Plant Layout of Pharmaceuticals

PLANT LAYOUT OF
PHARMACEUTICALS
Prepared by: Guided by:

Kamal Kardani Miss Shraddha Parmar
Vishruti Choksi
PG DEPARTMENT OF PHARMACEUTICAL SCIECES

SARDAR PATEL UNIVERSITY- VALLABH VIDHYANAGAR.
Contents
2
 Introduction
 Importance
 Types of plant layout
 Sample layouts
 References
Introduction
3
Plant Layout:
Arrangement of physical facilities such as
 Machinery
 Equipment
 furniture etc. within the factory building in such a manner so as to have
quickest flow of material at lowest cost & with the least amount of
handling in processing the product from the receipt of material to the
shipment of finished product.
Pilot Plant:
It is the part of the pharmaceutical industry where a lab scale formula is
transformed into a viable product by development of practical procedure of
manufacture.
Importance
4
 An ideal plant layout should provide the optimum relationship among

output, floor area & manufacturing process.
 Flexibility of operation
 Easy production flow
 Make economic use of building
 Promotes effective utilization of manpower
 Employee’s convenience
 Safety
 Comfort at work
 Maximum exposure to natural light & ventilation
Types of Layout
5
There are 3 types of plant layout:

 Manufacturing units
 Traders
 Services Centers And Establishment
Manufacturing Units
6
It divides in to four type

 Product or line layout
 Process or functional layout
 Fixed position or location layout
 Combined or group layout
Product or Line Layout
7
Principles:
All the machine tools or other items of equipment must be placed at the point
demanded by the sequence of operations.
There should no points where one line crossed another line. Materials may be fed
where they are required for assembly but not necessarily at one point. All the
operations including assembly, testing packing must be included in the Line.
Advantages:
 Low cost of material handling, due to straight and short route and absence of
back tracking.
 Continuous flow of work
 Lesser investment in inventory and work in progress
 Optimum use of floor space
 Shorter processing time or quicker output
8
 Lower cost of manufacturing per unit
Disadvantage:
 High initial capital investment in special purpose machine
 Heavy overhead charges
 Breakdown of one machine the whole production process are stop.
 Suitability Mass production of standardized products
Process Layout
9
Principle
The distance between departments should be as short as possible for avoiding
long distance movement of materials The departments should be in sequence
of operations The arrangement should be convenient for inspection and
supervision
Advantages:
 Lower initial capital investment in machines and equipments.
 Breakdown of one machine does not result in complete work stoppage
 Supervision can be more effective and specialized
 There is a greater flexibility of scope for expansion.
10
Disadvantage:
 Material handling costs are high due to backtracking.
 More skilled labour is required resulting in higher cost.
 Work in progress inventory is high.
 Needing greater storage space.
 More frequent inspection is needed which results in costly supervision.
Fixed Position or Location
11
Layout
Principle:
In this type of layout, the major product being produced is fixed at one
location. Equipment labour and components are not moved to that location.
All facilities are brought and arranged around one work centre.
Advantages:
 It saves time and cost
 The layout is flexible as change in job design and operation sequence can
be easily incorporated
 Adjustments can be made to meet shortage of materials or absence of
workers by changing the sequence of operations.
12
Disadvantage:
 Production period being very long.
 capital investment is very heavy.
 Very large space is required for storage of material and equipment near the
product.
 As several operations are often carried out simultaneously, there is
possibility of confusion and conflicts among different workgroups.
Combined Layout
13
Principle:
In most of industries, only a product layout or process layout or fixed location
layout does not exist. Generally, a combination of the product and process
layout or other combinations are found, in practice.
Traders
14
When two outlets carry almost same merchandise, customers are attracted
and kept by good layout. i.e. Good lighting, Attractive colours, Good
ventilation, Air conditioning, Modern design. All of these things mean
customer convenience, customer appeal and greater business volume.
There are three kinds of layouts in retail operations today.
1. Self service or modified self service layout
2. Full service layout
3. Special service layouts
Services Centers And Establishment
15
Services establishments, must give due attention to customer

convenience, quality of service, efficiency in delivering services
Sample Layout for Pharma Industry
16
SAMPLE LAYOUT OF A PRODUCTION DEPARTMENT SAMPLE LAYOUT OF F&D DEPARTMENT

Space required as per Schedule-
17
M
Oral liquid Filling of hard
Semi solid preparation
30 M2 basic gelatin cap.
30 M2 + 10 M2 for
installation+ 10 M2 25 M2 + 10
ancillary
ancillary M2ancillary
Solid dosage form Parenteral preparation

Total 150 M2 mfg. area+ 20 Powder
Granulating
30 M2
section m2ancillary svp or 150 M2 for

30 M2 lvp
Filling Eye ointmennt. And
General
and eye lotion
compression Coating room
sealing 25 M2 + 10
section 30 M22 + m2ancillary

30 M2 + 20 10
m2ancillary m22ancillary Aseptic Filling
Suppositories
and sealing
30 M2
Ancillary layout
18
References
19
 Pharmaceutical Production Facilities Design and Applications Cole

Graham c. Taylor & Francis e-Library, 2nd Edition, 2003, page no: 25-30.
 Encyclopaedia of pharmaceutical technology, James swarbrick , Informa
Healthcare USA,3rd edition, Vol-5, page no: 2879.
 Pharmaceutical Jurisprudence, G. K. Jani, Atul prakashan, 7th edition,
2008-2009, page no:102.
 Good design practices for GMP Pharmaceutical facilities, Terry Jacobs,
Adrew A. singore, vol-146, page no: 41-42
 Pharmaceutical Industrial management, Mehta R.M, 3rd edition, page no:
70-90.
Overhead expenses are all costs on the income
statement except for direct labour, direct materials,
and direct expenses.
Overhead expenses include accounting fees,

advertising, insurance, interest, legal fees, labor
burden, rent, repairs, supplies, taxes, telephone
bills, travel expenditures, and utilities.

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PLANT LAYOUT OF

Prepared by: Guided by:

PG DEPARTMENT OF PHARMACEUTICAL SCIECES

 An ideal plant layout should provide the optimum relationship among

There are 3 types of plant layout:

It divides in to four type

 Lower cost of manufacturing per unit

Services establishments, must give due attention to customer

SAMPLE LAYOUT OF A PRODUCTION DEPARTMENT SAMPLE LAYOUT OF F&D DEPARTMENT

Solid dosage form Parenteral preparation

 Pharmaceutical Production Facilities Design and Applications Cole

Overhead expenses include accounting fees,

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