NAME: NIVEDITA

COLLEGE: INDIAN INSTITUTE OF TECHNOLOGY(IIT) INDORE

BRANCH: CIVIL ENGINEERING (4TH YEAR)
DURATION OF INTERNSHIP: 15TH MAY – 10TH JULY

INTERNSHIP REPORT

Bureau of indian standards

Plot no 1, Sy no 367/1Industrial Development Park, Moula Ali, Hyderabad -500 040
 Table of Contents
1. Benefits To Interns 3
2. Introduction 4
2.1 Introduction to Indian Standards
2.2 Overview of BIS Product Certification and Conformity Assessment
2.3 Overview of General and Product Specific Guidelines
3. Dealing with Non-Conformity 7
3.1 Introduction to IT tools deployed in certification
3.2 Dealing with Non-Conformity
3.3 Management System Certification
4. Visits to Industry 10
4.1 PKL Limited
4.2 Kumar Enterprises
4.3 Varun Beverages Limited
4.4 Shri Balaji Cast Iron Private Limited
4.5 Ahlada Engineers Limited
4.6 Ultratech Cement
5. Visits to Laboratory 26
5.1 National Council for Cement and Building Materials
5.2 Sipra Labs
6. Visits to Industries to ascertain Standards on Good Practices/SOPs
being followed 33
6.1 Trans valves Private Limited
6.2 Ultratech Cement Limited
7. Visits to Industries who have not opted for BIS Certification for
Products under Voluntary Certification 41
7.1 Ahlada Engineers Limited
7.2 Balaji Cast Irons Private Limited
7.3 Kumar Enterprises
7.4 Varun Beverages Private Limited

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8. Visits to Manufacturing Units that follow Product Standards other than
Indian Standards 54
8.1 PKL Limited
8.2 Hyderabad Metropolitan Water Supply and Sewerage Board
9. Visits to Organized Consumers 65
9.1 Premier Hardware Industries
9.2 RK Steel Traders
10. Visit to Management System Licensees of BIS 69
10.1 Dharmaja Cylinders Private Limited
10.2 Indian Institute of Packaging
11. Miscellaneous Visits 68
12. Recommendations 80

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 Benefits to Interns

Prior to internship, my knowledge regarding the importance of standards, the

methods of filing a complaint in case of product not meeting the quality,
standardization process and the importance of management standards.
The internship has greatly enhanced my personal and professional development.
Exposure to various industries and their standards provided me with a deeper
understanding of the professional landscape. Networking with industry
professionals and receiving mentorship from experienced officers offered
invaluable guidance and career insights.
Additionally, I gained a thorough understanding of the standardization process,
conformity assessment, management certification, and the IT tools used in
certification. Completing visits and surveys allowed me to learn about industrial
practices, processes, and standards employed by manufacturing units. Overall,
this internship experience has been pivotal in shaping my career path and
fostering personal growth.

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 1. Introduction

1.1 Introduction to Indian Standards

BIS is the National Standard Body of India established under the BIS Act 2016
for the harmonious development of the activities of standardization, marking
and quality certification of goods and for matters connected therewith or
incidental thereto.
A Standard is a document, established by consensus and approved by a
recognized body, that provides, for common and repeated use, rules, guidelines
or characteristics for activities or their results, aimed at the achievement of the
optimum degree of order in a given context.
The structure of Standards including Product standard, Code of Practice,
Management system Standard, Test methods were discussed. An overview of
the Standardization process was given including the technical committees
involved and the review process. A brief introduction to some other National
Standard Bodies and ISO/IEC (International organisation of standardization/
International Electrotechnical Commission) Standards was given. The structure
of a standard consists of:
1. Foreword: A standard starts with a foreword the purpose of which is to
provide context and background information about the standard,
explaining its development, revisions, and relevance. It outlines the
history of the standard, including previous versions and significant
changes made in the current revision.

2. Scope: The scope defines the specific materials, products, or processes

covered by the standard. It specifies the conditions and limitations of the
product, ensuring clarity on the standard's applicability.
3. References: The purpose of references in an Indian Standard is to
incorporate provisions from other standards by citing them within the
text, thereby making them part of the standard's requirements. These
references ensure that users adhere to up-to-date and relevant guidelines.
4. Terminology: The important terms used in the Indian standard are
explained in this section.
5. There are further sections for test methods and results.

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1.2 Overview of BIS Product Certification and Conformity
Assessment Bodies
Product Certification Scheme of BIS (Scheme 1) aims at providing Third
Party assurance of quality, safety and reliability of products to the customer. The
presence of BIS Certification Mark, known as Standard Mark, on a product is
an assurance of conformity to respective Indian Standards.
BIS certification scheme is basically voluntary in nature. However, for a
number of products compliances to Indian Standards is made compulsory by
the Central Government under various considerations viz. public interest,
protection of human, animal or plant health, safety of environment, prevention
of unfair trade practices and national security. For such products, the Central
Government directs mandatory use of Standard Mark under a Licence or
Certificate of Conformity (CoC) from BIS through issuance of QCOs.
BIS has been authorised to undertake Conformity Assessment of Goods,
Articles, Service, Systems and Processes as per the schemes notified through
regulations, i.e. the BIS (Conformity Assessment) Regulations,2018. The
Conformity Assessment Schemes of BIS are based on ISO/CASCO Standards.
The Product Certification Scheme is based on principles laid down for the type
4 scheme as per ISO/IEC 17067.
Certification is awarded to the manufacturer for the use of ISI Standard Mark on
a product after:
1. Assessing the manufacturing and testing capabilities of the manufacturer.
2. Ensuring conformity of the product to the requirements of the relevant
Indian Standard(s) through testing.
During the operation of certification, BIS monitors operation of the
certifications and the quality of goods bearing BIS Standard Mark through:
1. Surveillance visits to the manufacturer’s premises.
2. Testing of products drawn from the factory.
3. Testing of products obtained from the open market.
The statutory provisions given under Section 10 (2) (c) of the BIS Act 2016 and
Section 30 of the BIS Rules, 2018 confer upon BIS, powers to recognize any
Standards Developing Organization in India for development of standards.

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1.3 Overview of General and Product Specific Guidelines
Indian Standards Institution (ISI) was established on 6 January 1947 as a
Registered Society under the Societies Registration Act, 1860. Being the
National Standards Body of India, the organization had a clear mandate of
preparing and promoting Standards for adoption by Indian Industry.
The BIS registration procedure involves licensing and surveillance visits. The
steps involved in licensing are:
1. The manufacturer has to submit the application for BIS registration
through the BIS Portal.
2. The BIS officer will visit the factory for a preliminary inspection which is
done to assess the manufacturing infrastructure, production process,
quality control and testing capabilities.
3. After the inspection, the product samples are taken for third party testing
and the test results of the industry laboratory is also submitted.
4. All the results and updates of the inspection process are updated on
Manak Online and the Officer derives the final result.
After the inspection process, the inspecting officer conducts surveillance visits
which involves following steps:
1. The inspecting authority will visit the factory to testify the test results.
2. The inspecting officer will send the samples to the independent labs.
3. The test report will give feedback on the product and if the product
sample is following the specifications mentioned in the standard.
4. Performance review report is prepared.
5. Based on the review report, the license is granted.
The BIS certification issued is valid for two years. Manufacturers can renew
the BIS certification provided there are no changes in the concerned products
and prescribed standards. The renewed BIS certificate will then be valid for a
minimum of one year and a maximum of five years.
Technical guidelines for all products under the Product Certification Scheme are
provided in 'Product Manuals.' These manuals include sampling guidelines, a
list of test equipment, the Scheme of Inspection and Testing (SIT), a description
of the scope, and other relevant information.

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 2. Dealing with non-conformity

2.1 Introduction to IT Tools deployed in certification

An introduction to Manakonline website and BIS Care App for factory and
market surveillance, Know your Standard module of BIS website, List of
Products under Compulsory BIS Certification was given.
Manakonline is an official online portal managed by the Bureau of Indian
Standards (BIS). This website facilitates various services related to
standardization, certification, and quality control.
BIS Care is used to track the product information which includes the date and
place of manufacture and all the other essential information about the product.
Jewelleries are checked with the help of the unique ID. Know your Standard
part of the website can be used to access various standards.

2.2 Dealing with non-conformity

A brief on the sample non-conformity, root cause analysis, corrective actions,
verification of corrective actions and post verification corrective actions by BIS
was given. Non-conformity refers to non-compliance of the product with the
standards specified.
The performance of a license will be considered unsatisfactory if discrepancies
are observed in its operation during the inspection.
In case of discrepancy and unsatisfactory performance, a review of performance
is done in following way:
1. In case of unsatisfactory performance observed during the inspection visit,
the inspection report along with the DAR shall be submitted with necessary
information and details in the IT portal during the inspection itself.
2. The discrepancies listed above may also come to the notice of BIS based on
information shared by the manufacturer through Manak Online.
3. In both the cases, the Review of Performance (RoP) of the manufacturer
shall be put up.
4. The Review of Performance (RoP) shall cover the past performance of 2
years and also determine whether it is a case of first instance of
unsatisfactory performance or consecutive instances of unsatisfactory
performance.

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5. The BO level decision making on RoP shall normally be completed
preferably within five working days from the date of reporting of
unsatisfactory performance.
In the first instance of non-conformity, a warning is issued to the manufacturer,
highlighting the issues. The problem must be rectified within a stipulated
timeframe, and new test results must be submitted. Failure to comply may result
in the product being recalled.
In the second instance of non-conformity, orders will be issued for the product's
recall, and the manufacturer will be given a short timeframe to comply or
present the reasons for the non-compliance. In case no action is taken product
will be recalled.
The major products under the BO where failure rates are high were identified
and discussed. The products with more than 20% failure rate for 2023-24
consist of Packaged Drinking water and some Plastic products like Polyethylene
Pipes for Water Supply, Unplasticized PVC pipes for Potable Water Supply etc.

2.3 Management System Certification

An overview of various management system standards and audit process was
given.
Bureau of Indian Standards has been operating Management Systems
Certification Scheme since 1991. Initially, the scheme was started by BIS with
Quality Management System Certification (IS/ISO 9001:2015) and over the
years, it has expanded its activities to various other Management Systems.
NABCB (National Accreditation Board for Certification Bodies), QCI has
accredited Quality Management System, Food Safety Management System and
Environmental Management System Certification Schemes of BIS.
BIS uses a combination of BIS and External Auditors for audit of various
Management system certification schemes.
The terms and conditions for BIS Management Systems Certification services
are outlined in the Application Form and referenced Certification Regulations
and Guidelines for Applicants.
1. These terms and conditions define the rights and responsibilities of both BIS
MSCS and applicants/licensees.
2. The specific sector for which the BIS MSC Scheme is accredited is
communicated to the applicant.

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3. Before accepting an application, BIS:
a) Reviews the certification requirements for other sectors.
b) Informs the applicant accordingly.
4. For any new sector to be certified, BIS:
a) Endeavours to identify competent auditors, experts, and other
personnel, either internally or externally.
b) Informs the applicant whether BIS has the expertise to understand the
sector and the administrative capacity to manage audits in the new
sector.
5. By signing the application form, the applicant agrees to the terms and
conditions.
6. The applicant's request is reviewed, and if necessary, actions are taken
according to the established procedures and guidelines.
7. Each application must be accompanied by the relevant documents containing
information about the applicant organization and its management system,
sufficient to develop an audit program.
8. After reviewing the application, a decision to accept or decline it will be
made and documented. The decision will also be communicated to the client.
9. An audit program for the full certification cycle is developed to ensure the
client's management system meets the relevant standards.
The certification cycle includes:
a) Stage 1 audit
b) Stage 2 audit
c) Surveillance audits for the first and second years
d) Re-certification audit in the third year before certification expiration.
[Link] initial three-year certification cycle begins with the certification
decision, and subsequent cycles start with the re-certification decision.
[Link] audit program is adjusted based on changes in client size, scope,
complexity, products, processes, and the management system's effectiveness
in previous audits.
A literature survey on the audit process and the management standards
including the standards for environment, occupational health and safety was
undergone.

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 3. VISITS TO INDUSTRY
The purpose of the visits was to understand the manufacturing processes and
performance requirements and controls exercised to manufacture products
meeting the quality requirements prescribed by Indian Standards and to avoid
product non-compliance

3.1. PKL Limited

A visit to the manufacturing plant was undergone on 27th May 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Portable Liquified Petroleum Gas Appliances operating at Vapour
Pressure.
Type of Visit: Inclusion Visit to verify additional manufacturing and testing for
addition in the scope of the standard.
Standards: IS11241-1985, IS2305-1988, IS 5116- 2020, IS 6910-1985,
IS4246- 2002
IS 1124-1985: Specifies construction, operation, safety requirements and tests
for portable liquefied petroleum gas appliances, such as cooking appliances,
lights, space heaters and blow torches intended for operating at the direct
vapour pressure of the gas in refillable and non-refillable gas containers.
IS 2305-1988: This standard prescribes the method for conducting mercurous
nitrate test for wrought copper and copper base alloy products.
IS 6910- 1985: This standard specifies the apparatus, reagents and the
procedure to be used and prescribes the conditions for conducting the acetic
acid salt spray (ASS) test for assessment of the quality, by way of corrosion
resistance, of metallic coatings applied in accordance with the requirements of
the respective coating or product specifications.
IS 5116-2020: This standard specifies general requirements and methods of test
relevant to these requirements, for domestic and commercial equipment, for

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households and other commercial catering organizations, using liquefied
petroleum gases at 2.942 kN/m2 (30 gf/cm2) gas inlet pressure.
IS4246-2002: This standard specifies construction, operation, safety
requirements and tests for domestic gas stoves with metallic bodies intended for
use with liquefied petroleum gases at 2 942 kN/m 2 (30 gf/cm2) gas inlet
pressure.
Laboratory Tests:
1. Stability Test- The appliance must remain stable and not tip over when
mounted on a cylinder and placed on a 15° incline with an empty
container.
2. Gas Soundness Test- All gas pathways and valves under working
pressure must be airtight when tested underwater with air at 0.35 kg/cm²
and 17 kg/cm², using a pressure regulator for all tests.
3. Ignition and Flame Test- There must be easy and safe access for match
lighting, and ignition should be clearly visible.
4. Flame Stability Test- Stoves must operate with control valves fully open
at gas inlet pressures from 30 to 200 Kn/m² (294 to 1960 gf/cm²) without
the flame extinguishing, blowing off, striking back, or producing soot.
5. Resistance to Draughts- The flame should not get extinguished on
being exposed to normal air current of 2m/s so it is tested by replicating
this condition using rotating vane anemometer.
6. Surface Temperature- The surface temperature of the material is tested
in working condition for the limiting maximum specified temperature
using a thermocouple.
Surfaces (other than working surface) likely to be touched accidentally= 120°C
Surfaces of appliances intended to be touched
Metallic= 50°C
Non-metallic= 65°C
Surfaces of gas container and container valve= 32°C
7. Combustion- Under the conditions specified in 17.2.1, the CO/CO₂
ratio of appliance exhaust gases must not exceed 0.02, as per Appendix C
of IS: 4246-1984.
8. Salt Spray Test- There is a spray cabinet where the temperature is
maintained
(35 + 2) °C to (35 – 2) °C and a pressure in the range of 70 pas to 170
pas. The specimen is kept in the container and a solution of 1L water and
(45-50) g/L of Sodium Chloride is added. Water is first added to the
container to maintain the pressure. The test duration is 12 hrs.

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 9. Mercurous Nitrate Test- This is a seasonal crack test for checking
cracks which can develop in varying temperature conditions. Materials
are used as per the clause 5.3 of IS5116 and clause 3.2.1 of IS2305 can
also be referred. Here the brass metal which is used in the valve bodies is
tested and the length of the metal is maintained at 150mm.
First the sample needs to be cleaned with distilled water and nitric acid.
The proportion of both is 1:1. After the sample material is cleaned, a
solution is created which contains 11.4 g of Mercurous Nitrate and 1L of
water. Mercury does not dissolve in water hence 40 ml of nitric acid and
this is stirred until everything is dissolved. The brass sample is kept in the
sample for 30 mins. After this time, the sample is cleaned with running
water and wiped with cotton. After this it is checked for cracks.
[Link] non-metallic or plastic materials are checked for distortion by
placing in an oven.
[Link] Test- This test is done to check for distortion of burner of
mixing tube due to flame that reflects back from container bottom. This
test is done for 30 mins. Pressure is seen in the pressure gauge.
[Link] thickness of the Nickel coating is tested using the instrument. The
tool should be kept perpendicular to the surface and an average of 5
readings is taken. The requirement for Nickel coating is 10 micro mm
and for Chromium coating it is 0.2 micro mm.
[Link] gas stove was tested for a safety feature designed to automatically
shut off the gas if it remains open without any utensils for an extended
period. This is to prevent gas leakage and potential accidents. According
to the Indian Standard IS 4246:2002, the maximum time allowed for the
gas to shut off by itself to prevent gas leakage and potential accidents is
100 seconds.
Manufacturing Process:
The company is responsible for the manufacture of 5 models of portable gas
stoves listed as below:
1. 4760490- Clix Non-Auto Portable LPG Stove with adaptor operating at
vapour pressure (PFD)
2. 4760480- Clix Non-Auto Portable LPG Stove operating at vapor pressure
(PFD)
3. 772122C- Non-Auto Portable LPG Stove operating at vapour Pressure
(PFD)
4. 4760400- Clix Automatic Portable LPG Stove operating at vapour
pressure (PFD)

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 5. 4760420- Clix Plus Non-Auto with FSD Portable LPG Stove operating at
vapour pressure (PFD)
In all these cases PFD stands for ‘‘Pilot Flame Device’’ or ‘‘Pressure Fuse
Device’’ which is a safety feature to ensure that the gas supply is cut off if the
pilot flame goes out thus preventing gas leaks and potential hazards. All these
models are equipped with this safety feature. Operating at vapor pressure
(PFD), this stove efficiently utilizes liquefied petroleum gas for cooking,
ensuring reliable performance in various outdoor settings.
Some of the components are different for each model and the working process
of every model can be seen from the flow charts attached.
The 4760490 model is a non-automatic portable LPG stove designed for
convenience and versatility. It is suitable for various outdoor activities such as
camping, picnics, or outdoor events. It includes an adaptor, enhancing its
usability and compatibility with different gas sources or setups.
The 4760480 model is a non-automatic portable LPG stove suitable for outdoor
cooking needs. It can be used for camping trips, picnics, or any outdoor
adventure. It does not contain an adaptor. This model has a wire leg and a
Bracket. A wire leg refers to the legs of the stove constructed from wire
material, usually metal such as steel and aluminium.
The model 772122C is similar to the previous model with certain differences. It
has a deflector plate, locking clop with roller, U Bracket, an ignitor and a Ball
type adaptor.
The main difference between bracket and ball type adapters lies in their design
and functionality. Bracket type adapters typically feature a bracket-shaped
structure that attaches securely to the gas stove using a hook or clamp
mechanism, providing stable and fixed connection. On the other hand, ball type
adapters incorporate a spherical or ball-shaped joint, offering flexibility and
freedom of movement. This allows for rotation and adjustment in positioning,
accommodating various setups or configurations. While bracket adapters
prioritize stability and secure attachment, ball type adapters prioritize flexibility
and versatility in connecting the gas source to the stove.
Brackets provide support and stability to the various components of the gas
stove assembly, enhancing its functionality and safety.
The process flow chart for the manufacturing of the products is provided on the
next page.

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3.2. Kumar Enterprises
A visit to the manufacturing plant was undergone on 6th June 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Irrigation Equipment – Emitting Pipes System, Emitters, Drip Hole
Pipe, Polyethylene Pipes for Irrigation Laterals, Polyethylene Pipes for Water
Supply
Type of Visit: Industry Visit for survey (Voluntary Products)
Standards: IS 13488:2008, IS 12786:1989, IS 13487:1992, IS 4984: 2016,
IS 14151:part 1:1999 and IS 14151: Part 2: 2008
IS 13488-2008: This standard specifies the mechanical and functional
requirements of the emitting pipes and their fittings, test methods and the data to
be supplied by the manufacturer to facilitate correct installation and operation in
the field.

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IS 12786-1989: is an Indian standard provides specifications for the
manufacturing of an Irrigation Equipment, Polyethylene Pipes for Irrigation
Laterals. The latest version is the one reviewed in 2024.

IS 13487-1992: This standard specifies mechanical and functional requirements

of irrigation emitters, test methods and the data to be supplied by the
manufacturer to permit correct installation and operation in the field. It applies
to emitters, with or without pressure regulation, intended for irrigation; it does
not apply to emitters which for man integral part of the pipe during manufacture
as well as microtubes.

IS 4984- 2016: This standard lays down the requirements for polyethylene (PE)
pipes (mains and service pipes) intended for the conveyance of water for human
consumption including raw water prior to treatment and also water for general
purpose. This standard is applicable for the water supplies with a maximum
operating pressure of 2.0 MPa. An operating temperature of 27ºC has been
taken as the reference temperature.

IS 14151:part 1:1999- This standard lays down requirements and method of

tests for polyethylene pipes of outside diameter from 40 to 200 mm to be used
for Sprinkler Irrigation Systems as mains, submains or laterals.

IS 14151: Part 2: 2008- This standard lays down the general requirements for
materials, manufacture, method of tests and testing of quick coupled
polyethylene pipes and fittings of outside diameters 40 mm to 200 mm used for
portable sprinkler and drip irrigation systems as mains, submains or laterals.

Manufacturing Process:
1. The primary raw material used for drip hole pipes is polyethylene (PE),
specifically Low-Density Polyethylene (LDPE) or Linear Low-Density
Polyethylene (LLDPE). These materials are chosen for their durability,
flexibility, and resistance to UV radiation and chemicals.
2. Additives such as antioxidants, UV stabilizers, and colorants may also be
mixed with the base polymer to enhance the pipe's performance and
longevity. This mix is called the masterbatch.
3. Extrusion of base pipe is carried out. This involves melting of
polyethylene resin pellets in a primary extruder, where they are heated
and compressed to form a molten polymer.
4. After the base material (e.g., a metal pipe or another extruded pipe) is
formed, a lining extruder may be used if an internal layer of polymer is

16
 required. The lining extruder injects or extrudes molten polymer (e.g.,
polyethylene) into the interior of the substrate.
5. In case coating is required, a coating extruder is used to protect the pipe
from corrosion.
6. The molten polymer is then forced through a circular die, which shapes it
into a continuous tube of the desired diameter. This tube forms the base
pipe of the drip irrigation system. The machines are programmable and
the required diameter is put as an input and the pipe is made based on this
diameter.
7. Drip hole pipes are designed with pre-drilled or laser-cut drip holes at
precise intervals.
8. The lateral irrigation pipes are made of High-Density Polyethylene
(HDPE) and has a somewhat similar process except for the holes which
are made in the drip hole pipe.
9. These pipes are put into the Auto coiler to coil the pipe as per the order
demands.
[Link] emitting pipes, also referred to as flat drip tapes or flat drip lines, are
engineered with closely positioned emitters or drippers installed along
their length, enabling effective and accurate distribution of water directly
to the plant roots.
Laboratory Test:
1. Shrinkage Test
2. Tensile Test as per IS 14151 for sprinkler.
3. Density sheet press is used to measure density of HDPE Pipes and other
pipes made according to IS 4984.
4. An "Emitter Pull-out Tester," as per IS 13487, is a device used to test the
strength and reliability of emitters when installed in drip irrigation
systems.
5. Carbon black content test to check for the specified requirement for UV
resistance and longevity.
6. Extension meters are devices used to measure the extension or elongation
of materials under tension.
7. Projection microscope is used to check the width and depth of the
regulator.
8. UTM is used for tensile testing, flexural testing and compression testing.

3.3. VARUN BEVERAGES LIMITED

17
A visit to the manufacturing plant was undergone on 10th June 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Packaged Drinking Water (other than Packaged Natural Mineral
Water), Aerated drinks including (Pepsi, soda), Soft drinks (Slice, Seven up etc.)
Type of Visit: Industry Visit for survey
Standards: IS 14543:2024, IS 10500: 2012
IS 14543-2020: This standard prescribes the requirements and methods of
sampling and test for packaged drinking water (other than natural mineral
water) offered for consumption and/or for sale in packaged form.
IS 10500-2012: This standard prescribes the requirements and the methods of
sampling and test for drinking water.
RO Plant
Product name: Aquafina packaged drinking water
Procedure:
Water is purchased form a vendor and it goes through a treatment process in the
RO plant before getting packaged and stored. The steps involved in the
treatment process are as follows:
1. On receiving the sample, the water undergoes initial filtration to filter out
foreign material. It is filtered using basket filter and pressure sand filter.
2. Ultrafiltration (UF) is a membrane filtration process that removes particles,
bacteria, viruses, and some dissolved substances from water by passing it
through a semipermeable membrane with pore sizes typically ranging from
0.01 to 0.1 micrometres. The treated water is stored in UF storage tank.
3. This water goes through the Activated carbon filter to remove chlorine,
organic compounds, and Odors improving taste and safety.
4. The micron polisher, typically a fine filtration unit with small pore sizes
(e.g., 1 micron or less), further removes any remaining fine particles and
microorganisms.
5. This water is sent to the RO feed pump pressurizes the water, ensuring it has
sufficient force to pass through the RO membranes, which remove dissolved
salts, minerals, and other impurities from the water.
6. After this the water goes through the reverse osmosis process, followed by 1
Micron polisher, a filtration unit to further remove fine particles. After this it

18
 is sent to the buffer tank where the water is stored with ozonation and
circulation happening simultaneously.
 For the production of bottle:

1. The PET resin pellets are heated and injected into a Mould cavity under high
pressure. This process forms preforms, which are hollow tube-like shapes
with the neck finish (where the cap will be screwed on) and threads already
formed.
2. The preforms are heated in a conditioning station to make them more
malleable and easier to stretch without causing defects.
3. The conditioned preforms are transferred to a blow moulding machine where
they are stretched and blown into the shape of a bottle mould using high-
pressure air. This process gives the bottles their final shape and size.
4. The newly formed bottles are cooled and then inspected for quality control,
ensuring they meet specifications such as thickness, shape, and integrity.
 The water is then filled into the bottles and properly inspected and
labelling is done before packaging.

Aerated Drinks (e.g. Pepsi, Mirinda etc.)

1. Water forms the base; hence a part of the treated water is directed towards
manufacturing of the drink.
2. Sugar is sourced from certain specific vendors and is first tested for quality
before use. This sugar is dumped and heated to up to 180 °C to convert into
syrup. Some external ingredients like flavours are added.
3. 1: 5 ratios of syrup to water are maintained for all the aerated drink.
4. Carbon dioxide (CO2) gas is infused into the mixture under pressure to
create the characteristic fizz and effervescence of the soda. The drink is
filtered to ensure no foreign particle is present. After filtration, the clarified
and purified beverage (often referred to as the base or concentrate) is
transferred to a syrup tank. This tank holds the concentrated flavouring syrup
that gives the beverage its specific taste profile.
5. After the carbonation and flavouring, it is checked for Colour, turbidity etc.
After ensuring that the specifying standards are reached, concentration is
added as per requirement.
6. After this drink is filled into bottles and packaging is done, with labelling
and marking as per requirements.

3.4. Shri Balaji Cast Irons Private Limited

19
A visit to the manufacturing plant was undergone on 12th June 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Horizontally cast iron double flanged pipes for water, gas and sewage,
cast iron fittings for pressure pipes for water, gas and sewage and Ingot Moulds.
Type of Visit: Industry Visit for survey
Standards: IS 7181:1986, IS 1538:1993
IS 7181-1986: This standard covers the requirements for double flanged cast
iron pipes of Class B only 1tp to D.N 750 for pressure main lines of water, gas
and sewage manufactured by horizontal castings in sand moulds.

IS 7181-1993: This standard covers the general requirements for cast iron
fittings for pressure pipes for water, gas and sewage. This standard is applicable
to all cast iron fittings having spigots, sockets or flanges as specified in this
standard and also to fittings with other type of joints, the general dimensions of
which, except those relating to the joints, conform to this standard.

Manufacturing Process:
1. Pig iron, scrap iron, and other alloying elements are selected based on the
desired properties of the final product.
2. The raw materials are melted in a furnace, typically a cupola furnace or
an electric arc furnace, to produce molten iron. The plant here generally
uses cupola furnace. The raw material is generally Hard coke for high
temperature, ferroalloys such as ferro silicon and ferro manganese are
essential additives and pig iron.
3. Alloying elements such as magnesium may be added to the molten iron to
produce ductile iron, which has better mechanical properties than
traditional grey iron. The proportion of Ferro silicon and ferro manganese
are specific in order to maintain tensile strength and hardness.
4. Sand moulds are prepared according to the desired dimensions and shape
of the pipes and flanges. The flanges are formed either integrally with the
pipe during casting or attached later. Integral flanges are formed in the
mould along with the pipe body. The cast pipes are allowed to cool and
solidify in the moulds.
5. Once solidified, the pipes are removed from the moulds.
6. The pipes may undergo annealing to relieve internal stresses and improve
ductility. The cooled pipe is then cleaned. The pipe ends and flanges are
machined to precise dimensions to ensure proper fitting and sealing. This

20
 includes facing, drilling bolt holes, and other necessary finishing
operations.
7. Internal and external surfaces of the pipes are coated for corrosion
protection. Common coatings include bitumen or zinc.
8. After the required tests and inspections, each pipe is marked with relevant
information, such as size, pressure ratings and other information required
by the client. Pipes are properly packaged to prevent damage during
transportation. Finished pipes are stored in a controlled environment to
prevent corrosion and damage before delivery.

Laboratory Tests:

1. Hydrostatic Testing: The pipes are subjected to hydrostatic pressure tests to

ensure they can withstand the specified pressure ratings without leaking or
deforming.
2. Dimensional Inspection: Pipes are measured to ensure they meet the
specified dimensional tolerances.
3. Visual Inspection: Pipes are visually inspected for surface defects, cracks,
and other imperfections.
4. Mechanical Testing: Additional mechanical tests (such as tensile and impact
tests) may be conducted to verify material properties.

3.5. Ahlada Engineers Limited

A visit to the manufacturing plant was undergone on 14th June 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Fire-rated Doors, Steel Flush Door Shutters
Type of Visit: Industry Visit for survey (Voluntary Products)
Standards: IS 3614:2021
IS 3614:2021-This standard lays down quality requirements including the
requirements regarding materials and details of construction of fire rated metal
swing doors, wooden composite swing doors, metal sliding doors and metal
rolling shutters.
Manufacturing Process:

21
1. The raw material is shaped in the form of Plates and sent into the Pneumatic
Punching Machine to punch the holes.
2. Some of the plates are sent to the laser cutting machine based on the width of
the plate. Thicker plates are sent to the laser cutting machine and the thinner
or low width plates are sent to the Pneumatic punching machine. The laser
cutting machine has a programme where required dimensions are filled as
input.
3. A quality check is conducted after the punching is done. After the material
passes the quality check, it is sent for panel bending.
4. There is also an automatic machine wherein the material is loaded directly
and the punching and bending takes place and the finished product is
received.
5. The material punched and bent is sent to the NC Shearing machine to trim
the sheets to the desired dimensions to ensure precise cuttings according to
programmed specifications.
6. A logo embossing press is used for imprinting or embossing a company or
brand logo onto various materials, typically using pressure and heat.
7. The additional accessories like Locks, Hinges etc are welded and the welded
surface of the product is cleaned.
8. The upper and lower part of the doors are then assembled. A Honeycomb
craft paper is stuck in the middle of both the parts to ensure that the area is
not hollow. The glue used here is imported from Germany and the
Honeycomb craft paper is imported form Netherlands.
9. After this assembly is completed, the parts are welded together to keep them
intact.
[Link] grinding of weld is done to provide smoothness to the surface. An outer
coating is provided to the product to prevent corrosion.
[Link] materials accumulated and labelling, packaging is done. The logo on the
product is based on the demands of the client, for e.g. Product which is
meant for TATA Pravesh (One of their major clients) contains the logo of the
company.
Laboratory Test:
1. Scratch Hardness Test: It is used to assess the hardness and scratch
resistance of the surface coatings or finishes applied to steel door panels.
2. Conical Mandrel Test: This method used to evaluate the flexibility and
resistance to deformation of materials, including steel doors.
3. Scratch Test: This test for steel doors is specifically used to evaluate the
surface hardness and scratch resistance of the materials used in the
construction of steel doors.

22
 4. UV Test: The UV test for steel doors aims to assess how well the surface
coatings or finishes can withstand prolonged exposure to ultraviolet (UV)
radiation from sunlight.
5. Salt Spray Test: The salt spray test for steel doors, also known as the salt
fog test or salt spray corrosion test, is used to evaluate the corrosion
resistance of steel door components and surface coatings when exposed to
a salt-laden environment

3.6. Ultratech Cement

Packaging unit of Ultratech cement was visited on 3rd July 2024 to understand
the procedures involved in the packaging process, laboratory tests and the
standards of procedures followed to ensure environment sustainability.
Product: OPC 53: Ordinary Portland Cement, PPC: Portland Pozzolana
Cement, PPCS: Portland Pozzolana Cement with Special Admixtures.
1. OPC 53: Ordinary Portland Cement (Grade 53), is a high-strength cement
that is commonly used in construction projects requiring higher strength
and faster setting times.
2. PPC: Portland Pozzolana Cement (PPC) is a type of blended cement that
includes a mixture of pozzolanic materials, which are natural or artificial
substances that have properties similar to volcanic ash. These materials,
when mixed with OPC (Ordinary Portland Cement), enhance certain
properties of the cement.
3. PPCS: PPCS, or Portland Pozzolana Cement (PPC) with Sulphate Resisting
properties, is a type of blended cement specifically designed to provide
enhanced resistance against sulphate attacks.
Type of Visit: Industry Visit for survey
Standards:
Ordinary Portland Cement (IS 269: 2015)- This standard covers the
manufacture and chemical and physical requirements of ordinary Portland
cements.
Portland Pozzolana Cement-Part1 Fly-ash based [IS 1489 (Part 1): 2015] - This
standard (Part 1) covers the manufacture and chemical and physical
requirements of Portland pozzolana cement using fly ash as pozzolana.

23
Portland Pozzolana Cement-Part 2 Calcined clay based [IS 1489 (Part 2):
2015]- This standard (Part 2) covers the manufacture and chemical and physical
requirements of Portland pozzolana cement using calcined clay pozzolana or a
mixture of calcined clay and fly ash pozzolana.

Process:
There are different units for different part of the production process of the
Cement:
1. Integrating Unit
2. Bulk Terminal: Packaging Unit
The Integrating unit is responsible for the manufacture of cement.
1. Limestone is extracted and sent to the ram mill for grinding and then it is
sent to the kiln, a clinker is made wherein additional materials are added
to create a mixture with appropriate proportions.
2. The material is sent to the cement mill where the cement is grinded as per
the Grade required.
3. The final cement is sent to the packaging unit through rail yards.
The functions carried out the Bulk Terminal are as follows.
1. The unit has rail yard to receive the cement from the Integrating unit in
open wagons.
2. The cement is taken and stored in the Silo.
3. A sample of the cement is tested for various parameters.
4. The cement is packed into jute bags which are bought from various
vendors.
5. These packed cement bags are transported in trucks.
Laboratory Test:
Cement cubes are made and stored in a curing tank and then tested on intervals
of 3 days, 7 days and 28 days as per the requirements stated in the standard.
Tests done are:

1. Fineness Test:
 Sieve Analysis: Determines the particle size distribution.
 Blaine Air Permeability: Measures the surface area per unit
weight.
24
2. Consistency Test
3. X-Ray Diffraction (XRD)
4. Phase Analysis: Identifies the mineralogical composition of the cement.
5. Workability Test (for concrete made with cement)
6. Slump Test: Measures the consistency and workability of fresh concrete.
7. Soundness Test (Le Chatelier): The soundness test is conducted to
ensure that the cement does not undergo excessive expansion after
setting.

Some further tests are conducted to ensure quality and strength.

25
 4. LABORATORY VISIT
Visit to laboratory focussing on working of laboratories starting from receipt of
samples at sample cell, basic concepts of testing and calibration up to test report
generation and uploading on LIMS was conducted. This visit focussed on
learning about the method of tests followed at labs especially for the products
identified as having high occurrence of non-conformities.

4.1 National Council for Cement and Building Materials

The visit to NCCBM was conducted on 7th June 2024 to understand the testing
and calibration methods involved in the laboratory.
National Council for Cement and Building Materials (NCB), then Cement
Research Institute of India (CRI) was founded on 24 th December 1962 with the
objective to promote research and scientific work connected with cement and
building materials trade and industry.
Activities conducted in NCCBM:
1. Calibration
2. Physical Tests
3. Chemical Tests
Calibration
Calibration is the process of adjusting and verifying an instrument’s accuracy by
comparing its measurements to a known standard. This ensures that the
instrument provides precise and reliable data, adhering to established standards.
Mass and Volume measurements are calibrated and the temperature of the room
is maintained at temperature ranging from (22 to 24) °C and the relative
humidity is maintained at 40 to 60%.
Weight is calibrated using weighing balance, two types of weighing balance,
one is the normal one and the other is analytical weighing balance. Weights are
checked on the bases of different classes of weights.
For length and other measurements, dial gauge is used which can measure
change in microns. RPM calibrator is present to calibrate the measuring device
called tacheometer.

26
Profile projector is used for the calibration of sieve, lengthwise the size is
checked in both x and y axis.
The calibration services provided by NCCBM can be concluded as may include:
1. Mass Calibration: Calibration of weights and balances to ensure accurate
measurements of mass.
2. Dimensional Calibration: Calibration of length measuring instruments such
as vernier callipers, micrometres, and gauges to ensure precise dimensional
measurements.
3. Pressure Calibration: Calibration of pressure gauges and transducers to
ensure accurate pressure measurements.
[Link] Calibration: Calibration of thermometers, thermocouples, and
other temperature measuring devices to ensure accurate temperature readings.
[Link] Calibration: Calibration of hygrometers and other humidity
measuring instruments to ensure accurate humidity measurements.
6. Volume Calibration: Calibration of volumetric flasks, pipettes, and other
volumetric instruments to ensure precise volume measurements.
8. Force Calibration: Calibration of load cells and force gauges to ensure
accurate force measurements.
9. Mechanical Calibration: Calibration of mechanical testing machines to
ensure accurate mechanical property measurements, such as tensile strength and
compressive strength.
10. Flow Calibration: Calibration of flow meters and flow measurement
devices to ensure accurate flow rate measurements.
These calibration tests help ensure that the equipment used in the production
and testing of cement and building materials provides accurate and reliable data,
supporting quality control and compliance with regulatory standards.
Physical tests

1. Fineness Test: Determines the particle size of cement.

2. Consistency Test: Measures the water content required to achieve standard
consistency.
3. Setting Time Test: Assesses initial and final setting times of cement.
4. Soundness Test: Checks the volume stability of cement.
5. Compressive Strength Test: Evaluates the strength of cement mortar cubes.
6. Tensile Strength Test: Measures the tensile strength of cement.

27
Chemical tests
1. Different amount of chemicals is identified in the cement. The grey colour of
the cement is due to magnesium.
2. Lime saturation factor: Amount of MgO and Cao.
3. A flame photometer is used for measuring the concentration of certain
elements in a sample by analysing the intensity of light emitted when the
sample is vaporized in a flame.
4. A spectrometer is used for analysing the properties of light and its
interactions with matter across various scientific disciplines. It measures
absorption or emission of light by substances over a range of wavelengths
for various analytical purposes.
5. The gravimetric method in cement analysis is used to determine the number
of certain components or constituents in cement by measuring their mass.
6. Heat of hydration:

The heat of hydration of cement can be determined experimentally using

specialized equipment designed to measure the temperature change that occurs
during the hydration process. Here’s a general outline of the experimental
procedure and equipment typically used:

 Calorimeter: A device designed to measure the heat released or absorbed

during a chemical reaction. In the case of cement hydration, a calorimeter
specifically designed for cementitious materials is used.
 Cement Sample: Typically, a small amount of cement (e.g., 200 grams)
is used for the test.
 Water: Distilled water is added to the cement to initiate hydration.
 Thermocouples: Temperature sensors placed at strategic points to
monitor temperature changes during hydration.
 Data Logger: To record and analyse temperature data over time.

7. Calorific value is calculated using a Bomb calorimeter.

8. X-ray florescence photometer: An X-ray fluorescence (XRF) spectrometer,
not "florescence photometer," is used for elemental analysis of materials. It
works by irradiating a sample with X-rays, which causes the atoms in the
sample to emit fluorescent X-rays. These emitted X-rays are characteristic of
the elements present in the sample and their intensities are proportional to
the concentrations of those elements.

28
The requests for testing are obtained from the BIS LIMS portal and the samples
can be tracked over there. The test results are uploaded on the portal.

4.2. Sipra Labs

The laboratory visit was conducted on 11 th June 2024 to understand the
testing procedures practiced, the use of LIMS to track the product
results and tests.
Sipra labs limited is USFDA registered & DSIR approved contract
research organization (CRO). Sipra Labs Limited is a global contract
research organization offering end to end regulatory compliant research and
developmental services to the Pharmaceutical, Biotech and Medical Devices
industries for two decades.
Functions of Laboratory: The laboratory is a centre for conducting Tests
related to pharmaceutical products, food products, radioactive samples etc.
Companies and firms send products for the testing in these labs in case third
party testing was required or the infrastructure for testing are not present at their
respective labs. These firms provide a list of tests which they need to be
conducted and the procedure mentioned in the Indian standards are followed for
the testing process.
Sample Registration:
The sample first arrives at the sample registration department, and the sample
details, storage conditions are noted and uploaded on the Sipra Lab
Information Management System. There is a pre-registration checklist, which
consists of criterial which need to be checked on the sample like the batch no.,
label etc. A QR code is stuck on the box with a unique registration number so
that the sample details can be easily accessed from the website.
The sample is sent to the sample custodian where the sample is stored as per the
storage conditions mentioned as per company requirements.
Sample Custodian:
The sample is sent to the Sample custodian where it is stored. Along with the
samples received, other chemicals which are required for the testing process
which require specific conditions like temperature, humidity etc. are stored. The
group of standards are also stored at this place.

29
The QR Code is scanned and the details like sample name, stock number appear
on the SLIMS. On the software, the name of the chemist who has been assigned
the responsibility of the sample has to be entered and chemist has to enter their
password then only they can take the sample for further procedure. The storage
conditions are also shown on SLIMS.
Refrigerators are present for the vaccines and certain products. Toxic substances
like cyanide are stored separately, similarly there are separate containers for
Nitrogen gas and other similar substances. The storage conditions are
maintained as per those specified by the firms.
Inorganic Analysis:
The analysis is conducted to detect the metals and other elements present in the
food samples for e.g. Na, K, Ca etc., Atomic Absorption Spectroscopy (AAS) is
being used for this purpose.
However, Inductively Coupled Plasma Mass Spectrometry (ICP-MS) is
preferred over AAS as it is most advanced and more effectively detects and
quantifies trace elements and isotopes in various types of samples. AAS can
measure known metals only, ICPMS can measure unknown metals also.
 The solutions required for the testing procedure are prepared in the Wet
Lab. Auto titrator is used for the titration.
 Some of the instruments available are polarimeter used to measure
Specific Optical Rotation (SOR), UV visible spectrophotometer, High-
Performance Liquid Chromatography (HPLC) which is an analytical
technique used to separate, identify, and quantify components in a
mixture.
 Ion chromatography (IC) is a technique used for separating and analysing
ions and polar molecules in a mixture. It is used to find the percentage of
ions such as Bromide, Nitride etc.
 Gas Chromatography is used to detect various solvents present in the
sample. GC separates volatile compounds using a gas mobile phase and
capillary column, ideal for volatile organics. HPLC separates a wide
range of compounds with a liquid mobile phase and packed column,
suitable for pharmaceuticals and biomolecules. HPLC is better to be used
for non-volatile compounds and GC is preferred for volatile compounds.
 A headspace instrument is used for analysing the gas phase above a
sample sealed in a vial or container. It operates by heating the sample to
allow volatile compounds to equilibrate into the headspace, which is then

30
 sampled and analysed using techniques like Gas Chromatography (GC)
or Mass Spectrometry (MS).
 An Automatic Liquid Sampler (ALS) is a sophisticated instrument used
in analytical chemistry to automate the introduction of liquid samples into
analytical instruments such as chromatographs and spectrometers.
 Further sophisticated instruments include:
1. XRD – X-ray Diffraction is used for understanding the
crystallographic structure of the sample such as crystalline,
amorphous etc.
2. CHNS – This is a type of elemental analysis that determines the
relative amounts of carbon (C), hydrogen (H), nitrogen (N), and
sulphur (S) present in a sample. Sometimes, this analysis is also
extended to include oxygen (O), making it CHNOS analysis.
3. DSA – Definite surface area is used to determine the surface area in
contact with the environment.
4. TGS – Thermogravimetric Analysis is a technique used to study the
thermal stability and composition of materials by measuring their
weight changes as a function of temperature.
5. PST – Particle size distribution, which is used to study the size of
particles of the sample.

 A microbiology lab is present to for studying microorganisms, including

bacteria, viruses, fungi, and protozoa. These labs are equipped to conduct
various types of analyses, experiments, and research to understand the
characteristics, behaviours, and effects of microorganisms. This lab
consists of various sophisticated instruments like:
1. LBPC - Lysogeny Broth (LB) Plate Count is a method used to
estimate the number of viable bacteria in a sample by culturing
them on LB agar plates.
2. TOC - “TOC" stands for Total Organic Carbon. TOC is a measure
of the total amount of carbon in organic compounds in a sample. It
is an important parameter for assessing water quality, environmental
monitoring, and in various industrial processes.
And further more instruments are present like Scanning Electron
Microscope and more.
More over specific instruments are present to detect toxic materials like
radioactive materials, etc. More tests are conducted to study the tensile
strength and other parameters. A bio-analytical lab is present with
instruments to detect genotoxic impurities.

31
 Process after the tests is done:
 After the tests are done, the results are compiled and uploaded on the SLIMS
portal.
 Similar processes are done on the LIMS portal of BIS where they receive the
sample request and have to upload the results there. Pending samples can also
be tracked through the portal.
 Standard procedure is followed for the tests.
 At the end, a copy of the certificate of Analysis is sent to the client.

Other labs visited:

1. ETDC: Tests mainly done for electronic equipment.
2. Lucid Labs: Mechanical testing, chemical testing are done on TMT bars,
aluminium material.
3. SIMCO Labs: Testing and Calibration lab, this lab is more well known for its
calibration services and it provides third party testing services also.

32
 5. Industries to ascertain Standards on Good
Practices/SOPs being followed
Visits to these industry units was conducted, to have an insight into the
standards/standard operating procedures relating to good practices for
manufacturing, sustainability (starting from sourcing of raw materials,
processing to end of life of the product and their disposal), circularity, energy
efficiency, service delivery, etc adopted by the firm.

5.1 Trans valves (India) Private Limited

Packaging unit of Ultratech cement was visited on 1ST July 2024 to understand
the procedures involved in the packaging process, laboratory tests and the
standards of procedures followed to ensure environment sustainability.
Survey Questions:
1. Which standards/SOPs are followed by them for various
processes/practices?

- ISO 14001: 2015 is used for Environmental Management System

- ISO 45001: 2015 is referred for Occupational Health and Safety.
- Sustainability is integral to our strategy, values, and daily operations. Decision-
making considers financial, social, and environmental impacts. Adherence to
the UN Global Compact principles on labour, environment, anti-corruption, and
human rights.
- Alignment with Finland's UN Agenda 2030 objectives and commitment to the
Science Based Targets initiative (SBTi). Goal of zero emissions by 2030, in
partnership with our parent company Posti. Concrete actions, such as
implementing green energy solutions at our Sipoo warehouse.
- Collaborative reduction of greenhouse gas emissions by 51 tonnes per year
through sustainable logistics with Paulig.
- Employees follow laws, regulations, and a strict Code of Conduct. Suppliers
adhere to Posti’s Supplier Code of Conduct and anti-corruption policies.
- Anonymous feedback form for reporting breaches of the Code of Conduct.
- Mandatory online training on operating instructions, data protection (GDPR),
and the Code of Conduct. Ensuring adherence to sustainability principles and
allowing for supplier inspections.
- The company practices rain water harvesting.

33
 2. Does an Indian Standard exist on the subject?

- Yes

3. If an Indian Standard exists, are they aware of the same?

- Yes

4. If they are aware and still have not adopted the standard then mention
the reasons.

- They are already following standards such as ISO 14001:2015 and ISO
45001:2015 and following guidelines and rules laid down by various
governmental organisation such as Pollution Control Board.

5. What is the difference between the standard followed by them and the
Indian Standard on the subject?

- No difference, they have just included some initiatives to reduce carbon

footprint.

6. Any difficulty in implementing the standard?

- They are not facing difficulties in implementing the guidelines.
7. Is there any legal/statutory requirement to be complied, which is
different from that in the Indian Standard?
- Yes, some of the guidelines laid by the organizations such as Pollution
Control Board need to be met.
8. Any changes required in the Indian Standard that can make it amenable
to use?
- No suggestions
9. If an Indian Standard exists and they are not aware of the same, the
intern shall inform the same to the firm and enquire whether the
requirements in the Indian Standard seem implementable to them.

- Not applicable

34
 [Link] the firm willing to implement the Indian Standard?

- They are already following the standard.

[Link] no, the reasons to be ascertained?

- Not applicable

12. If Indian Standard does not exist, does the firm feel that there is a need
to have an Indian Standard?

- Currently, the firm does not see the need for a new Indian Standard.

[Link] yes, is the firm willing to contribute towards development of the

standard?

- Not applicable
Recommendations
1. The company is already adhering to all relevant standards. Additionally, they
have implemented initiatives such as using solar energy and other renewable
energy sources, as well as rainwater harvesting.
2. There exist two Indian standards for the rainwater harvesting system:
a) IS 14961:2001 - Guidelines for rain water harvesting in hilly areas by roof
water collection system
b) IS 15797:2008 (Reviewed in 2023) – Roof top rainwater harvesting –
Guidelines
Both these guidelines deal with roof top rainwater harvesting. A standard can be
devised to cover other forms of rainwater harvesting systems like rain gardens,
Bioswales, Green Roofs etc. keeping in mind small-scale and large-scale
manufacturing units.
This would allow more industries to follow this sustainable practice in water
conservation.
3. The awareness among the officials at the manufacturing units regarding the
standards being employed should be ensured.

35
 5.2. Ultratech Cement
Packaging unit of Ultratech cement was visited on 3rd July 2024 to understand
the procedures involved in the packaging process, laboratory tests and the
standards of procedures followed to ensure environment sustainability.
Products:
OPC 53: Ordinary Portland Cement (Grade 53), is a high-strength cement
that is commonly used in construction projects requiring higher strength and
faster setting times.
PPC: Portland Pozzolana Cement (PPC) is a type of blended cement that
includes a mixture of pozzolanic materials, which are natural or artificial
substances that have properties similar to volcanic ash. These materials, when
mixed with OPC (Ordinary Portland Cement), enhance certain properties of the
cement.
PPCS: PPCS, or Portland Pozzolana Cement (PPC) with Sulphate Resisting
properties, is a type of blended cement specifically designed to provide
enhanced resistance against sulphate attacks.
Survey Questions:
1. Which standards/SOPs are followed by them for various
processes/practices?

- ISO 45001: 2015 is referred for Occupational Health and Safety.

Steps taken for Environment Management:
a) The company is committed to ensure that the green energy in total energy
mix reaches 85% by 2030.
b) Corporate Environment policy lays out the companies’ commitment to
measure and reduce the environmental impact of their operations.
c) More than 80% of the plants are ISO 14001:2015 certified which is an
Environment Management System.

d) Their Environment strategy focuses on five key areas:

1. Climate Change (Carbon emissions)
2. Energy Transition
3. Water Management
4. Circular Economy (Waste/Resource Management)

36
 5. Biodiversity Management

e) Cement is a carbon-intensive industry hence they have integrated low carbon

strategy into the business roadmap to address SDG 13 (climate change goal)
based on COP21 of the United Nations Framework Convention on Climate
Change (UNFCCC).
f) All the units have adopted energy and carbon policies. Their strategy
involves a voluntary commitment to reducing the impact of their operations
on climate change. As members of international and national organizations
such as GCCA, FICCI, CII, and CMA, they are dedicated to publishing their
emission data and setting environmental performance targets. UltraTech's
GHG emission reduction targets are validated by the Science Based Targets
Initiative and align with the requirements of the Paris Agreement.
g) Ultratech has committed to reduce scope 1 CO2 emissions 27% per ton of
cementitious material by FY2032, from a FY2017 base year. They have also
committed to reduce scope 2 CO2 emissions 69% per ton of cementitious
material within the same time frame.

- UltraTech has adopted the TCFD (Task Force on Climate-Related Financial

Disclosures) framework and supports the TCFD recommendations issued by
the Financial Stability Board (FSB).

- The Task Force on Climate-Related Financial Disclosures (TCFD) develops

voluntary disclosure recommendations for companies regarding financial risks
and opportunities related to climate change.

- They have championed the deployment of internal carbon pricing (ICP) in their
business processes which is an excellent tool for accelerating decarbonization
across the value chain and facilitating this transition within the company.

- The steel scrap is used for the Cement aggregate thus helping in the reuse.

Their contributions to climate action include:

a) Integrating a low carbon strategy.

b) Scaling up investments in the development of innovative products and

services.

37
 c) Improving energy efficiency.

d) Increasing the share of renewable energy.

e) Switching from fossil fuels to alternative materials.

- For Water conservation, UltraTech has also set up Zero Liquid Discharge
(ZLD) plants at several of its manufacturing Units to enable the reuse of 100%
treated water within the Units.

- The plants have rain water harvesting system across its site locations.

- Zero Liquid Discharge (ZLD) is a classification water treatment processes

intended to reduce waste water efficiently and produce clean water that is
suitable for reuse (e.g. irrigation). ZLD systems employ wastewater treatment
technologies and desalination to purify and recycle virtually all wastewater
received.

2. Does an Indian Standard exist on the subject?

- Yes, and they have taken certification.

3. If an Indian Standard exists, are they aware of the same?

- Not applicable

4. If they are aware and still have not adopted the Indian Standard, what
is the reason behind their decision?

- They are already following standards such as ISO 14001:2015 and ISO
45001:2015 and some of the safety and other company guidelines.

5. What is the difference between the standard followed by them and the
Indian Standard on the subject?

- The company is following the required standards and is a member of some of

the organizations working towards climate change and sustainability.
- The company has a number of internal policies including biodiversity policy,
safety policy, energy and carbon policy, water stewardship policy etc.

38
- There exists no standard for zero liquid discharge system.

6. Any difficulty in implementing the Standard?

- They are not facing difficulties in implementing the guidelines.

7. Is there any legal/statutory requirement to be complied, which is

different from that in the Indian Standard?

- Guidelines given by government organisations such as Pollution Control Board

and others.

8. Any changes required in the Indian Standard that can make it amenable
to use?

- No suggestions

9. If an Indian Standard exists and they are not aware of the same, the
intern shall inform the same to the firm and enquire whether the
requirements in the Indian Standard seem implementable to them.

- Not Applicable

[Link] the firm willing to implement the Indian Standard?

- Not applicable as the firm is implementing the standard, however they might be
interested in implementing standard for zero liquid discharge if available.

[Link] no, the reasons to be ascertained?

- Not applicable

12. If Indian Standard does not exist, does the firm feel that there is a need
to have an Indian Standard?

- Yes

39
 [Link] yes, is the firm willing to contribute towards development of the
standard?

- Not sure at present

Recommendations
1. A comprehensive standard needs to devised for the installation of Zero Liquid
Discharge.
2. The awareness among the officials at the manufacturing units regarding the
standards being employed should be ensured.
3. A standard can be formulated on Internal carbon pricing giving separate
guidelines for small scale and large-scale manufacturers which would include:
a) Step-by-step procedures for calculating internal carbon prices.
b) Recommendations on how to integrate carbon pricing into business
operations and decision-making processes.
c) Specific methodologies for assessing and reporting carbon emissions.

40
 6. Industries who have not opted for BIS
Certification for Products under Voluntary
Certification
Visit to industries was conducted to ascertain from them, the reasons for not
opting BIS Certification for the product. Literature survey of international
standards or standards of other National Standards Bodies available on the
subject was carried out.
6.1. Ahlada Engineers Limited
A visit to the manufacturing plant was undergone on 14th June 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Fire-rated Doors, Steel Flush Door Shutters
Standards: IS 3614:2021
IS 3614:2021-This standard lays down quality requirements including the
requirements regarding materials and details of construction of fire rated metal
swing doors, wooden composite swing doors, metal sliding doors and metal
rolling shutters.
The product steel flush door shutter is not certified for IS 16074: 2013 at
present.
Survey:
1. Whether the product is being produced according to the concerned
Indian Standard or any other standard (international/other
country/company standard)?

- The company is following IS 3614 for Fire-rated Doors and their company
standards for the steel doors at present.

2. Whether the product is meant for export or domestic market.

- The product 20% exported and 80% is meant for the domestic market.

41
 3. In case of production for domestic market, who are their major
customers, Government or private institutions or retail consumers
including their names and details?

- The products are sold to both private and government organisations. TATA
Pravesh is one of the major customers, and the product is also sent for the
Governmental projects. There are certain dealers who are responsible for the
sale of materials.

4. Are their customers seeking any kind of certification or compliance to

any other standard as a condition of purchase? If yes, the intern should
make an attempt to collect the copies of such tender specifications, and
details of those standards from the firm.

- There is no major demand for the IS 16074: 2013, the company will be the All
India first Licensee. However, for fire doors certification of IS 3614 is required.

5. In case a standard other than Indian Standard is being followed, what is

the reason for preferring that standard?

- Certain parameters mentioned in the standard IS 16074: 2013 are different from
the one required for the production.

6. Gap areas between the standard being followed and the corresponding
Indian Standard.

- The parameter is different and the firm has applied for an amendment in the
standard.

7. How is the marking and labelling being done on such products? In what
manner it deviates from the requirements given in Indian Standards?

- The labelling and marking are done as per the Indian standards.

8. In case third party certification by some other body against the adopted
standard has been obtained, what are the reasons for selecting that body

42
 and in what ways their process is different from BIS Certification
process?

- No third-party certification has been taken.

9. Suggestions for changes that may be required in the standard for

making it amenable?

- The changes and amendments have been added as comments, and as soon as the
changes are made, they will get the license.

10. In case Indian Standard is being followed, what is the reason for not
opting for BIS certification?

- Some of the testing parameters are different in the Indian standards, the product
will undergo certification as soon as the amendment is made.

[Link] changes in the BIS certification process would encourage them to

obtain BIS certification Voluntarily?

- No suggestion they are satisfied by the certification process.

Recommendations
1. The company is already adhering to all relevant standards. Additionally, for steel
doors, they have submitted the proposal for amendments in IS 16074:2013 and
are ready to take the certification as soon as the amendments are made. Hence,
there are no major recommendations.

6.2. Shri Balaji Cast Irons Private Limited

A visit to the manufacturing plant was undergone on 12th June 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Horizontally cast iron double flanged pipes for water, gas and sewage
Standards: IS 7181:1986

43
 IS 7181-1986: This standard covers the requirements for double flanged cast
iron pipes of Class B only 1tp to D.N 750 for pressure main lines of water, gas
and sewage manufactured by horizontal castings in sand moulds.
Survey:
1. Standard(s) that are followed (international/other country/company
standard) for the product requirements and methods of test.

- IS 7181:1986 is being referred to for CI DF Pipes that is cast iron double

flanged pipes.

2. Are they aware of Indian Standards pertaining to the product?

- Yes, they are aware

3. If yes and still not following the Indian Standards then reasons for
preferring those standards.

- They are following the specifications of standards with some modifications

4. Is the firm getting their product certified against that standard?

- The products are not yet certified; however, they have applied for the
certification at present. They were certified till 2014. however, the licence was
not renewed thereafter due to negligence.

5. Are the products meant for export or domestic use?

- At present the products are for the domestic market, however they are looking
forward to expanding and starting export.

6. In case of production for domestic market, who are their major

customers, Government or private institutions or retail consumers
including their names and details?

- The products are generally sold for the government projects through the
distributors present at various locations.

44
 7. Are their customers seeking any kind of certification or compliance to
any other standard as a condition of purchase? If yes, the intern should
make an attempt to collect the copies of such tender specifications, and
details of those standards from the firm.

- No

8. In case a standard other than Indian Standard is being followed, what is

the reason for preferring that standard?

- They are following specifications in Indian standards for the pipes.

9. Gap areas between the standard being followed and the corresponding
Indian Standard.

- Not Applicable

[Link] is the marking and labelling being done on such products? In what
manner it deviates from the requirements given in Indian Standards?

- Proper marking and labelling are not being done at present; the marking is done
in case the client demands it.

[Link] case third party certification by some other body against the adopted
standard has been obtained, what are the reasons for selecting that body
and in what ways their process is different from BIS Certification
process?

- No third-party certification is done.

[Link] for changes that may be required in the standard for

making it amenable?
- No suggestions

[Link] case Indian Standard is being followed, what is the reason for not
opting for BIS certification?

45
 - Due to internal conflict and lack of negligence.

[Link] changes in the BIS certification process would encourage them to

obtain BIS certification Voluntarily?

- No suggestion, they have applied for the certification.

Recommendations
1. The company official wasn’t aware of the importance of management standards
and importance of proper labelling and packaging as the products are being
marked with the sizes only if the client demands.
2. Awareness needs to be made among the manufacturers regarding the importance
of proper labelling and packaging.

6.3. Kumar Enterprises

A visit to the manufacturing plant was undergone on 6th June 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Irrigation Equipment – Emitting Pipes System, Emitters, Drip Hole
Pipe, Polyethylene Pipes for Irrigation Laterals, Polyethylene Pipes for Water
Supply
Standards:
IS 13488-2008: This standard specifies the mechanical and functional
requirements of the emitting pipes and their fittings, test methods and the data to
be supplied by the manufacturer to facilitate correct installation and operation in
the field.
IS 12786-1989: is an Indian standard provides specifications for the
manufacturing of an Irrigation Equipment, Polyethylene Pipes for Irrigation
Laterals. The latest version is the one reviewed in 2024.

IS 13487-1992: This standard specifies mechanical and functional requirements

of irrigation emitters, test methods and the data to be supplied by the
manufacturer to permit correct installation and operation in the field. It applies
to emitters, with or without pressure regulation, intended for irrigation; it does

46
 not apply to emitters which for man integral part of the pipe during manufacture
as well as microtubes.

IS 4984- 2016: This standard lays down the requirements for polyethylene (PE)
pipes (mains and service pipes) intended for the conveyance of water for human
consumption including raw water prior to treatment and also water for general
purpose. This standard is applicable for the water supplies with a maximum
operating pressure of 2.0 MPa. An operating temperature of 27ºC has been
taken as the reference temperature.

IS 14151:part 1:1999- This standard lays down requirements and method of

tests for polyethylene pipes of outside diameter from 40 to 200 mm to be used
for Sprinkler Irrigation Systems as mains, submains or laterals.

IS 14151: Part 2: 2008- This standard lays down the general requirements for
materials, manufacture, method of tests and testing of quick coupled
polyethylene pipes and fittings of outside diameters 40 mm to 200 mm used for
portable sprinkler and drip irrigation systems as mains, submains or laterals.

Survey:
1. Standard(s) that are followed (international/other country/company
standard) for the product requirements and methods of test.

- Emitters, regulators, Flat emitting pipe, Lateral pipes are made as per the Indian
standards.
- Drip Hole pipe is made as per the requirements demanded by the client and as
per company standards.

2. Are they aware of Indian Standards pertaining to the product?

- They are not aware if any standard is available for Drip Hole Pipe.
The standard for drip Hole pipe is IS 13488.

3. If yes and still not following the Indian Standards then reasons for
preferring those standards.

- They follow their own company standards and make the pipe as per the client
demands.

4. Is the firm getting their product certified against that standard?

47
- All products other than Drip hole pipe are certified by BIS.

5. Are the products meant for export or domestic use?

- The product is majorly meant for domestic use which is mainly for
Governments as well as private organisations.

6. In case of production for domestic market, who are their major

customers, Government or private institutions or retail consumers
including their names and details?

1. National Institute of Technology (NIT) Warangal

2. Shilpa Infratech Ltd
3. National Police Academy, Hyderabad
4. ORR, Telangana
5. Manepally Hills
6. Rural Development Trust
7. Micro irrigation projects across AP, TS, Karnataka, Tamil Nadu,
Maharashtra with subsidy in the past 20 years.; Farmers across AP
through APMIP with 90 % subsidy
8. Dr. YSR Smrithi Vanam, Kurnool
9. Happy Homes
10. Beauty Green
11. Aishwarya Estates
12. Manasa Giri Greenland
13. Mahendra Giri Greenland
14. Maxima Estates & many more...

7. Are their customers seeking any kind of certification or compliance to

any other standard as a condition of purchase? If yes, the intern should
make an attempt to collect the copies of such tender specifications, and
details of those standards from the firm.
- No

8. In case a standard other than Indian Standard is being followed, what is

the reason for preferring that standard?

48
- Lack of awareness

9. Gap areas between the standard being followed and the corresponding
Indian Standard.

- They are mostly following

[Link] is the marking and labelling being done on such products? In what
manner it deviates from the requirements given in Indian Standards?

- The marking is generally done specifying the size of the pipe. No other specific
packaging is followed for drip hole pipe.
- Packaging on other product is done as per the standards.

[Link] case third party certification by some other body against the adopted
standard has been obtained, what are the reasons for selecting that body
and in what ways their process is different from BIS Certification
process?

- No third-party certification.

[Link] for changes that may be required in the standard for

making it amenable?

- No suggestions

[Link] case Indian Standard is being followed, what is the reason for not
opting for BIS certification?

- All products except drip hole pipe are certified.

[Link] changes in the BIS certification process would encourage them to

obtain BIS certification Voluntarily?
- No suggestion.

49
 Recommendations
The officials need more awareness regarding the existence of standard on Drip
Hole Pipe.

6.4. Varun Beverages Limited

A visit to the manufacturing plant was undergone on 10th June 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Packaged Drinking Water (other than Packaged Natural Mineral
Water), Aerated drinks including (Pepsi, soda), Soft drinks (Slice, Seven up etc.)
Standards:
IS 14543-2020: This standard prescribes the requirements and methods of
sampling and test for packaged drinking water (other than natural mineral
water) offered for consumption and/or for sale in packaged form.
IS 10500-2012: This standard prescribes the requirements and the methods of
sampling and testing for drinking water.
Survey:
1. Standard(s) that are followed (international/other country/company
standard) for the product requirements and methods of test.

- For drinking water IS 14543 is referred and company standards are being used
for aerated drinks like Seven up, Mirinda etc. as the product comes under
voluntary certification.

2. Are they aware of Indian Standards pertaining to the product?

- Yes, IS 2346 is the Indian standard for carbonated beverages.

3. If yes and still not following the Indian Standards then reasons for
preferring those standards.

50
- The certain specifications required for the product are different for their
beverage hence they have their own company standards for the production
process.

4. Is the firm getting their product certified against that standard?

- They are not getting any certification as the standards being followed are
company standards. However, they experience regular inspection from AIB,
American Institute of Baking, which offer services related to food safety,
including audits, inspections, and training for the food industry. These visits are
unannounced, and the certification is provided for the particular day or period
of days the inspection is conducted. The result of the audit is given in the type
of Pass/Fail and in case of failure, an audit is conducted again.

5. What is the difference in the inspection process of BIS and AIB?

- AIB is more stringent in their inspection visits as compared to BIS, for e.g. in
case any external particle is noticed in the filtration process, AIB marks it as a
failure whereas on the other hand BIS marks it as passing as this indicates that
the filter is working properly. AIB inspections are more stringent and expensive
than BIS.

6. Are the products meant for export or domestic use?

- Currently products are being used for domestic purpose.

7. In case of production for domestic market, who are their major

customers, Government or private institutions or retail consumers
including their names and details?

- The major customers are private institutions or retail consumers.

8. Are their customers seeking any kind of certification or compliance to

any other standard as a condition of purchase? If yes, the intern should
make an attempt to collect the copies of such tender specifications, and
details of those standards from the firm.

- No such demand from the customers for compliance and certification.

51
 9. In case a standard other than Indian Standard is being followed, what is
the reason for preferring that standard?

- Certain requirements are different for the product as per the company and hence
they prefer following their company standards.

10. Gap areas between the standard being followed and the corresponding
Indian Standard.

- The concentration of materials stated in the code and that mentioned in the
company standards are different. The company standards are more stringent
than the BIS standards, for e.g., the TDS requirement as per the company
standards are much more stringent and maintained at a lower level.

11. How is the marking and labelling being done on such products? In what
manner it deviates from the requirements given in Indian Standards?

- The products are mostly as per the standards and the guidelines laid down by
the FSSAI.

12. In case third party certification by some other body against the adopted
standard has been obtained, what are the reasons for selecting that body
and in what ways their process is different from BIS Certification
process?

- AIB, American Institute of Bakery provides certificate for the days they have
done the audit related to the safety and quality of production.

13. Suggestions for changes that may be required in the standard for
making it amenable?

- No

14. In case Indian Standard is being followed, what is the reason for not
opting for BIS certification?

- Certification for Drinking water has been taken, for other products they follow
company standards laid down by PepsiCo.

52
 15. What changes in the BIS certification process would encourage them to
obtain BIS certification Voluntarily?

- No suggestion

Recommendations
No major recommendation as the company standards followed by the company
is maintained in order to maintain uniformity of product quality throughout the
various locations and their company standards are more stringent in some
parameters to ensure better quality and safety.

53
7. Manufacturing Units that follow Product
Standards other than Indian Standards
Visit to industries with products which follow international standards was
conducted in order to understand the reason of preferring international standards
and the improvements which can be made in the Indian standards.

7.1 PKL LIMITED

A visit to the manufacturing plant was undergone on 27th May 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Portable Liquified Petroleum Gas Appliances operating at Vapour
Pressure.
Type of Visit: Inclusion Visit
Standards:
IS 1124-1985: Specifies construction, operation, safety requirements and tests
for portable liquefied petroleum gas appliances, such as cooking appliances,
lights, space heaters and blow torches intended for operating at the direct
vapour pressure of the gas in refillable and non-refillable gas containers.
IS 2305-1988: This standard prescribes the method for conducting mercurous
nitrate test for wrought copper and copper base alloy products.
IS 6910- 1985: This standard specifies the apparatus, reagents and the
procedure to be used and prescribes the conditions for conducting the acetic
acid salt spray (ASS) test for assessment of the quality, by way of corrosion
resistance, of metallic coatings applied in accordance with the requirements of
the respective coating or product specifications.
IS 5116-2020: This standard specifies general requirements and methods of test
relevant to these requirements, for domestic and commercial equipment, for
households and other commercial catering organizations, using liquefied
petroleum gases at 2.942 kN/m2 (30 gf/cm2) gas inlet pressure.
IS4246-2002: This standard specifies construction, operation, safety
requirements and tests for domestic gas stoves with metallic bodies intended for
54
 use with liquefied petroleum gases at 2 942 kN/m 2 (30 gf/cm2) gas inlet
pressure.

Survey:
1. What are the international standards used?

- European standard EM 521 is used for appliances which is similar to the

IS11241.
- BS 970 is referred for some part of mix tube which is made of leaded steel. For
Saudi Arabian approval, TÜV Austria works with manufacturers, importers,
and exporters to ensure that products comply with local regulations and
standards set by the Saudi Arabian Standards, Metrology and Quality
Organization (SASO) and other regulatory bodies. It is mandatory for the
products being exported to Saudi Arabia to have the SASO mark.

2. Are they aware of the Indian standards pertaining to the product?

- Yes, they are aware and following Indian standards.

3. If yes and still not following the Indian standard then reasons for
preferring that.

- Not Applicable

4. Is the firm getting their product certified against that standard?

- Yes

5. Are the products used for export or domestic use?

- 80 % of the products are exported and only 20% are for the local markets.

6. List of their major customers (Government or Private institutions

or retail consumers)

55
- The product is supplied to mainly retail consumers and exported majorly to
Saudi Arabia.

7. Are their customers seeking any kind of certification or

compliance to any other standard as a condition of purchase? If
yes, the intern should make an attempt to collect the copies of such
tender specifications, and details of those standards from the firm.

- Local customers only demand for BIS certification.

8. Manner and extent to which the standards adopted by them

deviates from the requirements given in the Indian Standards.

- The temperature and environmental conditions are different in different places

based on that certain parameters like temperature conditions are different.

9. Suggestions for changes that may be required in the Indian

Standards for making them amenable for use.

- Not Applicable as they are already using Indian standards.

10. What can be done by BIS to lay the emphasis of buyers on

compliance and certification to Indian Standards rather than
these standards?

- More awareness amongst not only the consumers but also the sellers, dealers
and traders.

[Link] is difference in application process for certification? Any

change in BIS certification process required to allow easy
adoption.

- The SASO certification application process involves registering on the SABER

platform, submitting product details, and selecting a SASO-approved
certification body via the platform. The license issued is valid for a period of 3
years, with audits conducted approximately every 11 months. SASO provides a
Product Certificate of Conformity (Product COC) and a Shipment Certificate of
Conformity (Shipment COC).

56
- In contrast, the BIS application is done through the BIS portal, and a license is
granted to use the ISI mark on the product. The main difference between both
standards is that SASO considers the test results done at the factory and may or
may not conduct tests in their laboratories depending on certain conditions,
whereas BIS mandates tests conducted at certified labs and factory labs, with
BIS lab test results being decisive for granting the license.

- The application process and costs involved in the certification process are
higher for international standards. This is because the company or factory has
to bear the costs of travel and stay of the officials traveling to the country for
audits, in addition to the application expense. Appliances meant for export are
sent to Saudi Arabia, where any appliance from the batch may be checked.
European standards include the most comprehensive instruction manuals, and
the product requirements are more stringent.

[Link] is the difference in the marking and labelling as per both the
standards?

- The marking and labelling requirements are quite different for both the
standards and is more extensive for the international standards. As per the
international standards, marking and the labelling has been specified for
product, packaging separately whereas Indian Standards are mostly focussed on
products.

[Link] are the main appliances sold?

- Main appliances sold by them are different types of Single burner stoves, blow
lamps which can reach very high temperatures, Heaters etc.

Recommendations
The marking and labelling requirements for Indian standards can be expanded
to include detailed instructions for both products and packaging, similar to
international standards, to enhance product information transparency and
consumer trust.

57
According to the firm, Indian standards typically require markings primarily on
the product itself. In contrast, international standards mandate marking
requirements at all levels of packaging.

7.2. Hyderabad Metropolitan Water Supply and

Sewerage Board
The Hyderabad Metropolitan Water Supply and Sewerage Board (HMWSSB) is
a public utility organization that provides water supply and sewerage services to
the city of Hyderabad and its surrounding areas. Established to ensure the
availability of potable water and efficient sewage management, HMWSSB
plays a crucial role in maintaining the urban infrastructure and public health of
the region.
Domestic type water meters from 15mm and 20mm sizes, magnetically coupled,
multijet, inferential type dry dial Class-B water meters (Screwed end) AMR
compatible manufactured in accordance with ISO:4064 standards and its latest
amendments/IS 779/1994 and its latest amendments and having ISI/EEC/MID
pattern approval (valid life cycle certificate and IP 68 protection from FCRI,
GOI) to water-supply connections of HMWSSB consumers across all O&M
divisions is used.
GSM Water Meter Board: By integrating GSM technology into a water meter,
the device can transmit the collected data wirelessly to a central server or a
monitoring system. This allows for:

 Remote reading of water meters without the need for manual

intervention.
 Real-time monitoring of water usage.
 Detection of leaks or unusual water consumption patterns.
 Automated billing based on accurate and timely data.

AMR technology enables the automatic collection of consumption, diagnostic,

and status data from water meters.
Standards:
ISO 4064-1:2014/ OIMLR49-1:2013 contains metrological and technical
requirements for a water meter.
ISO 4064-2:2014/ OIMLR49-2:2013 describes the test methods for
verification of water meters.

58
 ISO 4064-3:2014/ OIMLR49-3:2013 explains format of test reports for water
meters.
IS: 779:1994 explains the specifications and technical requirements for
domestic water meters up to 50DN
IS: 6784:1996 states the testing methods for domestic water meters
Survey:
1. What type of metre board is used?

- Ultrasonic type meters with automatic meter reading using GSM Technology
for Type 2 consumers for 25mm to 500 mm diameter.

2. What are the standards followed?

- The meters are conforming to ISO 4064:2005 with latest amendments with
BIS /OMIL-R49 /CE/ MID (Measuring instruments Directive)-2014/32/EU
certification mark with valid life cycle test certificate from FCRI (Fluid Control
Research Institute) and protection class of IP 68)

3. What are the equivalent Indian Standards?

- IS 779:1994 for Class B water meters and IS 2373:1981 for Class C water
meters.

4. What are the differences between the standard used and the Indian
standard?

- ISO standard provides enhanced accuracy, better product, better value for
money for the customer etc.
- Moreover ISO 4064:2014 covers both cold potable water and hot water whereas
but IS 779:1994 covers cold potable water at ambient temperature.

5. What are the differences between the standard used and the Indian
standard?
- When following ISO standard, choosing class 1 meters for water temperature
above 30 °C can be selected for any regions in India.
- In ISO 4064: 2014, the critical flow rates are Q1, Q2, Q3 and Q4 compared to
Qmin, Qt, Qn and Qmax in the older version and in IS 779.

59
- The maximum allowable pressure loss across the meter as per IS 779 standard is
0.25 bar at Qn and 1 bar at Qmax. ISO 4064:2014 allows a maximum pressure
loss of 0.63 bar between Q1 and Q3.

IS 779:2020 ISO 4064:2014

Clause 1: Scope Covers domestic and some Covers water meters for
industrial water meters. both cold potable water and
Other requirements of water hot water, in addition to
meters with threaded end water meters based on
connections of size up to mechanical principles, ISO
and including 50 mm, 4064 & OIML R 49 applies
having nominal flow rates to devices based on
in the range of 1.5 to 15 electrical or electronic
kl/h, suitable for measuring principles, and mechanical
the flow of cold potable principles incorporating
water at a nominal pressure electronic devices, used to
of 1 MPa and ambient measure the volume of cold
temperature. potable water and hot water

Clause 2: References to BIS standards References to ISO standards

Normative and related documents and related documents
References

Includes updated definitions

Clause 3: Terms to align with international Comprehensive definitions
and Definitions terms and concepts including detailed terms for
various flow rates and
accuracy classes

Clause 4: Multiple accuracy classes Detailed accuracy classes

Metrological with stricter permissible (Class 1 and Class 2) with
Requirements error limits precise permissible error
limits

Clause 5: Enhanced specifications for Comprehensive technical

Technical pressure loss, temperature specifications covering a
Characteristics range, and operational broad range of parameters
parameters
Clause 6: Materials specified to meet Specifies internationally
Materials international health and recognized materials to
safety standards, ensuring ensure water quality and
no contamination durability

60
 Clause 7: Includes rigorous durability Incorporates stringent
Performance and life cycle testing to durability assessments and
Requirements ensure long-term accuracy performance requirements

Clause 8: Comprehensive Covers a wide range of

Environmental environmental environmental conditions
Conditions specifications including and high IP ratings for
high IP ratings for dust and protection
water ingress

Clause 9: Standardized testing Rigorous and standardized

Testing and procedures aligned with testing methods to ensure
Certification international standards consistent performance
Clause 10: Detailed guidelines for Comprehensive guidelines
Installation and proper installation and ensuring proper installation
Maintenance maintenance and long-term reliability
Clause 11: Enhanced marking and Detailed marking and
Marking and documentation documentation
Documentation requirements for traceability requirements for traceability
and compliance and user information

8. What are the differences between the marking and packaging?

- Marking: ISO 4064:2014 is more comprehensive, including additional details

like nominal flow rate, maximum permissible error, and certification marks. It
requires clear, indelible markings.
- Both IS 779:2020 and ISO 4064:2014 provide guidelines to protect water
meters against damage and environmental factors. However, ISO 4064:2014
offers more detailed and comprehensive guidelines, including the use of
sustainable materials, making it a more robust standard in these areas.
- ISO 4064:2014 is superior in both marking and packaging due to its detailed,
comprehensive requirements and focus on sustainability.

Recommendations
1. The marking and labelling requirements for Indian standards can be expanded to
include detailed instructions for both products and packaging, similar to
international standards, to enhance product information transparency and
consumer trust.

61
2. The international standard for Water metre Board is more comprehensive, the
Indian standard has been made based on the international standard however it
does not include hot water like ISO 4064:2014, so expanding the standard to hot
water can be considered.

7.3. Trans Valves (India) Private Limited

A visit to the manufacturing plant was undergone on 1st July 2024 to understand
the manufacturing process, standards employed for the products and the
differences in Indian standards and the standards followed by them.
Product: Valve Fitting for Use with Liquefied Petroleum Gas (LPG) Cylinders
for More than 5 Litre Water Capacity and Low-Pressure Regulators for Use with
Liquefied Petroleum Gas (LPG) Mixtures.

Standards:
IS-8738: 2017- This standard specifies the basic requirements of material,
dimensions and testing of valve fittings for liquefied petroleum gas (LPG) gas
cylinders of more than 5 litre water capacity. It covers valves with taper stems
only. Valve fittings for LPG cylinders of water capacity up to 5 litres are
covered in a separate standard IS 8776 ‘Valve fittings for use with LPG cylinder
up to and including 5 litre water capacity’ . Equivalent International Standard is
BS EN ISO 14245:2021.

IS-9798: 2013- This standard specifies materials, construction, performance and

testing requirements for low pressure single or two stage regulators for use with
liquefied petroleum gas mixtures in vapour phase up to 4.903 kN/m2 [50gf/
cm2 or 500 mm water column (WC)] outlet pressure. Equivalent International
Standard is EN 16129.

Survey:
1. What are the Indian standards and the equivalent international
standards used?
- Valves: Indian Standard – IS 8737
International Standard – BS EN ISO 14245:2021
- Regulators: Indian Standard – IS 9798
International Standard – EN 16129: SASO certification

62
 2. Are they aware of the Indian standards pertaining to the product?

- Yes, they are aware and following Indian standards.

3. If yes and still not following the Indian standard then reasons for
preferring that.

- Not Applicable

4. Is the firm getting product certified against that standard?

- Yes
5. Are the products used for exports or domestic use?

- The products are both exported and imported in almost equal proportion. In case
of export, the product is mostly sent to Saudi Arabia and other few countries.

6. Are their customers seeking any kind of certification or compliance to

any other standard as a condition of purchase? If yes, the intern
should make an attempt to collect the copies of such tender
specifications, and details of those standards from the firm.

- Local customers only demand for BIS certification.

7. Manner and extent to which the standards adopted by them deviates

from the requirements given in the Indian Standards.

- The temperature and environmental conditions are different in different places

based on that certain parameters like temperature conditions are different.

8. Suggestions for changes that may be required in the Indian Standards

for making them amenable for use.

- Not applicable as they are already using Indian standards.

9. What can be done by BIS to lay the emphasis of buyers on

compliance and certification to Indian Standards rather than these
standards?

- More awareness among dealers and traders.

63
 [Link] is difference in application process for certification?

- The SASO certification application process involves registering on the SABER

platform, submitting product details, and selecting a SASO-approved
certification body via the platform. The license issued is valid for a period of 3
years, with audits conducted approximately every 11 months. SASO provides a
Product Certificate of Conformity (Product COC) and a Shipment Certificate of
Conformity (Shipment COC).

- In contrast, the BIS application is done through the BIS portal, and a license is
granted to use the ISI mark on the product. The main difference between both
standards is that SASO considers the test results done at the factory and may or
may not conduct tests in their laboratories depending on certain conditions,
whereas BIS mandates tests conducted at certified labs and factory labs, with
BIS lab test results being decisive for granting the license.

- The application process and costs involved in the certification process are
higher for international standards. This is because the company or factory has
to bear the costs of travel and stay of the officials traveling to the country for
audits, in addition to the application expense. Appliances meant for export are
sent to Saudi Arabia, where any appliance from the batch may be checked.
European standards include the most comprehensive instruction manuals, and
the product requirements are more stringent.

[Link] is the difference in the marking and labelling as per both the
standards?

- The marking and labelling requirements are quite different for both the
standards and is more extensive for the international standards. As per the
international standards, marking and the labelling has been specified for
product, packaging separately whereas Indian Standards are mostly focussed on
products.

[Link] for Indian Standards?

- No suggestions

64
 [Link] Standard is easier to follow?

- Indian Standards are easier to follow comparatively.

Recommendations
The recommendations are same as those mentioned above, no major
recommendation and suggestions from the firm.

8. Visits to Organized Buyers

Visit to Organized buyers was conducted on 4th June to Ranigunj and 20th
June to Balanagar to understand the level of awareness regarding standards on
a ground level and the quality of the certified and non-certified products. Visit
to more than 10 organised buyers was undergone to understand the trend in
awareness among the dealers and traders and the about the products, the quality
and customer satisfaction level for BIS certified products.

8.1. Premier Hardware Industries

Product: HDPE Pipes, High-Density Polyethylene (HDPE) pipes are highly

durable, flexible, and lightweight, making them ideal for various applications,
including water supply, gas distribution, sewage, drainage, and irrigation. They
are resistant to chemicals and corrosion, ensuring a long lifespan of over 50
years. HDPE pipes are joined using heat fusion for leak-free joints, crucial for
water and gas transport.

Standards Used: IS 4984, IS 4984 is an Indian Standard that specifies the

requirements for High-Density Polyethylene (HDPE) pipes used in potable

65
 water supply. It covers material properties, dimensions, physical and hydrostatic
strength, and testing methods to ensure the pipes' durability and reliability. The
standard mandates clear marking for traceability and compliance, emphasizing
stringent quality control processes for manufacturers. IS 4984 ensures that
HDPE pipes used for drinking water are safe, reliable, and meet consistent
performance criteria.

Survey:

1. Evaluate if they use products conforming to standards other than Indian

Standards, either non-certified or certified by other bodies. If yes,
ascertain reasons for the same.

- They only use Indian Standards, IS 4984

2. If for that product category, they use both BIS certified and not
certified products, their views regarding comparison of both the types of
products

- They use only BIS Certified Products

3. Feedback regarding quality of BIS certified products

- The quality of the products is good.

4. Determine the additional quality checks, if any, performed by them for

accepting the BIS certified products

- The quality check is performed at the manufacturing unit itself and transported.
The shop receives the product from its own manufacturing unit itself.

5. Percentage of non-compliance of the ISI marked products; Actions

taken by the firm in case of non-compliance of ISI marked products;

- 99.5 percent products comply with the standards. In case of non-compliance, the
product is sent back to the manufacturing unit.

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 6. Actions taken by the firm in case of non-compliance of ISI marked
products.
- In case of non-compliance, the product is sent back to the manufacturing unit.

7. Suggestions to BIS for enhancing product compliance and reliability;

- No suggestions

8. Does the firm have any policy specifying purchase of ISI marked
products?

- The firm only accepts ISI marked products.

9. Awareness about BIS portals, such as BIS care App, Know Your
Standard, etc.

- Yes, the firm is aware about the BIS portal and standards.

8.2. RK Steel Traders

Product: High Strength Deformed Steel Bars and Wires for Concrete
Reinforcement
Standards Used: IS 1786 is an Indian Standard that defines the requirements
for high strength deformed steel bars and wires used in reinforcing concrete. It
specifies the chemical composition, mechanical properties such as yield and
tensile strength, and the deformations on the bars to ensure proper bonding with
concrete. The standard also outlines testing methods to verify compliance and
mandates clear marking for traceability. IS 1786 covers different grades of steel,
such as Fe 415, Fe 500, Fe 550, and Fe 600, to meet various construction needs,
ensuring the reinforcement steel is reliable and safe for structural applications.
Survey:
1. Evaluate if they use products conforming to standards other than
Indian Standards, either non-certified or certified by other bodies. If
yes, ascertain reasons for the same.

67
- All the products received from various manufacturers abide with the IS 1786
code.

2. If for the product category, they use both BIS certified and not
certified products, their views regarding comparison of both the types
of products.

- They use only BIS Certified Products

3. Feedback regarding quality of BIS certified products

- The quality of products is good.

4. Determine the additional quality checks, if any, performed by them

for accepting the BIS certified products

- They take into account the test reports of tests on products conducted in the
industry labs and BIS recognised labs.

5. Percentage of non-compliance of the ISI marked products; Actions

taken by the firm in case of non-compliance of ISI marked products;

- The precent of non-compliance is very low and in case of non-compliance the

product is sent back to the manufacturer and a fresh batch is demanded.

6. Actions taken by the firm in case of non-compliance of ISI marked

products.

- In case of non-compliance, the product is sent back to the manufacturing unit

and a fresh batch is demanded.

7. Suggestions to BIS for enhancing product compliance and reliability;

- According to the firm, it appears that the laboratories can sometimes be

manipulative. For instance, when Fe 550 grade steel is required, they often pass
it off as meeting the standards for Fe 550 D.

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 8. Does the firm have any policy specifying purchase of ISI marked
products?

- The firm only accepts ISI marked products.

9. Awareness about BIS portals, such as BIS care App, Know Your
Standard, etc.

- The company official was not aware of the BIS Care App, Know your standard
and BIS portal.

Recommendations
1. A group of traders and dealers can be made and for bigger firms, awareness
programs can be conducted and they should be guided on the action to be taken
in case the product they receive does not comply.
2. 90% of the buyers were not aware of the BIS portal, know your
standard feature and the BIS Care App.

9. Management System Licensees of BIS

A visit to Management System Licensees of BIS was undergone to understand
the processes followed by them for successfully implementing the management
system and understand the benefits accrued to them after obtaining BIS’ licence.

9.1. Dharmaja Cylinders Private Limited

Product: Welded Low Carbon Steel Cylinders for Low Pressure Liquefiable
Gases
Management Standards: IS 9001: 2015 – Quality Management standard
Product Standards: IS 3196 (part 1):2013, IS 6240: 2008 for hot rolled coil
steel
IS 3196(part 1):2013 deals with welded low carbon steel cylinders intended for
storage and transportation of liquefied petroleum gases (1S 4576:2021) of
nominal capacity exceeding 5 l up to and including 250 l water capacity
IS 6240:2008- This standard covers the requirements for deep drawing quality
hot rolled steel plate (up to 6 mm), sheet and strip for the manufacture of low-
pressure liquefiable gas cylinders.

69
 Survey:
1. Performance of the firm prior to obtaining BIS licence;

- The firm has been following the management standard ISO 9001:2015 since the
beginning. The system performance, store maintenance and the documentation
process improved and is more systematic.

2. Enhancement in performance after obtaining BIS licence and

parameters in which enhancement is observed;

- The performance enhanced as all the processes became more systematic.

3. Increase in market share after obtaining licence;

- Not much difference in the market share.

4. Reduction in expenditure after obtaining licence;

- Not much difference has been observed.

5. Other benefits accrued;

- Data of any department is easily available and accessible in a systemised

manner.

6. Whether the firm has any other branch who has also obtained the same
licence from BIS;

- No other branch

7. Suggestions for improvements in processes of BIS;

- No suggestions

8. Any other Management System licence being held by the unit from
some other certifying body as well as the reasons for the same and the
differences in the services provided;

- No other management system Licenses

70
 9.2. Indian Institute of Packaging
A visit to the manufacturing plant was undergone on 28th June 2024 to
understand the management system standards and their implementation.
Survey:
1. Performance of the firm prior to obtaining BIS licence;

- The firm has been following the management standard ISO 9001:2015 since the
beginning. The system performance, store maintenance and the documentation
process improved and is more systematic.

2. Enhancement in performance after obtaining BIS licence and

parameters in which enhancement is observed;

- The management standard has helped in the better documentation of the records
and better overall management of the institute.
- The management and update of the equipment are maintained and the overall
working of the management has improved.
- Logbooks are maintained, Forms and formats for customers, sample details and
the documents are maintained as per the standards.
- All products are reviewed on an annual basis, vendor details, incoming
materials are checked as per the form.

4. Increase in market share after obtaining licence;

- Not much difference in the market share.

5. Reduction in expenditure after obtaining licence;

- Not much difference has been observed.

6. Other benefits accrued;

- Data of any department is easily available and accessible in a systemised

manner.

7. Whether the firm has any other branch who has also obtained the same
licence from BIS;

71
 - Every location of institute has the license.

8. Suggestions for improvements in processes of BIS;

- No suggestions
Recommendations
No major recommendations as the firms are successfully following management
standards without any specific problems.

10. MISCELLANEOUS VISITS

10.1. Stallion Tyres Limited

A visit to the manufacturing plant was undergone on 21st May 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Ply pneumatic tyres
Type of Visit: Inspection Visit
Product Standards: IS 15627:2022
This standard specifies the general, dimensional and performance requirements
of new diagonal and radial ply pneumatic tyres designed for two wheelers (L1
and L2 category of vehicles as defined in IS 14272), three wheelers (L5
category of vehicles as defined in IS 14272), quadricycles (L7 category of
vehicles as defined in IS 14272), E-rickshaws and E-carts.
Manufacturing process:
Components of a Tyre:
Tread: The outer part that comes in contact with the road.
Bead: Steel wires covered with rubber to ensure the tyre grips the rim.
Casing: Includes various layers of fabric or steel chords coated with rubber
compounds to form the tyre's base.

72
Materials Used:
Rubber Compounds: Mixed with carbon black for strength and hardness.
Chemicals: Stearic acid, zinc oxide, and antioxidants.
Reinforcement:
1. Steel chords (used in radial tyres for strength and flexibility).
2. Polyester and nylon (used in bias-ply and diagonal-ply tyres for flexibility
and durability).
Production Stages:
[Link] Compound Formation:
 Mixing rubber, carbon black, etc., in a mixer.
 Aging the mixture for 24 hours.
2. Final Compound Formation:
 Adding an accelerator (curing agent) to the aged mixture.
 Obtaining the final compound after processing.
 Aging the final compound for 8-10 hours.
Tyre Compounds:
[Link] Compound
[Link] Tread Cushion
[Link] Compound
[Link] Compound
[Link] Liner Compound
Assembly Process:
1. Extrusion: Rubber compounds extruded into sheets for treads and sidewalls.
2. Carcass Construction:
 Layers of fabric or steel chords coated with rubber.
 Steel chords for radial tyres, polyester and nylon for bias-ply and
diagonal-ply tyres.
 Carcass cut into bias angles.
3. Bead Formation:
 Steel wires covered with rubber.
73
  Bead wound into the required size.
4. Inner Liner Application: Rubber or synthetic material layer applied to the
inside of the tyre.
[Link] Cushion Application: Layer of rubber between the carcass ply and the
tread.
[Link] Tyre Assembly: All parts assembled into a green tyre.
[Link]: Green tyre taken to a curing press for the vulcanization
process.
[Link] Cutting: Rubber sheets' ends cut at an angle to join together.
Types of Tyres:
[Link] Tyre: No tube required; air directly inflates the tyre.
[Link] Tyre: Contains a detachable tube that can be refilled with air.
Markings: Indicate the tyre's purpose (e.g., red and yellow for autorickshaw
tyres).
Testing:
 Dimension Test: Ensures the tyre meets dimensional standards.
 Plunger Test: Verifies the tyre's strength and puncture resistance.
Tests must match the conditions specified in the product manual with standard
results. A list of tests mentioned in the product manual are conducted as per
standards.

10.2 Dharmaja Cylinders Limited

A visit to the manufacturing plant was undergone on 24th May 2024 to
understand the manufacturing process, standards employed for the products and
the differences in Indian standards and the standards followed by them.
Product: Welded Low Carbon Steel Cylinders for Low Pressure Liquefiable
Gases
Type of Visit: Surveillance Visit
A quality manual is fixed at the time of certification and the same is checked at
the time of inspection if the manual is being followed. This manual is based on
the quality management standard.

74
Management Standards: IS 9001: 2015 – Quality Management standard
Product Standards: IS 3196 (part 1):2013, IS 6240: 2008 for hot rolled coil
steel
IS 3196(part 1):2013 deals with welded low carbon steel cylinders intended for
storage and transportation of liquefied petroleum gases (see 1S 4576:2021) of
nominal capacity exceeding 5 l up to and including 250 l water capacity.
Laboratory Tests:
Tests to be done in factory from the cylinders of prototype batch:
4. Acceptance test- Conducted on three cylinders at random, one each from
first one-third, middle one-third and last one-third of the prototype batch.
5. Burst test- Conducted on two cylinders selected at random, one each from
one-half of the prototype batch.
6. Fatigue test- Conducted on three cylinders selected at random, one each
from first one-third, middle one-third and last one-third of the prototype
batch.
Tests required for quality as per product manual:
1. Checks for various parts of the cylinder and holes punched.
2. Heat Treatment- The heat treatment test conducted on gas cylinders
involves subjecting them to elevated temperatures to assess their
resistance to heat-induced deformation or failure.
3. Radiographic examination- Radiographic examination of gas cylinders
involve directing X-rays or gamma rays through the cylinder wall to
create an image on a detector. This process helps detect internal defects
such as cracks or weld imperfections, ensuring the structural integrity and
safety of the cylinder. It's a vital non-destructive testing method used
during manufacturing and periodic inspections to identify potential flaws
that could compromise cylinder performance or lead to safety hazards.
4. Checking of Water Capacity
5. Hydrostatic test- The hydrostatic test of a gas cylinder involves filling it
with water and pressurizing it to a level higher than its normal working
pressure. This test checks the cylinder's structural integrity by assessing
its ability to withstand internal pressure without leaking or deforming. If
the cylinder passes the test without any signs of failure, it is deemed safe
for use.
6. Valve fixing and Pneumatic leakage test- Valve fixing involves securely
attaching the valve assembly to the gas cylinder per specified standards,
ensuring proper sealing and attachment. The pneumatic leakage test
75
 pressurizes the cylinder with air or gas to detect any leaks in the valve or
sealing components.
7. Fatigue Testing/Cycle testing- Fatigue testing, also called cycle testing, is
a standard procedure on gas cylinders to evaluate their endurance and
ability to withstand repeated pressurization cycles. It involves subjecting
the cylinder to multiple cycles of pressurization and depressurization,
mimicking real-world usage. This test ensures gas cylinders remain
structurally sound and safe for prolonged use, meeting industry standards.
8. Burst Test- The burst test, conducted as per standards, evaluates the
maximum pressure capacity of gas cylinders by subjecting them to
pressure until failure. This test determines the cylinder's ability to
withstand extreme pressures without rupturing or bursting. Compliance
with standards ensures that gas cylinders meet safety requirements and
can safely contain the intended gas pressure without risk of failure.
9. Additional tests include tests related to tensile strength, Yield stress, test
for welding etc.

Test Equipment:
Test equipment used are as per IS 3196(Part 1): 2013 and the Product
Manual.

76
77
 Manufacturing Process:

Manufacturing Process Flow Chart, Source - [Link]

10.3 Transe Valve (India) Private Limited

A visit to the manufacturing plant was undergone on 1st July 2024 to understand
the manufacturing process, standards employed for the products and the
differences in Indian standards and the standards followed by them.
Product: Valve Fitting for Use with Liquefied Petroleum Gas (LPG) Cylinders
for More than 5 Litre Water Capacity and Low-Pressure Regulators for Use with
Liquefied Petroleum Gas (LPG) Mixtures.
Type of Visit: Industry Visit for survey (Products with International Standards)
Standards: IS-8737: 2017, IS-9798: 2013

IS-8738: 2017- This standard specifies the basic requirements of material,

dimensions and testing of valve fittings for liquefied petroleum gas (LPG) gas
cylinders of more than 5 litre water capacity. It covers valves with taper stems
only. Valve fittings for LPG cylinders of water capacity up to 5 litres are
covered in a separate standard IS 8776 ‘Valve fittings for use with LPG cylinder
up to and including 5 litre water capacity’.

IS-9798: 2013- This standard specifies materials, construction, performance and

testing requirements for low pressure single or two stage regulators for use with
liquefied petroleum gas mixtures in vapour phase up to 4.903 kN/m2 [50gf/
78
 cm2 or 500 mm water column (WC)] outlet pressure. Equivalent International
Standard is EN 16129.

Manufacturing Process:
1. Raw material used for Valves is Brass, for regulators, Zinc is used. These
products come under mandatory certification.
2. For Valves, the raw material that is Brass goes through the process of Forging
which is the process in which any material is heated up to its plastic temperature
and then deformed through mechanical application of force to get the desired
shape.
3. For Regulators, the raw material that is Zinc goes through the casting process
where the molten metal goes through die casting.
4. As a part of the forging:
 Heating: Heat the metal billets to the appropriate forging temperature.
 Shaping: Use hydraulic or mechanical presses to shape the heated
metal into the desired valve components.
 Cooling: Allow the forged components to cool and harden.
5. The excess material from the surface is removed from the forged components
and the surface is cleared and smoothened.
6. Machining is carried out:
 CNC Machining: Precisely machine components using CNC
machines to achieve final dimensions and tolerances.
 Threading: Cut threads where necessary.
 Drilling and Shaping: Perform additional drilling and shaping
operations.
7. Surface finishing is done:
 Polish, grind, or plate the machined components to achieve the
required surface finish.
 Apply any necessary coatings (e.g., powder coating, electroplating) for
corrosion resistance.
8. Regulators go through the Die Casting Process wherein the liquified molten
metal is added to a mould and allowed to cool down to get the required shape.
9. All the products made go through machining process to smoothen the surface
and coating and painting.
[Link] products are then tested in the laboratory.
[Link] the testing is done, they go to the assembly area where the product is
inspected for leakages at various stages of assembly to ensure quality and safety
of the product.
[Link] the product is marked and labelled and put into packaging boxes.

79
Laboratory Test:
1. Hydrostatic Pressure Test: Ensures the regulator or valve can withstand
high internal pressures without leaking or failing. Components are
subjected to a pressure higher than their rated working pressure.
2. Leakage Test: Detects any leaks in the body, joints, and seals of the
regulator or valve. Often performed with air or inert gas under pressure
while the valve is submerged in water or monitored with detection
equipment.
3. Flow Capacity Test: Measures the flow rate through the regulator or
valve to ensure it meets specified performance requirements. Verifies that
the device can handle the required flow rates under different conditions.
4. Endurance Test: Assesses the durability and operational reliability over
an extended period. The valve or regulator is cycled open and closed
repeatedly to simulate long-term use.
5. Temperature Cycling Test: Evaluates performance under varying
temperature conditions. The device is subjected to cycles of high and low
temperatures to ensure it maintains functionality across a wide
temperature range.
6. Corrosion Resistance Test: Checks the resistance to corrosion,
especially in harsh environments. Components are exposed to corrosive
agents such as salt spray or chemicals to evaluate their long-term
durability.
7. Pressure Drop Test: Measures the pressure drop across the regulator or
valve at different flow rates. Ensures that the device does not cause
excessive pressure loss in the system.
8. Tensile Strength Test: Determines the mechanical strength of the valve
or regulator components. Ensures the materials can withstand the forces
they will encounter in operation.
9. Burst Pressure Test: Establishes the maximum pressure the valve or
regulator can withstand before bursting. Provides a safety margin beyond
the normal operating pressure.
10. Seat Leakage Test: Evaluates the sealing capability of the valve seat.
Ensures that the valve can completely shut off flow when in the closed
position.
Further some tests are conducted to ensure proper quality and the product
does not degrade due to the actions of the weather.

80
 11Recommendations

As a result of the industry visits and surveys , following action points can be
concluded:
Following areas should be considered for standard formation:
1. Rain water harvesting including the system for all kinds of topographical
areas and conditions.
2. Zero Liquid Discharge system to ensure water conservation.
3. A standard on the Internal Carbon Pricing which can help in providing
companies with proper guidelines for calculating carbon prices and
integrating them into business operations.
4. Consider Hot water under the Water meter board specification IS 779:2020
and make the standard more comprehensive like ISO 4064:2014.

As per the firms which are following international standards, the packaging
as per the International Standards makes it compulsory to add all the details
on every layer of packaging .The packaging and labelling guidelines
mentioned in international standards are much more extensive and stringent,
the similar should apply in Indian standards too.

Apart from standards , industry officials , traders and dealers also need to be
educated regarding standards and BIS Care App.

81
THANKYOU

82