Plant Support Service Layouts

1. Presented By ,
Miss. Janhavi S. Zope.
M. Pharm SEM 
Department : Pharmaceutics
R . G . SAPKAL COLLEGE OF PHARMACY , NASHIK
1

2. CONTENTS
 Introduction
 Plant Support Services
 References
2

3. 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

4. PLANT SUPPORT SERVICES
 Plant Support Services includes ;
A. Services related to Manufacturing
B. Services related to Employees
4

5. CONT…
A. Services related to Manufacturing
1) Security Office
2) Fuel Storage
3) Scrap Yard
4) Toilet Facility
5

6. 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

7. PHARMACEUTICAL PLANT LAYOUT
Production block
Admin
Parking
place
Canteen
Utilities
block
Security
Main road
FactoryRoad
Warehouse
Scrap yard
Fuel
storage
7

8. SECURITY OFFICE
 In every factory 1000 or more workers are ordinarily
employed .
 Also number of Safety Officers may be specified in
factory .
 The duties , qualification and conditions of service of
Safety Officers shall be prescribed by the State
Government .
 Pharmaceutical industry is one of the most diverse fields ,
encompassing research , manufacturing , distribution and
marketing with a board range of potential security
vulnerabilities .
8

9. 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

10. 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

11. DESIGNING OF SECURITY OFFICE
Entry to Factory
Locker
Document Room
Alarm
Section
Sitting
Table
Waiting Room
Security Cloth
Room
Toilet
Facility
Exit
from
Factory
11
Entry Exit

12. VEHICLE PARKING
 Parking design is result of various policies and programs
which result in more efficient use of parking resources .
 Parking is an essential component of the transportation
system .
 Parking area is generally located at the periphery of the
premises .
 Separate area provided for parking vehicles of the
employee’s and the visitors .
 Separate are allocated for parking of 2 wheelers and 4
wheelers .
 Allottment of parking area depends on industry’s size ,
scope and operations .
12

13. 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

14. 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

15. CONT…
 Criteria for Design of Parking :-
1) Parking Facility for Personnel Vehicle
2) Parking Facility for Commercial Vehicle
 Parameters in Design of Vehicle Parking :-
1) No of Personnel
2) Public Transport Services
3) Distance of Factory from City
4) Private Transports Facilities
5) Feasible Land for Design of Vehicle Parking
6) Environment Condition
7) Vehicle Dimension in Parking Design
15

16. 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

17. CONT…
TYPE I (a)
17

18. CONT…
TYPE I (b)
18

19. CONT…
TYPE I (c)
19

20. CONT…
TYPE II
20

21. CONT…
TYPE III
21

22. 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

23. 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

24. 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

25. 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

26. CANTEEN AND COOKING
A. Canteen :-
 These area shall not lead directly to the manufacturing and
storage 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 workers
employed .
 The canteen furniture will be in accordance to GMP .
 Food may be provided by company which will lead to
maintaining a hygienic cooking facility in canteen .
 Employees can have their food in the canteen .
 Proper safety equipments are to be kept in place.
26

27. CONT…
B. Cooking :-
 Cooking area has to be maintained under total hygienic
condition .
 People involved in preparation , serving , cleaning of area are
to be well trained in each activity like personal hygiene
practices , washing of utensils , cleaning of food materials .
 Personnel working in canteen have to undergo periodic medical
examination .
 These personnel are vaccinated for Typhoid periodically .
 Sanitation is the general problem associated with canteen
facility .
 Presence of food creates a potential rodent and insect problem .
27

28. DESIGN OF CANTEEN FACILITY
Cooking
place
Grain
storage
Wash
area
Cooked
food
storage
Service
counter
area
Hand
wash
34 M
13 M
28

29. 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

30. 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

31. DESIGN OF SCRAP YARDS
FACILITY
Receiving Area Inspection Room
Disposable
scrap
Nondisposabl
e scrap
Scrap
treatment
Scrap
treatment
31

32. 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

33. 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

34. DESCRIPTION OF ADMINISTRATIVE
BLOCK
Sr. 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

35. 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

36. 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

37. 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

38. DESIGN OF TRAINING HALL
Library
Training
Manager
office
rReception
Wash
room
White board
Table
Speaker
30 chairs
12.50 M
11 M
Lobby
38

39. 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

40. 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

41. 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

42. 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

43. DESIGN OF SPORTS AND
ENTERTAINMENT BLOCKCoridor
Table Tennis
Carom
12 M
14 M
10 M
Study Room
43

44. DESCRIPTION OF SPORTS &
ENTERTAINMENT BLOCK
Sr. No. Room Name Description Dimension
(m)
1 Table Tennis Room Arrangement for 2
table tennis board
4.44 x 6.8
2 Carom Board Room Arrangement for 2
carom board
4.44 x 3.2
3 Study Room Seating arrangement
for 20 people 5.52 x 5
4 Wash Room - 5.46 x 2.70
44

45. 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

46. DESIGN OF RESIDENCE MANAGER’S
BUNGALOW
Car
Parking
Residence Manager’s
Bungalow
12.5 M
12.5M 46
15 M
20 M

47. 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

48. 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

49. 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

50. 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

51. 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

52. REFERENCES
1) Parking Management Strategies , Evaluation and
Planning by Todd Litman Victoria Transport Policy
Institute 5 November 2008 .
52

53. 53