PRODUCTION QUESTIONS
2004 Exams
3.
Your company is a toiletries manufacturing company that has
expanded over the last five years and has now been approached to
manufacture a new range of colour cosmetics. A project team is to
be set up to review and make recommendations on the equipment
required, factory layout and how the products should be Quality
Controlled at both the bulk and filling stages.
You are to be the technical services representative (R&D and QC) on
this project. Outline the different types of bulk manufacturing and filling
equipment required and what type of grouping/layout should be used.
When answering this question I would be looking for a discussion on the types of
equipment used and their layout in the factory to manufacture of powder, emulsion
and stick colour cosmetics.
4.
Answer both parts:a) Write a short essay on the various process steps and equipment
necessary for the large-scale manufacture of a water in oil emulsion.
Include a brief outline formulation and discuss the importance
of Good Manufacturing Practice in the production environment
and raw material usage traceability .
When answering this question I would be looking for the different steps in the
manufacture of an emulsion from weighing out the raw materials (outline
formulation), cleaning the vessel, GMP.
b) You are responsible for the manufacture of a new oil in water
formulation. The first three batches have not met specification.
There has been one batch with a microbiological failure, one batch with
low viscosity and one batch with both low viscosity and microbiological
failure. Outline the steps you would take to investigate the possible
causes.
To answer this question you will need practical experience either in the lab or from a
Production site on route cause analysis. What raw materials in your formulation would
affect the product viscosity and what would affect the microbiological condition of the
production batch.
2005 Exams
3.
Answer both parts:a) Describe the main techniques used to manufacture and fill a lipstick.
b) Describe the main techniques used to manufacture and fill liquid
foundations.
Please give outline formulations for your answers and describe
how you would adjust the colour if it needed correction.
In this two part question I would be looking for a discussion on the different types of
equipment used in the factory to manufacture and fill:
a. lipsticks both automatic and manual – melting and mixing vessel
b. liquid foundation emulsions – cream processing vessel
Details of how you would apply colour correct each type should also be included.
4.
Answer both parts:a) What design features need to be considered when planning a
new toiletry production unit?
I would be looking for a discussion on why equipment should be grouped together
according to product type, raw materials used, filling speed and production
volumes.
b) Identify the major departments of such an operation and briefly
describe their primary responsibilities and how they interact with
each other.
I would be looking for a description and responsibilities of each department and how
they interact with each other in your organisation or from the module as there are no
right or wrong answers as there are so many different organisational structures
depending upon the size of the company.
2006 Exams
3.
Answer both parts:a. Write a short essay describing the manufacturing process and
equipment used in large scale manufacture of a shower gel. Include
an outline formulation based on using 70% SLES, (Sodium Lauryl Ether
Sulphate), the importance of Good Manufacturing Practice and raw
material usage traceability. Also discuss what quality testing is required
to be carried out on the bulk product.
I would be looking for discussion of a typical formulation and equipment used to
manufacture a shower gel, storage and traceability of raw materials, bulk and the
importance of Good Manufacturing Practice – plant hygiene. How the SLES and other
raw materials are added to the water as well as how the final bulk product is tested –
pH, viscosity, and microbiological.
b. You are responsible for the manufacture of a new carbomer based hair
gel formulation with 5% ethanol. The first two batches have failed the
microbiological test and have low viscosities, therefore they have not met
the specification. Outline the steps you would take to investigate the possible
causes. Include a discussion on the importance of water quality in this type of
formulation.
I would be looking for a discussion on a carbomer based hair gel formulation, the
manufacturing method used and the manufacturing equipment used – high shear
mixing vessel with side phase units.
What can influence the effectiveness of the preservative system and viscosity. Here we
are looking for a Route Cause Analysis covering each stage.
4.
Answer both parts:a. When preparing production plans for (a) one week and (b) one month what
is the key information required. Comment on the importance of this
information
I would looking for a breakdown of the key issues that would effect a production run –
component and bulk availability, equipment, staff, bulk and new raw materials, launch
dates for NPD.
b. Write brief notes on key departments involved in in the new product launch
process. Briefly describe their primary responsibilities and why they are
important.
I would be looking for a description and responsibilities of each department marketing,
R&D, operations, technical group, finance, customer service, - to name few and how
they interact with each other in your organisation or from the module as there are no
right or wrong answers as there are so many different organisational structures
depending upon the size of the company
2007 Exams
2.
Discuss the advantages and disadvantages of grouping the different types of bulk
manufacturing and filling equipment together along product lines when designing
a factory layout. Include in the discussion a description of the different types of
manufacturing and filling equipment used for each product type; the importance
of Good Manufacturing Practice in the layout of a manufacturing and filling area
and the importance of clean water.
I would be looking for a discussion on why manufacturing and filling equipment
should be grouped together according to product type: detergent based products,
creams coloured and uncoloured, coloured powders, raw materials used, filling speed
and production volumes when laying out a factory. Also include a discussion on the
quality of water which is a major raw material used in many products and the
importance of GMP – good clearing procedures, how raw materials should be
dispensed – labelled and sealed.
2008 Exams
2. Answer any TWO of the following:a. Write a short essay on the importance of good process vessel design. Include
the factors that will influence the different types of flow patterns generated
in a process vessel and how the flow patterns can be improved. The use of
diagrams will help to demonstrate your understanding.
Here I would be looking for a discussion on the design of a mixing vessel including:
Shape of the vessel, design of the impellers, the position of the impeller
and baffles, tangential flow, Radial flow, Axial flow. Flow patterns
generated by differing positions of the impeller and baffles. The
rotor/stator mixer functions by reducing the particle size the bulk passes
through the very small gap between the two surfaces
I would be looking for a discussion on good process vessel design – so
b.
Discuss the manufacturing procedures and equipment used in the
manufacture of a powder cosmetic of your choice. Include how you would
adjust the colour if it required correction
Here I would be looking for a discussion on the different types of equipment used to
manufacture powder cosmetic – the types of mills used to grind the pigments, the types
of mixer – trough etc. Colour adjustment is made by mixing neat colour with a small
amount of the batch, passing the resulting mix through mill to fully extent the colours
before adding it to the main batch and mixing until uniform.
2009 Exams
2. Answer both parts:a) Describe the various types of flow that can be generated in a mixing
vessel used for the manufacture of a low to medium viscosity liquid.
Also describe why you would use a rotor/stator homogeniser. Illustrate
your answer with appropriate labelled diagrams.
Here I would be looking for a discussion on the design of a mixing vessel including:
Shape of the vessel, design of the impellers, the position of the impeller
and baffles, tangential flow, Radial flow, Axial flow. Flow patterns
generated by differing positions of the impeller and baffles. The
rotor/stator mixer functions by reducing the particle size the bulk passes
through the very small gap between the two surfaces.
b) You are responsible for the manufacture of a new carbomer
based hair gel formulation with 5% ethanol. Include an
outline formulation indicating the function of each raw material.
The first two batches have not met the specification and there has
been:i) One microbiological failure
ii) One low viscosity
Outline the steps you would take to investigate the possible causes.
Include in your answer the importance of water quality in this type
of formulation.
I would be looking for a discussion on a carbomer based hair gel formulation, the
manufacturing method used and what can influence the effectiveness of the
preservative system and viscosity. Here we are looking for a Route Cause Analysis
covering each stage.
8. Answer both parts:a) Write an essay describing the manufacturing process and the equipment
used in the large scale manufacture of a shower gel. Include in your
answer an outline formulation that uses 70% active sodium laureth
sulphate. Describe the function of each raw material, the
importance of Good Manufacturing Practice and raw material usage
traceability. Also describe what quality testing is required for
the bulk product.
I would be looking for discussion of a typical formulation and equipment used to
manufacture a shower gel, storage and traceability of raw materials, bulk and the
importance of Good Manufacturing Practice – plant hygiene. How the SLES and other
raw materials are added to the water as well as how the final bulk product is tested –
pH, viscosity, and microbiological.
b) Write an essay on your understanding of the term Good Manufacturing
Practice, as used in the cosmetics and toiletries industry. Give clear
examples to demonstrate your understanding.
Here I would be looking for a detailed discussion on your understanding of GMP
covering – the testing, control and traceability of raw materials, bulk, components, and
procedures used for cleaning manufacturing and filling equipment.