CONTENTS

1.1 INTRODUCTION................................................................................................................... 1
1.2 LOCATIONS.......................................................................................................................... 2
2.1 LEAF GODOWN....................................................................................................................3
2. 2 PRIMARY MANUFACTURING DEPARTMENT....................................................................4
2.3 CUT TOBACCO STORE........................................................................................................6
3.1 CONTROL CABINET.............................................................................................................7
3. 2 MAIN CONTROL PANEL......................................................................................................8
3.3 AIR LOCK, TOBACCO FEEDER AND SPLICER................................................................8
3. 4 SUCTION ROD CONVEYORS, TRIMMING POD AND TRIMMING RETURN......................8
3.5 MAIN FRAME........................................................................................................................ 8
3.6 SYNCHRONOUS MOTORS..................................................................................................9
4.1 FLOW CHART..................................................................................................................... 12
5.1 PROJECT FLOWCHART.....................................................................................................20
5.2 ABOUT ARDUINO............................................................................................................... 21
5.3 HC Serial Bluetooth............................................................................................................. 21
5.4 Selection of the Module.......................................................................................................24
5.5 HC-05.................................................................................................................................. 24
5.6 PROGRAM CODE............................................................................................................... 26
5.7 PROJECT PHOTOGRAPHS...............................................................................................28
5.8 CONCLUSION..................................................................................................................... 29
LIST OF FIGURE

Figure 1 - Cigarettes Brand..........................................................................................................4

Figure 2 Leaf Godown.................................................................................................................6
Figure 3 - Lamina Conditioner.....................................................................................................7
Figure 4 - Stem Conditioner.........................................................................................................8
Figure 5 - Cut Tobacco Store.......................................................................................................9
Figure 6 - LOGA DX -85............................................................................................................ 12
Figure 7 - Cigarette making machine.........................................................................................13
Figure 8 - Secondary Manufacturing..........................................................................................15
Figure 9 - PACKER MACHINE...................................................................................................16
Figure 10 - Finished Goods.......................................................................................................21
Figure 11 - Arduino Bluetooth module........................................................................................30

LIST OF TABLE
Table 1 - Motor description.........................................................................................................18
Table 2 - Valve and pressure switches.......................................................................................19
Table 3 - Pressure switches.......................................................................................................20
 CHAPTER 1
ABOUT ITC
1.1 INTRODUCTION

ITC (Imperial tobacco company) is started in 24 th August 1910 by its chairman

Yogeshchander deveshwar. The company was renamed as the INDIAN TOBACCO
COMPANY Ltd in 1970 and changed to ITC Ltd in 1974. Now with the brand name of
ITC Ltd it has completed its 100 years in 2010. At present, there are more than 25,000
employers working in several cigarette division plants across the country. During the
year of 2012- 2013 the company has produced largest turnover of about 8.31 US billion

It has started with the different variety of cigarettes such as

1.Scissors

2.Flake and Gold Flake

3.Wills and classic Wills

4.Bristol

5.Benson&Hedges

These cigarettes have the largest turnover in exports and imports. Benson &
Hedges is the largest exporting cigarettes among all.

1
 Figure 1 - Cigarettes Brand

1.2 LOCATIONS

ITC has many branches in India for manufacturing cigarettes. The leading
cigarette manufacturing plants in India are:

1.Bengaluru

2.Pune

3.Munger

4.Saranghpur

5.Kolkata

The head office for cigarette division is located in Kolkata west Bengal.

2
 CHAPTER 2
MANUFACTURING OF CIGARETTES

Here we are going to witness about the manufacturing and packing of

variety of cigarettes at Bengaluru plant located in Meenakunte village, Jala Hobli.ITC
cigarette division in Bangalore is manufacturing cigarettes and it has four main divisions
in manufacturing and packing process.

1.Leaf Godown

2.Primary Manufacturing Department

3.Cut Tobacco Store

4.Secondary Manufacturing Department

2.1 LEAF GODOWN

Raw materials will be first stored in this section. Once the storage is
done the raw materials such as tobacco leaves and stem parts will undergo through the
several steps which includes of treating them in high temperature and pressure to make
it suitable for the manufacture.

Figure 2 Leaf Godown

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2. 2 PRIMARY MANUFACTURING DEPARTMENT

This is one of the preliminary stage where the tobacco is divided into

stem and leaves. The over flow diagram of PMD section is explained as follows :

PMD

LAMINA LINE STEM LINE

SLICER STEM
CONDITIONER

LAMINA STEM CUTTER

CONDITIONER

LAMINA CUTTER STEM DRYER

LAMINA DRYER
FLAVORING
CYLINDER

CFC FILLING CUT TOBACCO SILO BOX FILLING

4
Figure 3 - Lamina Conditioner

Figure 4 - Stem Conditioner

5
2.3 CUT TOBACCO STORE

The treated tobacco from the PMD is stored in the cut tobacco store.
Based upon the treatment the tobacco stored in the different levels. High quality treated
tobacco is mainly used for the exporting purposes and being used in the manufacturing
cigarettes like Benson & Hedges etc.,

Figure 5 - Cut Tobacco Store

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 CHAPTER 3
CIGARETTE MAKING MACHINE

3.1 CONTROL CABINET

Separate from the machine, the control cabinet contains all of the power,
monitoring and supply components. The link with the machine is provided by the cables
routed in a rigid overhead cable tray. In this way, the side of the cabinet only leaves the
essential parts accessible, main cut off switch (pad lockable), power-supply indicator
light, machine-running time-counter and electrical maintenance button with special key.
Connections are located in the upper section of the cabinet.

3. 2 MAIN CONTROL PANEL

The main control panel is monitored by a supervision program called

DISTAC. The control panel is formed by a PC-panel (PC40) Providing access to all the
line controls, an emergency stops button (SCP1) and a potentiometer(R11). The control
panel is located on the cigarette maker:

Operator manual -DMO

Configuration manual DMC

3.3 AIR LOCK, TOBACCO FEEDER AND SPLICER

The air-lock supplies the cigarette maker with tobacco in accordance with
transmission from the factorys distribution unit. The tobacco feeder provides transfer of
tobacco from the air-lock to the geniture base. During its transport, the flow of tobacco is
regulated to avoid damage. The functions of the splicer are to ensure continuity if its
machine operation when changing bobbins.

3. 4 SUCTION ROD CONVEYORS, TRIMMING POD AND TRIMMING RETURN

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 The suction rod conveyor transfers the tobacco from the suction chimney
up t the entry in the geniture base. While it is being transferred, the tobacco is regulated
by the cigarette weight control system.

3.5 MAIN FRAME

This supports all the elements ensuring formation of the cigarette rod and
consists, mainly, of a geniture bas providing guidance of the flow of tobacco on its paper
envelope as well as closing by gluing and drying of this rod. A cut-off unit, located just
afterwards, provides cutting to length of single or double cigarettes transferred to the
downstream by an elliptical or cam transfer unit.

3.6 SYNCHRONOUS MOTORS

The machine comprises of six synchronous motors used to drive the

various parts of the machine. The motors are synchronized with respect to a virtual
master(VM), which variable pulses as a function of the speed.

LOGA DX -85
8
Figure 6 - LOGA DX -85

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Figure 7 - Cigarette making machine

10
 CHAPTER 4
SECONDARY MANUFACTURING
4.1 FLOW CHART

CT transferred into Delivered blend/ Planed CT being fed

metal charges operation being into shake feeder
stacked in CTs rows

Formed cigarette Packer from packets Maker converter CT,

packets get packed in using cigs, HLC, foil/ cig paper, PPCT &
CFC and CFCs met. paper, inner filter rod into
stacked on FG. frame BOPP. cigarettes

Filled pallet get

identified with
dockets and moved
to marshaling yard

Finished goods gets

checked by receipt
clerk and stored in
FGs

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Figure 8 - Secondary Manufacturing

12
 PACKER MACHINE
HINGE LID PACKER MODEL 349-FOCKE & CO

Figure 9 - PACKER MACHINE

TECHNICAL DATA

1.Machine capacity:

Quantity -300Up to ppm

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2.Noise Emission:

Sound pressure level 70 dB/65.5 dB(A)

3.Electrical Installation:

Mains connection - 415 V

Input frequency - 50 Hz

Connected load - 16 KVA / 11.4KW

4.Pneumatic:

Pressure - Pmin 4.5 bar abs

Pmax 6 bar abs

5.Vaccum: Pressure - 0.6 bar abs

Air consumption - 12

14
 Table 1 - Motor description

S.no Designation Motor Function

1 E 0.2 Three phase a.c The motor drive the
Motor external vacuum pump.
2 M 0.3 Three phase a.c The agitation motor actuates the
Motor agitating bars of the cigarette
hopper. The agitation motor is
installed at the rear (R.H. side.) of
the cigarette hoper
3 M 0.5 Three phase a.c The motor drives the central
Motor lubrication unit. The unit is located
on the front side of the machine
below the cigarette hopper.
4 M 14.5 D.C. motor 24 V The motor drives the central
lubrication unit. The unit is located
on the front side of the machine
below the cigarette hopper.
5 M E 1 0.0.6 + B Three phase a.c. The main drive motor is a
1.0 Servomotor continuously variable three-
phase a.c. servomotor. The
individual speeds are preselected
via the PLC and can be set via the
visual display unit. The main drive
motor drives the main gearbox.
6 M 0.4 Three phase a.c The motor drives the discharge belt
and is installed below the discharge
Motor belt.

VALVES AND PRESSURE SWITCHES

15
VALVES:
The PC- control energizes the solenoid valves. The control voltage is 24V

Table 2 - Valve and pressure switches

S. No Designation Function
1 -Y 12.5 This valve, when de-energized, blocks the elevator into the
transfer turret, such that the bad packets will be rejected. For
conveying the packets into the transfer turret, the valve must
be energized
2 -Y12.6 The glue valve is responsible for the supply of the glue in the
blank unit. In conjunction with the glue level probe it ensures
the automatically replenishing of the glue pot
3 -Y12.7 The glue valve is responsible for the supply of the glue in the
packet track. In conjunction with the glue level probe it
ensures the automatically replenishing of the glue pot.
4 -Y12.0 This valve apply vacuum to the rubber pad covered knife arm
-Y12.1 surfaces of the foil splicer. Alternately vacuum is applied to
this surface. The change is carried out by means of a sliding
switch
5 -Y12.3 Compressed air instead of vacuum will be applied to the
blank suction cap for few revolutions after an automatic foil
splicing. The suction cup will be blown
6 -Y12.2 This valve, when de energized, causes an inner frame to be
rejected downward. To transport the inner frames to the
cigarette track, the valve must be energized.
7 -Y12.4 This valve, when de- energized, inhibits the vacuum-operated
blank removal from the hopper. For removing the blanks from
the hopper, the valve must be energized.

PRESSURE SWITCHES

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 Table 3 - Pressure switches

S. Function Setting
No values
1 Pressure switch oil pressure-B 19.5 The oil pressure is 0.4 0.4 bar
bar. When the oil pressure has not reached within the
selected time or the pressure drops below this value, the
pressure will be activated. The machine will stop. The oil
pressure switch is located in the main gearbox. The oil
pressure is indicated on the oil pressure gauge.
2 Pressure switch compressed air B19.4 The pressure switch 6 to 4 bar
controls the compressed air at the maintenance
unit. When the pressure drops below 4 bar, the machine will
be stopped.
3 Pressure switch vaccum-B19.3 The pressure switch controls 0.6 to 0.4 bar
the vacuum of the machine. When the vacuum drops below
0.4, the machine will be stopped.

FINISHED GOODS

17
 The tobacco after gone through several steps in the PMD and SMD, is now being
made into cigarettes and it is getting packed in the SMD and gets stored in the in this
section called finished goods.

Figure 10 - Finished Goods

CHAPTER 5
18
 COUNTING REJECTION OF CIGARETTE USING
ARDUINO BLUETOOTH MODULE

5.1 PROJECT FLOWCHART

GET THE INPUT DATA

FROM THE WEIGHING
SENSOR

RECEIVEING THE INPUT

IN THE ARDUINO

PROCESSING THE DATA

SENDING THE DATA TO

THE MOBILE APP VIA THE
BLUETOOTH MODULE

VIEWING THE DATA IN

THE MOBILE APP

19
5.2 ABOUT ARDUINO

Arduino is a prototype platform (open-source) based on an easy-to-use hardware

and software. It consists of a circuit board, which can be programmed (referred to as a
microcontroller) and ready-made software called Arduino IDE (Integrated Development
Environment), which is used to write and upload the computer code to the physical
board.

The key features are:

Arduino boards are able to read analog or digital input signals from different
sensors and turn it into an output such as activating

You can control your board functions by sending a set of instructions to the
microcontroller on the board via Arduino IDE (referred to as uploading software).

Unlike most previous programmable circuit boards, Arduino does not need an
extra piece of hardware (called a programmer) in order to load a new code onto
the board. You can simply use a USB cable.

Additionally, the Arduino IDE uses a simplified version of C++, making it easier to
learn to program.

Finally, Arduino provides a standard form factor that breaks the functions of the
micro-controller into a more accessible package.

5.3 HC Serial Bluetooth

HC serial Bluetooth products consist of Bluetooth serial interface module and Bluetooth
adapter, such as:

(1) Bluetooth serial interface module:

Industrial level: HC-03, HC-04 (HC-04-M, HC-04-S)

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Civil level: HC-05, HC-06(HC-06-M, HC-06-S)

HC-05-D, HC-06-D (with baseboard, for test and evaluation)

(2) Bluetooth adapter:

HC-M4

HC-M6

This document mainly introduces Bluetooth serial module. Bluetooth serial module is
used for

converting serial port to Bluetooth. These modules have two modes: master and slaver
device. The

device named after even number is defined to be master or slaver when out of factory
and cant be

changed to the other mode. But for the device named after odd number, users can set
the work mode

(master or slaver) of the device by AT commands.

HC-04 specifically includes:

Master device: HC-04-M, M=master

Slave device: HC-04-S, S=slaver

The default situation of HC-04 is slave mode. If you need master mode, please state it
clearly or

place an order for HC-O4-M directly.The naming rule of HC-06 is same.

When HC-03 and HC-05 are out of factory, one part of parameters are set for activating
the device.

The work mode is not set, since user can set the mode of HC-03, HC-05 as they want.

21
The main function of Bluetooth serial module is replacing the serial port line, such as:

1. There are two MCUs want to communicate with each other. One connects to
Bluetooth master device while the other one connects to slave device. Their
connection can be built once the pair is made. This Bluetooth connection is
equivalently liked to a serial port line connection including RXD, TXD signals.
And they can use the Bluetooth serial module to communicate with each other.

2. When MCU has Bluetooth salve module, it can communicate with Bluetooth
adapter of computers and smart phones. Then there is a virtual communicable
serial port line between CU and computer or smart phone.

3. The Bluetooth devices in the market mostly are salve devices, such as Bluetooth
printer, Bluetooth GPS. So, we can use master module to make pair and
communicate with them. Bluetooth Serial modules operation doesnt need drive,
and can communicate with the other Bluetooth device who has the serial. But
communication between two Bluetooth modules requires at least two conditions:

(1) The communication must be between master and slave.

(2) The password must be correct.

4. However, the two conditions are not sufficient conditions. There are also some
other conditions basing on different device model. Detailed information is
provided in the following chapters. In the following chapters, we will repeatedly
refer to Livors (Formerly known as Guangzhou HC Information Technology Co.,
Ltd.) material and photos

22
5.4 Selection of the Module

The Bluetooth serial module named even number is compatible with each other;
The salve module is also compatible with each other. In other word, the function of HC-
04 and HC-06, HC-03 and HC-05 are mutually compatible with each other. HC-04 and
HC-06 are former version that user cant reset the work mode (master or slave). And
only a few AT commands and functions can be used, like reset the name of Bluetooth
(only the slaver), reset the password, reset the baud rate and check the version number.
The command set of HC-03 and HC-05 are more flexible than HC-04 and HC-06s.
Generally, the Bluetooth of HC-03/HC-05 is Recommended for the user.

5.5 HC-05

Master and slave mode can be switched

Bluetooth name: HC-05

Password:1234

Master role: have no function to remember the last paired salve device. It can be
made paired to any slave device. In other words, just set AT+CMODE=1 when
out of factory. If you want HC-05 to remember the last paired slave device
address like HC-06, you can set AT+CMODE=0 after paired with the other
device. Please refer the command set of HC-05 for the details.

Pairing: The master device can not only make pair with the specified Bluetooth
address, like cell-phone, computer adapter, slave device, but also can search
and make pair with the slave device automatically. Typical method: On some
specific conditions, master device and slave device can make pair with each
other automatically. (This is the default Method.)

Multi-device communication: There is only point to point communication for

modules, but the Adapter can communicate with multi-modules.

23
 AT Mode 1: After power on, it can enter the AT mode by triggering PIN34 with
high level. Then the baud rate for setting AT command is equal to the baud rate
in communication, for example: 9600.

AT mode 2: First set the PIN34 as high level, or while on powering the module
set the PIN34 to be high level, the Baud rate used here is 38400 bps. Notice: All
AT commands can be operated only when the PIN34 is at high level. Only part of
the AT commands can be used if PIN34 doesnt keep the high level after entering
to the AT mode. Through this kind of designing, set permissions for the module is
left to the users external control circuit that makes the application of HC-05 is
very flexible.

During the process of communication, the module can enter to AT mode by

setting PIN34 to be high level. By releasing PIN34, the module can go back to
communication mode in which user can inquire some information dynamically.
For example, to

Inquire the pairing is finished or not.

Default communication baud rate: 9600, 4800-1. 3M is settable.

KEY: PIN34, for entering to the AT mode.

LED1: PIN31, indicator of Bluetooth mode. Slow flicker (1Hz) represents entering
to the AT mode2, while fast flicker (2Hz) represents entering to the AT mode1 or
during the communication pairing. Double flicker per second represents pairing is
finished, the Module is communicable. LED2: PIN32, before pairing is at low
level, after the pairing is at high level. The using method of master and slavers
indicator is the same. Notice: The PIN of LED1 and LED2 are connected with
LED+.

Reset: PIN11, active if its input low level. It can be suspended in using.

Level: Civil

24
5.6 PROGRAM CODE

char input;

int Count=0;

float W;

void setup()

Serial.begin(38400);

// pinMode(LED, OUTPUT);

Serial.println(">> START<<");

void loop()

if(Serial.available()>0)

input= Serial.read();

input=input-'0';

W=input/255;//

Serial.println("wieght in grms: ");

Serial.print((byte)W);

Serial.println("\r\n");

if(W > 0.92 )

25
 {

Count++;

Serial.println("over wieght\n");

Serial.print((byte)Count);

Serial.println("\r\n");

//digitalWrite(LED, HIGH);

delay(2000);

else if(W < 0.82 )

Count++;

Serial.println("under wieght\n");

Serial.println("\r\n");

Serial.print((byte)Count);

Serial.println("\r\n");

//digitalWrite(LED, HIGH);

delay(2000);

else

Serial.println("NORMAL WIEGHT\n");

// Serial.println(input);

} code

26
5.7 PROJECT PHOTOGRAPHS

Figure 11 - Arduino Bluetooth module

27
5.8 CONCLUSION

In the LOGA 3D 85 cigarette making machine, an output wire was taken from the
MR3 weighing sensor and the output was given to the ARDUINO and data was
processed in the microcontroller and it was viewed in the Arduino Bluetooth mobile app.
The data from the microcontroller is sent to the app using the HC 05 Bluetooth module.
This project enables us to monitor the rejection count of the cigarettes per minute from a
remote location.

28