Magnificent ACG capsule plant

Thirty seven of us boarded the same train, albeit our boarding stations were different. However, we all got down at Dahanu station. Surprisingly, the Borivali-Surat Memu was on time.

We all crossed the bridge and came to Dahanu east. The company had arranged a bus for us. I looked out for 0762 number bus. It was parked just few feet away. Happily, we boarded the bus.

And then started the journey to ACG capsules Ltd Industrial visit. The third year students were excited and enthusiastic. They loved the bus and the journey, and were singing songs. I was seating in the first row with Hitanshu.

After about 15 minutes of bus ride, we arrived at the company. The entrance was guarded, however our principal had already arrived in the company. She travelled by road from Borivali. So, the arrangement was already made before we reached the industry.

At the reception, we were told to deposit our mobile phones and other electronic devices, which we did.

After an instructive safety video demonstration, we were ready to explore the company. We left the reception and headed to the main plant of the company. There, we met our instructor Mr Ganesh Vichare, he was very friendly person and later we understood that he was associated with the company for past 14 years.

We assembled in the conference room, all of us around a central circular table. The third years, enjoyed the moment there.

It was about 10:00 and we all were really hungry, some of us left the home at 6.30 in the morning. Mr Ganesh, told us that first we will have our breakfast. So happily we all went to canteen and had sandwich and upma with hot tasty chai.

Soon, we were back to the conference room, there Mr. Ganesh explained in detail about the company, its inception, functioning and expansion. I was enthralled to know that this plant produces 500 lacs capsules a day, that is the production rate of their 24 machines which works 24 by 7, 365 days a year, amazing. I liked the videos he showed us at the end of the presentation. The new video of ACG was awesome, dynamic and kind of aggressive.

So with that 45 mins of presentation we were ready for the plant visit. The first thing we visited is their global analytical testing lab. That was awesome. I was particularly fascinated with the MS machine use to analyse metals in their products. That MS costs 1.5 Cr. Also, the weighing balance was fascinating too, it was a sensor operated digital balance of Mettler costing around 15 lacs.

There were usual instruments like GC, HPLC and Karl Fischer auto titration all of expensive models. Being a chemist I liked that lab a lot. I was feeling great in the lab. I actually did remembered my PhD days.

After that we visited the chemical lab. Now this is my area of expertise. The chemist of the lab told us they do 4 major tests on their samples in that lab. 1. Average weight, 2. LOD, 3. DT and 4. Odour. And he showed us different instruments in that lab.

What intriguing me was the reagent bottles, they were clear spotless and well labelled. I simply loved it. It shows the level of care chemist take to assure the quality of their products. There were 4 fuming hoods as well where they did some chemistry.

Enthralled and enlightened we moved to the next lab the microbiology lab. Mr Ganesh, in his presentation had told us that there are only 5 such labs in the country. Only 5 labs in the country! That's amazing, I was fascinated to see the lab. And here, we were at microbiology lab.

Since it was a microbiology lab we did not entered that lab but observed and understood the principle from outside. There were windows through which we saw the working of micro lab. It was great exp. the lab tests for absence of 5 bacterias and fungus (including E. Coli.) and absence of 4 pathogens including Shigela. Which is banned by Indian government in any oral preparation.

This visit of three different labs was about an hour long, we were overwhelmed to see the international standards of the company.

Soon, we climbed down to ground floor from the first floor and headed towards the plant. Before entering the plant we had to were protective clothing. Mr Ganesh had arranged for the aprons. He actually showed us how to wear our head caps and masks which was great, we all wore apron which was knee length, shoe covers along with the head cap and masks.

And then after washing our hands with alcohol hand sanitiser we entered the main plant. The main plant is a huge production area where actual production of capsules takes place.

Mr. Ganesh, took us to the quarantine area where the raw materials were stored. We were surprised to see the sheer volume of raw gelatine and HPMC packs kept in the quarantine along with natural printing ink. The area was maintained at 24 degrees and with controlled humidity.

Gelatine is obtained from animal fats so is kind of non veg, but now ACG also produces Nature caps which is a veg alternative of the gelatine. Nature caps are made from HPMC, which is obtained from pine tree, the cellulose of which is used to prepare HPMC.

After the quarantine we all moved to actual production site. I was excited to see the gigantic 25000 litre tankers used to form mucilage, the first step in the preparation of capsule where the gelatin or HPMC was mixed with water in 1:2 ration and formed in, colourless odourless transparent solution. There where two tanks of 25k capacity, one for body and the other for cap.

Since body and cap have different colours they were prepared in different tanks. The required colour for the mucilage was mixed before it was taken to dipping station where the capsules get their shape.

We  moved from the mucilage production area to actual capsule manufacturing area. Here the magic takes place. Robotic automated machines working uninterrupted were producing capsules at a ferocious rate.

First the pins were dipped in the gelatine solution and then the dyes made a half and one rotation and were send for drying. After the drying, the capsules body and caps were stripped, cut and locked all in 2 seconds. The sight was awesome. The machines were doing this work faster than I had imagined. We could see how the liquid gelatine solution was transformed into solid gelatine capsules.

Then, we moved to the first floor of plant. Here, the finished capsules prepared in ground floor was sucked on first floor by vacuum. These capsules were then passed through printers. The capsule printing could be linear or could be circular. The one which we saw had a circular printing. The body and caps were printed separately.

At the end of the printing station, Mr Ganesh told us the cameras used to inspect the correct printing on the capsules, if the system found the capsules inadequate they removed it from the load and separated them to discard section.

The capsules manufactured by ACG was packed in 5 layer ply cartoons. This specification is prescribed by IIP (Indian Institute of Packaging.). We all loved the boxes with similar liking as the capsules. Awesome pickings.

At the end of our tour we meet Mr Kailash who was handling the printing and packaging section of the production.

Soon, we climbed down to ground floor, walked to the place where we had covered ourselves in apron. I saw the enthusiasm and excitement in the students after this visit. We removed our aprons, caps masks and shoe covers and come back to conference room.

It was nearly 3.00 pm and I was hungry like hell. I was delighted to know that we will be having food first. And so we all moved to canteen once again to have food. The food was great.

Stomach filled we left the cafeteria and assembled in conference room for the last session of today's visit. The feedback session. Here we gave our positive and constructive feedback to Mr Ganesh.

I looked at Mr Ganesh when students were giving feedback. He was happy and cheerful to hear the positive feedbacks. After the feedback session we left the plant and came outside.

There we took pics, the memorable ACG plant visit had come to an end. Mr ganesh told the students to remember two things, 1: grow trees and 2. Wear helmets. Enthusiastically students gave affirmation.

I was so content in the visit that, I did not realised I had deposited my mobile phone along with all the students at the reception before entering the plant. We went to reception and got our mobile phone back. Students clicked the selfies with their phone.

The bus was arranged for the return journey as well. All the students boarded the bus and left for Dahanu station to catch Churchgate train. I joined principal madam in car.

Thus came the happy ending of our industrial visit to ACG capsules limited.