Materials & Streams Reportfor Tugas2_SPF_AuliaRahmi-EtriDianK-SandraMonica

April 13, 2015

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1. OVERALL PROCESS DATA

Annual Operating Time 2,078.55hRecipe Batch Time 22.35hRecipe Cycle Time 22.35hNumber of Batches per Year 93.00MP = Undefined

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2.1 STARTING MATERIAL REQUIREMENTS (per Section)

Section Starting Material Active Product

AmountNeeded

(kgSin/kg

MP)

MolarYield

(%)

MassYield

(%)

GrossMassYield

(%)

Main Section (none) (none) Unknown Unknown Unknown Unknown

Sin = Section Starting Material, Aout = Section Active Product

2.2 BULK MATERIALS (Entire Process)

Material kg/yr kg/batch kg/kg MPActive Ingredie 186 2.000Carton Box 20,150 216.667Deionized Water 12,812 137.760Emulsifier 5,580 60.000Emulsifying Wax 670 7.200Excipient 22 0.240Foam Stable 2,678 28.800Ointment 2,232 24.000Pallet Box 60,450 650.000Tube Plastic 806 8.667Water 102,178 1,098.693TOTAL 207,764 2,234.026

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2.3 BULK MATERIALS (per Section)

SECTIONS IN: Main Branch

Main SectionMaterial kg/yr kg/batch kg/kg MPActive Ingredie 186 2.000Carton Box 20,150 216.667Deionized Water 12,812 137.760Emulsifier 5,580 60.000Emulsifying Wax 670 7.200Excipient 22 0.240Foam Stable 2,678 28.800Ointment 2,232 24.000Pallet Box 60,450 650.000Tube Plastic 806 8.667Water 102,178 1,098.693TOTAL 207,764 2,234.026

2.4 BULK MATERIALS (per Material)

Active IngredieProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-3 100.00 186 2.000TOTAL 100.00 186 2.000

Carton BoxProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-6 100.00 20,150 216.667TOTAL 100.00 20,150 216.667

Deionized WaterProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-4 100.00 12,812 137.760TOTAL 100.00 12,812 137.760

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EmulsifierProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-1 50.00 2,790 30.000P-2 50.00 2,790 30.000TOTAL 100.00 5,580 60.000

Emulsifying WaxProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-1 50.00 335 3.600P-2 50.00 335 3.600TOTAL 100.00 670 7.200

ExcipientProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-3 100.00 22 0.240TOTAL 100.00 22 0.240

Foam StableProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-1 50.00 1,339 14.400P-2 50.00 1,339 14.400TOTAL 100.00 2,678 28.800

OintmentProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-1 50.00 1,116 12.000P-2 50.00 1,116 12.000TOTAL 100.00 2,232 24.000

Pallet BoxProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-8 100.00 60,450 650.000TOTAL 100.00 60,450 650.000

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Tube PlasticProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-5 100.00 806 8.667TOTAL 100.00 806 8.667

WaterProcedure % Total kg/yr kg/batch kg/kg MPMain Section (Main Branch)P-1 13.78 14,076 151.354P-2 13.78 14,076 151.354P-3 72.45 74,026 795.984TOTAL 100.00 102,178 1,098.693

2.5 BULK MATERIALS: SECTION TOTALS (kg/batch)

Raw Material Main SectionActive Ingredie 2.000Carton Box 216.667Deionized Water 137.760Emulsifier 60.000Emulsifying Wax 7.200Excipient 0.240Foam Stable 28.800Ointment 24.000Pallet Box 650.000Tube Plastic 8.667Water 1,098.693TOTAL 2,234.026

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2.6 BULK MATERIALS: SECTION TOTALS (kg/yr)

Raw Material Main SectionActive Ingredie 186Carton Box 20,150Deionized Water 12,812Emulsifier 5,580Emulsifying Wax 670Excipient 22Foam Stable 2,678Ointment 2,232Pallet Box 60,450Tube Plastic 806Water 102,178TOTAL 207,764

2.7 DISCRETE MATERIALS (Entire Process)

Material Entities/yr Entities/batch Entities/kg MPTube In 1,612,000 17,333.333Carton Box In 80,600 866.667Pallet Box In 4,030 43.333

2.8 DISCRETE MATERIALS (per Section)

SECTIONS IN: Main Branch

Main SectionMaterial Entities/yr Entities/batch Entities/kg MPTube In 1,612,000 17,333.333Carton Box In 80,600 866.667Pallet Box In 4,030 43.333

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2.9 DISCRETE MATERIALS (PER MATERIAL)

Tube InDiscrete Stream % Total Entities/yr Entities/batch Entities/kg MPMain Section (Main Branch)Tube In 100.00 1,612,000 17,333.333TOTAL 100.00 1,612,000 17,333.333

Carton Box InDiscrete Stream % Total Entities/yr Entities/batch Entities/kg MPMain Section (Main Branch)Carton Box In 100.00 80,600 866.667TOTAL 100.00 80,600 866.667

Pallet Box InDiscrete Stream % Total Entities/yr Entities/batch Entities/kg MPMain Section (Main Branch)Pallet Box In 100.00 4,030 43.333TOTAL 100.00 4,030 43.333

2.10 DISCRETE MATERIALS (Entities/batch): PER SECTION

Raw Material Main SectionTube In 17,333.333Carton Box In 866.667Pallet Box In 43.333TOTAL 18,243.333

2.11 DISCRETE MATERIALS (Entities/yr): PER SECTION

Raw Material Main SectionTube In 1,612,000Carton Box In 80,600Pallet Box In 4,030TOTAL 1,696,630

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3. STREAM DETAILS

Stream Name Emulsifying Wax Foam Stable Emulsifier OintmentSource INPUT INPUT INPUT INPUTDestination P-1 P-1 P-1 P-1Stream PropertiesActivity (U/ml) 0.00 0.00 0.00 0.00Temperature (C) 25.00 25.00 25.00 25.00Pressure (bar) 1.01 1.01 1.01 1.01Density (g/L) 1,258.08 994.70 1,258.08 1,258.08Total Enthalpy (kW-h) 0.06 0.42 0.50 0.20Specific Enthalpy (kcal/kg) 14.39 24.96 14.39 14.39Heat Capacity (kcal/kg-C) 0.58 1.00 0.58 0.58Component Flowrates (kg/batch)Emulsifier 0.000 0.000 30.000 0.000Emulsifying Wax 3.600 0.000 0.000 0.000Foam Stable 0.000 14.400 0.000 0.000Ointment 0.000 0.000 0.000 12.000TOTAL (kg/batch) 3.600 14.400 30.000 12.000TOTAL (L/batch) 2.862 14.477 23.846 9.538

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Stream Name Emission 1 P1 Out DI Water Heated DI WaterSource P-1 P-1 INPUT P-4Destination OUTPUT P-3 P-4 P-3Stream PropertiesActivity (U/ml) 0.00 0.00 0.00 0.00Temperature (C) 62.50 28.80 25.00 50.00Pressure (bar) 1.01 7.77 1.01 1.01Density (g/L) 1.05 1,180.79 994.70 985.59Total Enthalpy (kW-h) 0.00 1.36 4.00 7.99Specific Enthalpy (kcal/kg) 15.14 19.50 24.96 49.91Heat Capacity (kcal/kg-C) 0.24 0.68 1.00 1.00Component Flowrates (kg/batch)Deionized Water 0.000 0.000 137.760 137.760Emulsifier 0.000 30.000 0.000 0.000Emulsifying Wax 0.000 3.600 0.000 0.000Foam Stable 0.000 14.400 0.000 0.000Nitrogen 0.012 0.000 0.000 0.000Ointment 0.000 12.000 0.000 0.000Oxygen 0.004 0.000 0.000 0.000TOTAL (kg/batch) 0.016 60.000 137.760 137.760TOTAL (L/batch) 15.452 50.814 138.493 139.774

Stream Name EmulsifiyingWax 2 Foam Stable 2 Emulsifier 2 Ointment 2

Source INPUT INPUT INPUT INPUTDestination P-2 P-2 P-2 P-2Stream PropertiesActivity (U/ml) 0.00 0.00 0.00 0.00Temperature (C) 25.00 25.00 25.00 25.00Pressure (bar) 1.01 1.01 1.01 1.01Density (g/L) 1,258.08 994.70 1,258.08 1,258.08Total Enthalpy (kW-h) 0.06 0.42 0.50 0.20Specific Enthalpy (kcal/kg) 14.39 24.96 14.39 14.39Heat Capacity (kcal/kg-C) 0.58 1.00 0.58 0.58Component Flowrates (kg/batch)Emulsifier 0.000 0.000 30.000 0.000Emulsifying Wax 3.600 0.000 0.000 0.000Foam Stable 0.000 14.400 0.000 0.000Ointment 0.000 0.000 0.000 12.000TOTAL (kg/batch) 3.600 14.400 30.000 12.000TOTAL (L/batch) 2.862 14.477 23.846 9.538

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Stream Name Emission 2 P2 Out ExcipientActive IngredientSource P-2 P-2 INPUT INPUTDestination OUTPUT P-3 P-3 P-3Stream PropertiesActivity (U/ml) 0.00 0.00 0.00 0.00Temperature (C) 62.50 28.80 25.00 25.00Pressure (bar) 1.01 7.77 1.01 1.01Density (g/L) 1.05 1,180.79 994.70 994.70Total Enthalpy (kW-h) 0.00 1.36 0.01 0.06Specific Enthalpy (kcal/kg) 15.14 19.50 24.96 24.96Heat Capacity (kcal/kg-C) 0.24 0.68 1.00 1.00Component Flowrates (kg/batch)Active Ingredie 0.000 0.000 0.000 2.000Emulsifier 0.000 30.000 0.000 0.000Emulsifying Wax 0.000 3.600 0.000 0.000Excipient 0.000 0.000 0.240 0.000Foam Stable 0.000 14.400 0.000 0.000Nitrogen 0.012 0.000 0.000 0.000Ointment 0.000 12.000 0.000 0.000Oxygen 0.004 0.000 0.000 0.000TOTAL (kg/batch) 0.016 60.000 0.240 2.000TOTAL (L/batch) 15.452 50.814 0.241 2.011

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Stream Name P3 Out Tube In Tubed Cream Carton Box InSource P-3 INPUT P-5 INPUTDestination P-5 P-5 P-6 P-6Stream PropertiesActivity (U/ml) 0.00 0.00 0.00 0.00Temperature (C) 25.00 25.00 25.00 25.00Pressure (bar) 1.01 1.01 1.01 1.01Density (g/L) 1,073.54 2,521.33 1,093.80 1,173.66Total Enthalpy (kW-h) 6.42 0.07 6.49 2.99Specific Enthalpy (kcal/kg) 21.25 7.03 20.79 11.87Heat Capacity (kcal/kg-C) 0.85 0.28 0.83 0.47Component Flowrates (kg/batch)Active Ingredie 2.000 0.000 2.000 0.000Carton Box 0.000 0.000 0.000 216.667Deionized Water 137.760 0.000 137.760 0.000Emulsifier 60.000 0.000 60.000 0.000Emulsifying Wax 7.200 0.000 7.200 0.000Excipient 0.240 0.000 0.240 0.000Foam Stable 28.800 0.000 28.800 0.000Ointment 24.000 0.000 24.000 0.000Tube Plastic 0.000 8.667 8.667 0.000TOTAL (kg/batch) 260.000 8.667 268.667 216.667TOTAL (L/batch) 242.190 3.437 245.628 184.608

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Stream Name Tubed Cream inCarton Wrapped Cream Pallet Box InCream in Pallet

BoxSource P-6 P-7 INPUT P-8Destination P-7 P-8 P-8 OUTPUTStream PropertiesActivity (U/ml) 0.00 0.00 0.00 0.00Temperature (C) 25.00 25.00 25.00 25.00Pressure (bar) 1.01 1.01 1.01 1.01Density (g/L) 1,128.06 1,128.06 1,173.66 1,153.72Total Enthalpy (kW-h) 9.48 9.48 8.97 18.45Specific Enthalpy (kcal/kg) 16.81 16.81 11.87 13.98Heat Capacity (kcal/kg-C) 0.67 0.67 0.47 0.56Component Flowrates (kg/batch)Active Ingredie 2.000 2.000 0.000 2.000Carton Box 216.667 216.667 0.000 216.667Deionized Water 137.760 137.760 0.000 137.760Emulsifier 60.000 60.000 0.000 60.000Emulsifying Wax 7.200 7.200 0.000 7.200Excipient 0.240 0.240 0.000 0.240Foam Stable 28.800 28.800 0.000 28.800Ointment 24.000 24.000 0.000 24.000Pallet Box 0.000 0.000 650.000 650.000Tube Plastic 8.667 8.667 0.000 8.667TOTAL (kg/batch) 485.333 485.333 650.000 1,135.333TOTAL (L/batch) 430.235 430.235 553.824 984.059

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4. OVERALL COMPONENT BALANCE (kg/batch)

COMPONENT INITIAL INPUT OUTPUT FINAL IN-OUTActive Ingredie 0.000 2.000 2.000 0.000 0.000Carton Box 0.000 216.667 216.667 0.000 0.000Deionized Water 0.000 137.760 137.760 0.000 0.000Emulsifier 0.000 60.000 60.000 0.000 0.000Emulsifying Wax 0.000 7.200 7.200 0.000 0.000Excipient 0.000 0.240 0.240 0.000 0.000Foam Stable 0.000 28.800 28.800 0.000 0.000Nitrogen 0.346 0.000 0.025 0.321 0.000Ointment 0.000 24.000 24.000 0.000 0.000Oxygen 0.105 0.000 0.008 0.097 0.000Pallet Box 0.000 650.000 650.000 0.000 0.000Tube Plastic 0.000 8.667 8.667 0.000 0.000Water 0.000 1,098.693 1,098.693 0.000 0.000TOTAL 0.450 2,234.026 2,234.058 0.418 0.000

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5. EQUIPMENT CONTENTS

V-101Procedure Operation Time (in h) Volume (in L)P-1 START 0.000 0.000P-1 CHARGE-1 (Charge) 0.670 2.862P-1 HEAT-1 (Batch Heating) 2.750 2.976P-1 CHARGE-2 (Charge) 3.080 17.403P-1 CHARGE-3 (Charge) 3.410 41.272P-1 CHARGE-4 (Charge) 3.740 50.814P-1 AGITATE-1 (Agitation) 4.240 50.814P-1 TRANSFER-OUT-1 (Transfer Out) 4.660 0.000P-1 CIP-1 (In-Place-Cleaning) 4.740 0.000

V-102Procedure Operation Time (in h) Volume (in L)P-2 START 0.000 0.000P-2 CHARGE-1 (Charge) 0.670 2.862P-2 HEAT-1 (Batch Heating) 2.750 2.976P-2 CHARGE-2 (Charge) 3.080 17.403P-2 CHARGE-3 (Charge) 3.410 41.272P-2 CHARGE-4 (Charge) 3.740 50.814P-2 AGITATE-1 (Agitation) 4.240 50.814P-2 TRANSFER-OUT-1 (Transfer Out) 4.660 0.000P-2 CIP-1 (In-Place-Cleaning) 4.740 0.000

V-103Procedure Operation Time (in h) Volume (in L)P-3 START 0.000 0.000P-3 TRANSFER-IN-1 (Transfer In) 0.500 139.774P-3 CHARGE-1 (Charge) 0.830 140.017P-3 AGITATE-1 (Agitation) 0.997 140.017P-3 TRANSFER-IN-2 (Transfer In) 1.417 190.980P-3 TRANSFER-IN-3 (Transfer In) 1.837 241.890P-3 AGITATE-2 (Agitation) 2.087 241.890P-3 COOL-1 (Batch Cooling) 21.087 240.180P-3 CHARGE-2 (Charge) 21.167 242.190P-3 AGITATE-3 (Agitation) 21.417 242.190P-3 TRANSFER-OUT-1 (Transfer Out) 22.100 0.000P-3 CIP-1 (In-Place-Cleaning) 22.350 0.000

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