Presented By ,

Miss. Janhavi S. Zope.

M. Pharm SEM

Department : Pharmaceutics

R . G . SAPKAL COLLEGE OF PHARMACY , NASHIK

1

CONTENTS

Introduction

Plant Support Services

References

2

INTRODUCTION

Definition :- Activity or function required for successful

completion of a process , program or project in the plant is

called as plant support services .

Pharmaceutical manufacturing facility required 2 principle

areas ;

1) Production Area

2) Support Area

Requirement for the construction of plant :-

1) Requirements related to GMP

2) Requirements related to Factories Act and Rules

3

PLANT SUPPORT SERVICES

Plant Support Services includes ;

A. Services related to Manufacturing

B. Services related to Employees

4

CONT…

A. Services related to Manufacturing

1) Security Office

2) Fuel Storage

3) Scrap Yard

4) Toilet Facility

5

CONT…

B. Services related to Employees

1) Vehicle Parking

2) Canteen and Cooking

3) Garden and Horticulture

4) Administrative Block and Training Centre

5) Sports and Entertainment Block

6) Resident Managers Bungalow

7) Residences for Essential Service Staff

8) Medical Services

6

PHARMACEUTICAL PLANT LAYOUT

Production block

Admin

Parking

place

Canteen

Utilities

block

Security

Main road

Facto

ry R

oad

Warehouse

Scrap yard

Fuel

storage

7

SECURITY OFFICE

In every factory 1000 or more workers are ordinarilyemployed .

Also number of Safety Officers may be specified infactory .

The duties , qualification and conditions of service ofSafety Officers shall be prescribed by the StateGovernment .

Pharmaceutical industry is one of the most diverse fields ,encompassing research , manufacturing , distribution andmarketing with a board range of potential securityvulnerabilities .

8

CONT…

Facilities protection requires highest level of security

services related to access control , ingress and egress

monitoring , after-hours protection and alarm monitoring .

Security services required ;

1) Access control

2) Fire prevention and life safety programs

3) Demonstration mitigation

4) Facilities protection

5) Crisis management

6) Emergency or unusual event response

9

CONT…

Security offices also required Security Guards working in

private organizations have to keep a tab on people which

entering and leaving the building .

Security guards maintain a book which contains name or

in and out time of the person .

Security guards are responsible for safety of people

working in building .

Security guards also check each and every person before

entering the building .

10

DESIGNING OF SECURITY OFFICE

Entry to Factory

Locker

Document Room

Alarm

SectionSitting

Table

Waiting Room

Security Cloth

Room

Toilet

Facility

Exit

from

Factory

11

Entry Exit

VEHICLE PARKING

Parking design is result of various policies and programswhich result in more efficient use of parking resources .

Parking is an essential component of the transportationsystem .

Parking area is generally located at the periphery of thepremises .

Separate area provided for parking vehicles of theemployee’s and the visitors .

Separate are allocated for parking of 2 wheelers and 4wheelers .

Allottment of parking area depends on industry’s size ,scope and operations .

12

CONT…

Parking Management Principles :-

1) Consumer Choice

2) User Information

3) Sharing

4) Efficient Utilization

5) Flexibility

6) Prioritization

7) Peak Management

8) Quality Vs Quantity

9) Comprehensive Analysis

13

CONT…

Parking Management Benefits :-

1) Facility Cost Saving

2) Improved Quality of Service

3) More Flexible Facility Location and Design

4) Reduces Land Consumption

5) Supports Mobility Management

6) Supports Smart Growth

7) Improved Walkability

8) More Livable Communities

14

CONT…

Criteria for Design of Parking :-1) Parking Facility for Personnel Vehicle2) Parking Facility for Commercial Vehicle

Parameters in Design of Vehicle Parking :-1) No of Personnel2) Public Transport Services3) Distance of Factory from City4) Private Transports Facilities5) Feasible Land for Design of Vehicle Parking6) Environment Condition7) Vehicle Dimension in Parking Design

15

DESIGN OF VEHICLE PARKING

Personnel Vehicle

Vehicle Parking

Commercial Vehicle

VIP Staff

Other Staff

Workers

Cars

4 Whealer Parking 2 Whealer Parking

Heavy Vehicle

Cars

Cars

16

CONT…

TYPE I (a)

17

CONT…

TYPE I (b)

18

CONT…

TYPE I (c)

19

CONT…

TYPE II

20

CONT…

TYPE III

21

FUEL STORAGE FACILITY

Fuel is required in pharmaceutical industries for generating

power during interruption of regular power supply .

Generally Coal , Diesel can be used for this purpose and

storage of these material is necessary .

Canteen required gas for cooking purpose , LPG cylinders are

utilized for the activity .

Care has to be taken while storing these substances .

Storage has to be near the generator room .

Constant check has to be kept on the quantity of the material

stored .

22

CONT…

As these substances are highly inflammable , protection

from fire becomes a basic requirement .

Fire safety equipments are to be in vicinity of such facility

and people are to be trained in handling of the same .

All such fuel are to be stored in a secured area , to avoid

tampering or misuse of these substances .

23

DESIGN OF FUEL STORAGE

FACILITY

C o m m o n P a s s a g e

Receiving Fire Extinguisher

Intermediate

Liquid Fuel

Storage

Final Liquid

Fuel

Storage

Final Gas Fuel

Storage

Intermediate Gas

Fuel

Storage

Fire Extinguisher

24

GARDEN AND HORTICULTURE

Horticulture is the industry and science of plant

cultivation including the process of preparing soil for the

planting of seeds , tubers or cutting .

In industry , gardens are maintained surrounding the

facility .

Trees are planted at proximity of the facility .

Clarified water from effluent treatment can be used for

watering the gardens .

25

CANTEEN AND COOKING

A. Canteen :-

These area shall not lead directly to the manufacturing andstorage areas .

Canteen usually located at the periphery of the industry .

It is included in the ancillary area of the company .

Area of canteen will depend on the number of workersemployed .

The canteen furniture will be in accordance to GMP .

Food may be provided by company which will lead tomaintaining a hygienic cooking facility in canteen .

Employees can have their food in the canteen .

Proper safety equipments are to be kept in place.

26

CONT…B. Cooking :-

Cooking area has to be maintained under total hygieniccondition .

People involved in preparation , serving , cleaning of area areto be well trained in each activity like personal hygienepractices , washing of utensils , cleaning of food materials .

Personnel working in canteen have to undergo periodic medicalexamination .

These personnel are vaccinated for Typhoid periodically .

Sanitation is the general problem associated with canteenfacility .

Presence of food creates a potential rodent and insect problem .

27

DESIGN OF CANTEEN FACILITY

Cooking

place

Grain

storage

Wash

area

Cooked

food

storage

Service

counter

area

Hand

wash

34 M

13 M

28

SCRAP YARDS FACILITY

During working in the industry , large amount of waste

material or scrap is generated .

This includes the empty cartons in with raw material or

packaging material is plastic sheets , discarded powders ,

discarded or rejected products , printed packaging materials ,

machinery/equipments or parts of machinery/equipments .

The most common method employed for destruction of these

material is incineration .

Monitoring of particulate matter entering the environment is

critical .

29

CONT…

All materials moved to the scrap yard are to be

documented systematically , record of destruction is also

to be maintained .

Precaution during incineration process are necessary with

respect to the material to be destroyed , fumes generated ,

toxic gases evolved .

If material is to be discarded then complete procedure for

metal processing is to be used .

Security measures are also important as any material in

scrap yard should not get stolen .

30

DESIGN OF SCRAP YARDS

FACILITY

Receiving Area Inspection Room

Disposable

scrap

Nondisposabl

e scrap

Scrap

treatment

Scrap

treatment

31

ADMINISTRATIVE BLOCK AND

TRAINING CENTRE

A. Administrative Block :-

Administrative block involves cabin of HOD .

Conference rooms having a capacity of 4 people and 8

people .

Meeting room having capacity of 20 people . There

should be small library . There should be room for tea

making and crockery storage .

Relative location of the administrative area is of

importance .

32

DESIGN OF ADMINISTRATIVE BLOCK

7

6

14

12

11

10 9 8

17

5

4

3

13

1

2

15 16

24.6 M

16 M 33

DESCRIPTION OF ADMINISTRATIVE

BLOCKSr. No. Room Name Dimension

(m)

Description

1 Conference Room 4 x 4 4 Peoples

2 Office – 2 3 x 3 Production Head

3 Office –3 3 x 3 Q. A. Head

4 Office - 4 3 x 3 P.A. of loacation

Head

5 Office – 5 4 x 4 Location Head

6 Wash Room-M 7.6 x 4 -

7 Conference Room 12 x 4.5 20 Peoples

8 Office - 8 3 x 3 Engg. Head

34

Sr. No. Room Name Dimension(m) Description

9 Office - 9 3 x 3 Q. C. Head

10 Office - 10 3 x 3 Personnel Head

11 Tea Making &

Crockery Storage

3 x 2.5 -

12 Wash Room - F 5 x 4 -

13 Conference Room 6 x 4 8 Peoples

14 Library 8.54 x 4.5 -

15 Office - 15 3 x 3 Finance & Factory

Administration

16 Office - 16 3 x 3 Prod. Planning &

Control Head

17 Clark Office - 17 6 x 6 - 35

CONT…

B. Training Centre :-

It is the area where training sessions for employees can be

arranged .

Its location is in the administrative block .

It should contain Projector , T. V , White board .

Sitting arrangement of 25 people or it is also depend on

capacity of plant .

Training varies according to the activity of personnel

which carries out in the industry .

36

CONT… Design Aspects :-

1) Sitting arrangement for a maximum of 30 persons

(30sq.m) .

2) Trainees table and chair (4 x 2 m)

3) White board (2 x 1.5 m)

4) Projection screen (2 x 1.5 m)

5) LCD projector for slide show

6) Flip charts and mounting stand

7) Disposables

8) Speaker phone / TV set with DVD

9) Training manager office

10) Washroom facility 37

DESIGN OF TRAINING HALL

Library

Training

Manager

office

rReception

Wash

roomWhite board

Table

Speaker

30 chairs

12.50 M

11 MLobby

38

RESIDENCE FOR ESSENTIAL

SERVICE STAFF Essential Services means services that are necessary to

enable the employer to prevent ;

1) Danger to life , health or safety .

2) The destruction or serious deterioration of machinery ,

equipment or premises .

3) Serious environmental damage .

4) Disruption of the administration of the courts or of

legislative drafting . 39

CONT…

Essential Services Employee means an employees who is

required to work during a work stoppage .

The residences for these employees have to be in vicinity

of the industry .

As they will be required for the said job at any point of

time , either there will be people working in shifts or in

vicinity .

So that problems can be resolved immediately without any

loss of time and money in the company .

40

SPORTS AND ENTERTAINMENT BLOCK

Company can have recreation activity facility in their

premises .

Employees can use these facilities after their working

hours .

Large scale plants depends on company policy of indoor

sports facility .

Facilities can be for sports , gym , etc .

A common area can be utilized for the purpose like

gatherings or meets of the industry .

Generally table tennis and carom board are placed in these

area .41

CONT…

There is a separate room for study to this wash room is

attach .

There should be facility for drinking water .

Common toilet should be attached to study room .

42

DESIGN OF SPORTS AND

ENTERTAINMENT BLOCKC

ori

dor

Table Tennis Caro

m

12 M

14 M

10 M

Study Room

43

DESCRIPTION OF SPORTS &

ENTERTAINMENT BLOCK

Sr. No. Room Name Description Dimension

(m)

1 Table Tennis Room Arrangement for 2

table tennis board4.44 x 6.8

2 Carom Board Room Arrangement for 2

carom board4.44 x 3.2

3 Study Room Seating arrangement

for 20 people 5.52 x 5

4 Wash Room - 5.46 x 2.70

44

RESIDENT MANAGERS BUNGALOW

Objective :- To provide residence facility for essential staff

within premises .

These area shall not lead directly to the manufacturing and

storage areas .

Bungalows are to be located at the periphery of the industry .

These can be utilized by the managers who have either come

from corporate or other site of company on official duty .

Bungalows ;

Resident Managers Bungalow (about 150 m2)

Staff Quarters (about 75 m2/flats) – 4 block

Workers (about 50 m2/flats) – 6-8 flats

45

DESIGN OF RESIDENCE MANAGER’S

BUNGALOW

Car

Parking

Residence Manager’s

Bungalow

12.5 M

12.5

M

46

15 M

20 M

TOILET FACILITY

Objective :- To provide separate toilet facility for male as

well as female .

The area should be well lighted and ventilated .

Sweepers shall be employed to clean latrines , urinals and

washing places .

Facilities for washing shall be provided and maintained

for the use of the male and female workers separately .

Facilities for changing , storing clothes and for washing

and toilet purposes shall be easily accessible and adequate

for the number of users .

47

CONT… These area shall not be directly connected with production or

storage areas .

There shall be a written instruction for cleaning and

disinfection of these area .

A routine sanitation program shall be drawn up , observed and

properly recorded .

It indicate that :-

1) Specific areas to be cleaned and cleaning intervals .

2) Cleaning procedure to be followed including equipment and

materials to be used for cleaning .

3) Personnel assigned to and responsible for the cleaning

operation .48

DESIGN OF TOILET FACILITY

Change Room

Staff (Women)

Change Room

Staff (Men)

Change Room

Worker (Women)

Change Room

Worker (Men)

Toilet

(Women)

Toilet

(Men)

49

MEDICAL SERVICES

State Government may appoint qualified medical

practitioners to be certifying surgeons .

Duties of Surgeons :-

1) The examination and certification of young persons .

2) The examination of persons engaged in factories in such

dangerous occupations or processes .

3) Supervising the factories .

50

CONT…

Prior to employment , all personnel , shall undergo

medical examination including eye examination .

Also shall be free from Tuberculosis , Skin and other

communicable or contagious diseases .

They should be medically examined periodically at least

once a year .

All records shall be maintained .

The licensee shall provide the services of qualified

physician for assessing the health status of personnel

involved in different activities .

51

REFERENCES

1) Parking Management Strategies , Evaluation and

Planning by Todd Litman Victoria Transport Policy

Institute 5 November 2008 .

52

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