Efficient production management of formulation processing

--How to save energy and increase efficiency in pesticide formulation production

In 2014, the "First Expert Diagnosis and Improvement Activity for Pesticide Formulation Processing and Packaging Technology" was held by the China Pesticide Industry Association. In response to the current pesticide formulation processing industry in China, it was proposed to focus on four aspects to achieve efficient production: formula, equipment, regulations, and workflow. Through diagnostic activities, enterprises have learned how to use better methods to solve problems in product production, which has improved production efficiency and energy-saving level, and significantly increased enterprise benefits. A brief summary of their views is as follows:

1、 Formula

Excellent formulation products are based on excellent formulas. The quality and stability of the formula are important indicators that determine whether the product is truly qualified. While completing formula development, it is important to pay attention to the biological testing and efficacy testing of the product, in order to observe its efficacy and drug toxicity. In addition, in actual production, formula research and production process research must be matched with the application of production equipment.

2、 Equipment

In terms of equipment selection, factories need to consider the following points - equipment performance, ease of cleaning, ease of operation, ease of maintenance and upkeep, and cost.

Working performance is a fundamental attribute of a device, and the level of ease of cleaning plays an important role in controlling the risk of cross contamination. If the equipment has many dead corners, is prone to residue, and is not easy to clean, it will greatly increase the probability of cross contamination, which is particularly important in herbicide workshops. The ease of operation of equipment is aimed at users, and the simpler the operation method, the lower the various risks caused by operational errors in production. Another important aspect is the ease of maintenance of the equipment. If the equipment requires too many repairs during operation, the time, manpower, and material costs incurred in this regard should also be considered in the comprehensive evaluation of the equipment. From the current situation of domestic formulation production factories, cost is generally the first factor that factories pay attention to when purchasing equipment. However, in reality, the above aspects should be comprehensively considered. If not selected properly, the additional costs caused by the first four factors in production operation may be much higher than the original cost of the equipment.

3、 Regulations

What are the regulations? Regulations are clear and documented regulations related to the production process. Each production step should have reasonable regulations. In the production process of factories, there is often a "generation gap of understanding" - the regulations set by product research and engineering technicians say the same thing, the operation method said by workshop managers is the same thing, and the actual operation by workers is the same thing, all three of which are inconsistent with each other. Such regulations are invalid and even harmful. Effective regulations have clear and reasonable regulations for each production process, which are suitable for actual production operations. A workshop that formulates such a reasonable set of regulations requires sufficient communication between engineering and technical personnel, workshop managers, and operators regarding the production process. Once the regulations are finally determined, they should be documented and documented, and operators should receive training on the regulations. The workshop manager and operators need to ensure that they fully understand and refer to them for implementation.

During the production process, key data should be collected for each batch to analyze and improve production efficiency, while continuously improving procedures to achieve a virtuous cycle.

4、 Workflow

The workflow is a reflection of workshop management methods. In the workflow, the following points should be clearly defined: production goals, steps (and sequence) required to achieve the goals, responsible persons for each production process, and standards for judging (the next production action).

An effective method is to use block flowcharts to display and analyze all production processes in the process flow. In the flowchart, each step, production sequence, responsible person, and other elements should be refined. Once a problem occurs, it is ensured that the cause can be identified and effective measures can be taken to remedy it in a timely manner.

In the processing and packaging of formulations, common projects that require workflow include: introduction of new products, distribution of product costs, scheduling of batch production, quality control and cross contamination control, preventive (equipment) maintenance plans, safety and environmental protection, workshop cleaning and organization (5S management), etc.

The above four aspects are missing to varying degrees in the production process of pesticide formulations in China, and are important parts that urgently need to be optimized and improved.