
CHILLERS
- Use to produce chilled water
> Chilled Water requirement (18-24°C)
> With quarterly preventive maintenance ( c/o Nextchill )
• Converting (4 units)
▫ Chiller #1A 20 tons
▫ Chiller #1B 20 tons
▫ Chiller #2 40 tons
▫ Chiller #3 40 tons
• Molding (7 units)
▫ 5 units 5 tons
▫ 1 unit 7.5 tons
▫ 1 unit 15 tons
• Ink Making (2 units)
▫ 1 unit 5 tons
▫ 2 units 10 tons
Air Compressors
- Use to produce compressed air
> Use for the pneumatic parts / functions of the machines.
> Preventive Maintenance ( c/o Utilities Operators )
>> For Change oil - Every 1000 RH
>> For replacement of Filter - Every 1000 RH
>> For replacement of Air oil separator - Every 4000 RH

• Converting , requirement (6-8 bars)

▫ 5 units 50 HP

• Molding requirement,
- low pressure 6 – 8 bars
- high pressure 28 – 32 bars
▫ 4 units 50 HP
▫ 1 unit 75 HP
Cooling Tower
- Use to cooldown water supply return.
> Temperature requirement ( 30 – 34 deg. Celcius)
>> With monthly monitoring of water quality ( c/o Ambient )
Parameters Std. Limits
Ph 7-9
Total Alkalinity ppm CaCO3 500
Total Hardness ppm CaCO3 150
Chlorides ppm NaCl 400
Total Disolved solids 1200

- Total Quantity
> Converting - 1 unit 125 tons capacity
> Mold / Ink Making - 1 unit 40 tons capacity
- 2 units 60 tons capacity
Generator Set
- Use as back up power supply incase of Meralco blackout.
> Requirements
>> 220 Volts , 60 hertz

Gen Set no. Capacity KW > Converting

1 500 Molding
2 500 Converting

3 600 Converting

- Preventive Maintenance c/o ELECON ( yearly )

- With weekly testing c/o Electrical Engrs.
Transformer
- Use to step-down voltage ( power supply ) from primary supply ( Grid ).
> Requirements,

>> From 34.50 KV down to 220 Volts

- Preventive Maintenance c/o ELECON ( yearly )
Fire Pump
- To be use during fire incident ( emergency ), operator – maint. utilities operator
> Manually operated
> Model – 4BC2 diesel engine
> Brand - USUZU
> With weekly test run c/o utilities operator ,
a. Battery
> Solution level - full
> Charge volts - 24 volts
b. Water Pressure - 100 psi
c. Fuel oil - full
d. Radiator water - full
Civil Works
• INSECUTORS – Weekly • WINDOW SCREEN CLEANING
• GARBAGE – Thursday, Friday (all buildings) – Quarterly
• WATER FILTRATION • EXHAUST BLOWER SCREEN
MONITORING– Weekly CLEANING – Quarterly
• FIRE HYDRANT – Monthly • PVC STRIPS MAINT – Quarterly
• FIRE EXTINGUISHER – Monthly
• ROOF CLEANING – Quarterly
• ROOF CLEANING (BLDG. 4 &
• PEST CONTROL – Monthly
CANOPY,5A,5B,6 & 7) – 6 months
• GRASS CUTTING – Monthly
• TRIMMING OF INDIAN TREE
• TIN CAN DISPOSAL – Monthly – 6 months
• CLEANING OF STAINLESS
CLEANING OF OMNIPACK AREA GUTTER – Yearly
• WALL PAINTING ( all buildings)
• ROAD CLEANING– Everyday – 5years
• CR CLEANING – Everyday • GATE PAINTING - Yearly
• WINDOW GLASS CLEANING (all • CALIBRATION – Yearly
buildings) – 6 months
HEALTH and SAFETY
• Safety Officer acts as the employer’s consultant
in the application of programs to remove
hazards from the employees and correct unsafe
work practices
• Conducts investigation of accidents and submit
his report and analysis to the employer
• Conducts health and safety inspection
• Coordinate all health and safety training
program for the employees and employer
POLLUTION CONTROL
• Submit reports to DENR and LLDA
▫ Self Monitoring Report (Quarterly)
▫ Compliance Monitoring Report
(every 6 months)

Fire brigade
• Caloocan Fire Chief conducts training
twice a year to selected employees (Fire Brigade).
Molding
- Is the process of manufacturing by shaping
liquid or pliable raw material using a rigid frame
called a mold or matrix.

Types of molding
• Blow Molding
• Injection Molding
• IM/BM PET
Raw Materials

• PET (Poly Ester Teraphthalate)

• PVC (Poly Vinyl Chloride)
• PE (Poly Ethylene)
• PP (Poly Propylene)
▫ Homopolymer
▫ Copolymer
• Masterbatch
Machines
• Injection Molding
▫ Jet Master 128 Tons (3)
▫ Jet Master 138 Tons (1)
▫ TNR 350 Tons
▫ HTF 450 Tons
▫ Hai Xing 368 Tons (3) - PET
• Blow Molding
▫ SMC 2000 DST (4)
▫ SMC 3000 DST (2)
• PET Blowing Machine
▫ Single Station (2)
▫ Double Station (2)
Molding Process Flow
Receive JO/Request Raw Material

Mix Raw Material

Molding Process Yes

Passed No
Recyclable?
Quality?
Yes
Packing and Labeling No

Transfer to Warehouse
 Blow Molding Machine
•Resin Drum
•Vacuum Auto loader
• Hopper
•Hopper Dryer
• Extruder barrel
• Goose neck
• Die cap
(Cycle time)
• Carriage up
• Mold close
• Carriage down
• Blowing and cooling
simultaneously
• Crown and Tail deflashing
Blow Molding Process
Injection Molding Machine
Injection Molding Process
Common Defects
Blow Molding
• Black spot – (High Temp, Contamination)
• Short Shots – (RM shortage)
• Orange Peel – (Mold Problem)
• Deformed – (Machine Utilities)
Injection Molding
• Poor Dispersion – (Poor parameter)
• Off color – (Wrong mixing ratio)
• Flashing – (Material block in mold)
• Short Shot – (RM Shortage, , Check O-ring and
nozzle)
• Black Spot – (High Temp, Dirty Molder)
Composition of Ink
• Colorant • Solvent
– gives color to ink -flow of the ink
-printability and drying
 Pigment
 Dyestuff  Toluene
 Ethyl Acetate
• Resin  MEK
- carrier of the pigment  IPA
- binder of ink to the film
• Additives
 Ethylene Vinyl Acetate - improves and enhances the ink
 Vinyl Chloride Vinyl Isobutyl Ether
 CLPP  Dispersing Agent
 Polyamide  Anti-Static
 Wax/Matting Agent
 Viscosity Stabilizer
 Plasticizer
 Azeotropic Agent
General Work Flow
Check JO

Raw material requisition

Varnish Making

Premixing/Millbase

Grinding

Pass No
FOG?
Yes
Letdown

Inspection

Filtering/Packing
Raw Material Acceptance

Evaluation of
Delivery of RM Sampling RM
(compounding)

Yes
Delivery
Acceptance Passed? QC Checking

No

Confirmatory Delivery
Passed Failed Rejection
Testing
Pre-Mixing / Millbase
Batch Size:
White 750 kg
Colored 324 kg
Black 340 kg

Operating Standard:
Weighing Time: 30 mins
Mixing Time: 1 hr
Mixing Speed: 1000 rpm
Grinding
Grinder #1 and #2 Grinder #3

• Disk Type • Pin Type

• 15 Liter Capacity • 30 Liter Capacity
• Single Vessel • Double Vessel
• Use Zirconium Silicate Ceramic • Use Yttrium Stabilized Ceramic
Beads Beads
• Flow rate: • Flow rate:
Flow rate No. of No. of Flow rate No. of No. of
Pass hours Pass hours

White 145.5 kg/hr 2 5 hrs White 250 kg/hr 1 3 hrs

GS & RS Yellow, 108 kg/hr 2 3 hrs Colored 150 kg/hr 1 2 hrs
YS Red, Green
BS Red, Blue, 90 kg/hr 3 3 hrs
Black, Violet 40 min
Grinding

Operating Standard:
Temp : 60°C max
Air Pressure: 4 bars
Ink Pressure: 2 bars max
Motor Mill: 1000 rpm
Final Mixing / Letdown
Operating Standard:
Weighing Time: 30 min
Mixing Time: 1 hr (white)
45 min (colored)
Mixing Speed: 1000 rpm
Quality Control Checking
• FOG
• Density
• Temperature
• Viscosity
• % TNV
• Color Strength
• Adhesion
• Drying Time
• Blocking/Crinkle Resistance
• Gloss
Filtering and Packing
 Filter media:
-110 mesh polyester film screen
-double filtration

 Packing Size:
-White 200 kg/drum
25 kg/ tin can
-Black 190 kg/drum
-Colored 180 kg/drum
20 kg/tin can
-Extender Varnish 180 kg/drum
20 kg/tin can
Warehouse
Raw Material Acceptance
• Film
• Resin
• Ink Making Raw Materials
• Solvent
• Adhesive
• Paper core
Raw Material Acceptance
NO Inform
Verification Conformed? Accounting/
Purchasing

YES

Checking/ Reject
Unloading Delivery
Weighing

Sampling
 Raw Material Acceptance
(Resin and solvent)
NO Inform
Verification Conformed? Accounting/ Reject
Purchasing Delivery

YES

YES NO Advice to
Checking/ Truck
conduct
Sampling Scale?
Truck scale

Unloading Truck scale

Raw Material Withdrawal Procedure

Receiving of Counterchecking
Check RM Status
RMRIS of specs/weight

Acknowledgment Issuance of RM
Finished Goods Acceptance
Procedure

Receiving Checking of Transfer to

of FGSTS FGSTS Warehouse
Finished Good Delivery Procedure

Loading of
Preparation Delivery to
Finished
of Stock Customer
Goods
SCRAP RECEIVING AND DISPOSAL
Procedure

Truck No Conduct
Segregation Receiving
scale? truck-scale

Yes

Truck-scale Loading Weighing

Rejected Raw material RECEIVING AND DISPOSAL
Procedure

YES
Correct Transfer to
Receive MTS
MTS? Warehouse

NO

Return MTS for

Revision
Rejected finished goods RECEIVING
Procedure
Pick up rejects Unload items

NO Correct DR
(Quantity Checking
Revise DR and Specs)?

YES

Transfer Reject to
Production