TECHNOLOGY FOR MANUFACTURE OF LOW COST NAPKINS

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TECHNOLOGY FOR MANUFACTURE OF LOW COST NAPKINS
SHRIRAM INSTITUTE FOR INDUSTRIAL RESEARCH 19,
UNIVERSITY ROAD, DELHI - 110007
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An Insight of Asia

• Five most populous third world countries ar
• China
• India
• Indonesia
• Pakistan
• Bangladesh
• Majority of the women folk are deprived of
  hygiene conditions

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Demographic Trends

• Expected population growth in Asia by 2050
• East Southeast Asia
• China-12
• Indonesia-3
• South West Asia
• India-21
• Bangladesh-4
• Pakistan-5
• Expected population of women between the age
  group of 15-45 is 500 million

4
Indian Scenario

• Population 1.2 billion
• Rural 71 Urban 29
• Male 51.9
• Female 48.1
• Sex ratio 933females/1000males
• Birth rate 27.9
• Death Rate 7.6
• 0.15 billion women in the age group 15-45 in
  rural India

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POPULATION EXPLOSION

• Poverty

• Illiteracy

• Unemployment

• Poor-Health

• Women are the worst affected by population
  explosion

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WOMEN HEALTH ISSUES

• Physiological Disorders

Women In Poverty

• Poor Hygiene

• Reproductive Health

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STEPS TAKEN BY THE GOVERNMENT

• Women empowerment
• Improving education
• Improving the economic status by setting up
  training
• cum-employment programme
• Handicraft and cooperative industry
• Employment Generation
• Employment generation through entrepreneurship
• Value based creative education
• Value addition from biodiversity
• Value addition to agricultural products
• Swa -Shakti project Establishing self-reliant
  women Groups

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Women -Oriented Mission Projects

• Education through distance education
• Family planning by participation
• Empowerment by employment generation
• Health of mother and child

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Relevance Of the Technology

• To provide better hygienic conditions
• Minimizing the spread of infections
• Employment generation
• Self entrepreneurial opportunities
• Easy accessibility and affordability of the
  product

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I. SANITARY NAPKIN DEVELOPED BY SRI
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LOW COST NAPKIN

• A. Sanitary Napkin A Product
• B. SRIS Work Development of Technology
• C. Plan to Transfer Technology Path forward

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THEME OF THE TECHNOLOGY
A. To develop a cost effective product which
could be made affordable to the majority of the
women population of India B. A cost effective
technology that can be easily adopted by the
rural women, means of generating employment
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PERIOD OF TECHNOLOGICAL DEVELOPMENT
A. Development upto lab scale 1999-2001 B.
Developments up-scaled 2001-2003 C.
Patents filed 2004 D.
Technology commercialized 2004-2005
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CONSTRUCTION OF SANITARY NAPKINS
TOP LAYER
ABSORBENT LAYER
BACK LAYER

• Napkin involves 3 layers
• Absorbent layer sandwiched between protective
  porous and non-porous layers

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FUNCTION OF LAYERS
LAYER FUNCTION MATERIAL Top ? Porous ?
Biocompatible ? Allows passage ?
Non-irritant of liquid Absorbent ? Helps in
even distribution ? Biocompatible ? Capillary
action ? Non-irritant Back ? Non-porous ?
Non-irritant ? Prevents leakage

• All layers are important for performance of Napkin

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NAPKINS FOR HIGH END MARKET

• High absorption

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NAPKINS FOR MIDDLE END MARKET

• Optimum performance against cost

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NAPKINS FOR LOW END MARKET

• Scope for innovations and indigenisation

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SYNTHETIC vs. NATURAL ABSORBENTS
PARAMETERS SYNTHETIC NATURAL Absorbency Excellent
Moderate Retention Excellent Moderate Aesthetic
s Good Good Feel Good Good Cost High Affordable Bi
odegradability Non-biodegradable Biodegradable Sus
tainability Low High Technology Not available Not
available

• For sustainability and accessibility, natural
  absorbent have to be identified and developed

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COST FACTORS FOR NAPKINS BASED ON SUPER ABSORBENT
COMPONENTS COST () REMARKS Technology 25 Closel
y guarded Raw materials 40 No local
manufacturer Processing 20 Imported
machinery Marketing 15 High end market

• Overall cost is bound to be high due to
  non-availability of raw material as well as
  technology

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TECHNOLOGY COMPONENT

• High investments for plant and machinery
• Continuous process using automatic plant
• Use of Imported raw material
• Local production of raw material will involve
  technology component

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COST FACTORS FOR NAPKINS BASED ON NATURAL
ABSORBENT
COMPONENTS COST () REMARKS Technology 10 Closel
y guarded Raw materials 70 No local
manufacturer Processing 15 Imported
machinery Marketing 5 Low and high end
market

• Affordable and easily accessible to low and high
  end market

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KEY FACTORS

• Identifying right material
• Developing technology to achieve absorbency in
  cost effective manner
• Development of process method to convert raw
  material to usable product
• Design of plant machinery
• Setting quality norms method development
• Training of operators for operation and quality
  control

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POSSIBLE WAYS FOR COST REDUCTION

• Use low cost raw materials
• Use of alternative cellulosic fibres viz. bamboo
  fibre, jute, pineapple fibre, kenaf, etc.
• Use of fibre waste e.g. cotton, rayon
• Development of indigenous machinery
• Production at block level
• Direct selling

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B. SRIS WORK DEVELOPMENT OF TECHNOLOGY

• Development work and Methodology
• Setting up of pilot plant

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WORK CARRIED OUT BY SRI

• OBJECTIVES
• A technology for manufacture of low cost napkins
  has been developed at laboratory scale
• Using appropriate fibre waste
• Developing indigenous machinery
• Scaling up of technology
• Setting up of a demonstration unit for
  manufacturing 3000 pieces per day

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METHODOLOGY
ABSORBENT LAYER

• Rayon Waste
• Coning
• Thready

Cutting of Fibre
Treatment Washing
Hydro-extraction
Drying of Fibre
Non Woven Web making machine
Opening Laying
Opening of Fibre
BACK LAYER
Cutting
Laying Compaction
PE Sheets
Cutting of PE
Sealing of layed web between the back layer Top
layer
TOP LAYER
PP Sheets
Cutting of PP
Sterilization
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SANITARY NAPKIN PLANT
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FIBRE CUTTING
FIBRE TREATMENT
FIBRE OPENING
DRYER
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HYDRAULIC PRESS
CUTTING MACHINE
SEALING MACHINE
PACKED SAMPLE
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COST BENEFIT ANALYSIS
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COST BENEFIT ANALYSIS
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COST BENEFIT ANALYSIS
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TOXICOLOGICAL STUDIES
S.No. Tests Results Protocol 1. Sterility Compli
es IP-46 Guidelines 2. Skin irritation Non-irrit
ant OECD-404 Guidelines 3. Skin
sensitization No dermal OECD-404 sensitization
Guidelines
Indian Pharmacopoeia Organization for Economic
Cooperative Development
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C. PLAN TO TRANSFER TECHNOLOGY PATH FORWARD

• Demonstration of Technology
• Training operators for production of quality
  napkin

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DEMONSTRATION OF PROCESS TECHNOLOGY

• A demonstration has been given to -
• Officials from Department of Science and
  Technology
• Government officials from South Africa
• Officials from Gujarat government
• Personnel of NGOs
• Accomplished successfully

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ACHIEVEMENTS

• A simple and cost effective technology
• Production cost per piece is lt Rs.1.0
• Quality comparable to commercial product of
  Rs. 2.50 - Rs.3.50
• The rural women can adopt the technology. It can
  provide a source of income for the rural women

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IMPACT OF THE TECHNOLOGY

• Improve the general health and hygiene of the
  rural women
• The rural women can adopt the technology and the
  plant can be run by the women.
• It can provide a source of income for the rural
  women
• Improve the economic status of the women
• The developed technology shall affect 40-50
  population of India, which falls in the low
  income group

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ROLE OF SRI

• Help the government in setting up of plants
• Providing training to women for running a plant
• Further economization of the technology
• Research for other natural absorbents as per
  local needs
• Product development and technology development
  relevant for socio-economic upliftment

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II. PROFILE OF SHRIRAM INSTITUTE FOR INDUSTRIAL
RESEARCH (SRI)
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SHRIRAM INSTITUTE FOR INDUSTRIAL RESEARCH (SRI)
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ABOUT SRI

• Not-for-profit
• Autonomous, private contract research institute
  with a Board of Governors including eminent
  Academicians, Scientists, Professionals, Civil
  Servants and other distinguished persons
• Provides R D and analytical services to various
  government and private agencies
• Qualified and experienced technical and
  scientific staff
• LABORATORIES
• Delhi
• Total area of plot 10 Acres
• Bangalore
• Total area of plot 3.86 Acres

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STRENGTH OF SRI

• PERSONNEL
• Scientists/Technologists 250
• Non-Technical 85
• Total 335
• QUALIFICATIONS OF SCIENTISTS/TECHNOLOGISTS
• Ph.D 30
• Post graduate 100
• Graduate 120
• Total 250

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ACCREDITATIONS/RECOGNITIONS

• National Organisations In Different Sectors
• Health Sector
• Ministry Of Health And Family Welfare
• Drug Contollers Of all States
• Indian Council Of Medical Research
• Agriculture
• APEDA
• Indian Council of Agricultural Research
• Food Corporation of India
• Export Promotion Council
• Central Insecticide Board
• Defence
• Ministry Of Supply DGS D
• Ministry of Defence
• Defence Research And Development Organization
• Airport Authority of India
• Export Promotion Council of India
• Central Insecticide Board
• Punjab Health Systems

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ACCREDITATIONS/RECOGNITIONS

• National Organisations In Different Sectors
• Space
• Indian Space Research Organisation
• Air Authority of India
• Atomic Energy
• Bhabha Atomic Research Centre
• Department Of Atomic Energy
• Indira Gandhi Centre for Atomic Research
• Transport
• Delhi Metro Rail
• Rail India Technical and Economic Services
• UP State Bridge Construction Company
• National Highway Authority of India
• Ministry Of Railways
• Maruti Udyog Ltd.
• International Organisations
• Saudi Arabia Standards Organisations
• Department Of Drug Administraytion, Nepal

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ACCREDITATIONS/RECOGNITIONS

• International Organisations
• Saudia Arabia Standards Organisations
• Department of Drug Adiistration, Nepal
• Sri Lanka Standards Institutions
• European Commission
• Accreditations
• National Accreditation Board For Calibration and
  Testing Laboratories (NABL)
• ISO9001 by DNV, The Netherlands

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SHRIRAM INSTITUTE FOR INDUSTRIAL RESEARCH

• Independent Autonomous
• Self-Sustainable
• Contract Research

• Material Science Division
• Environment Protection Division
• Analytical Science Division
• Biological Science Division
• Applied Radiation Services
• Calibration Services

Thrust Areas

• ISO 9001
• NABL
• International Agencies

Accreditations
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ACTIVITIES OF SRI

• Development of new processes / products
• Analytical services
• Development and validation of methods for
  analysis
• Environmental Protection Services
• Biological / Toxicological studies
• Gamma Irradiation facility for enhancing
  shelflife of food products sterilisation and
  RD
• Quality assurance as per national / international
  standards
• Consultancy services
• Training

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ANALYTICAL SCIENCE DIVISION

• Inspection, analysis and certification of
  following major areas

• Agrochemicals
• Building Materials
• Paints and Coatings
• Petroleum, Wood, Leather, Textile and paper

• Metals and Alloys
• Minerals and Ores
• Rubber and Plastics
• Drugs and Pharmaceuticals
• Food and Farm Products

• Development of new analytical techniques and
  specialized facilities viz.
• Migration studies
• Trace analysis of pesticides and toxic metals and
  chemicals in food products
• VOCs, POPs, PAHs and PCBs in environment
• Quality certification as per BIS, Agmark, etc.
• Consultancy for setting up laboratories

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ENVIRONMENT PROTECTION DIVISION

• Activity started 3 decades back
• Profile of beneficiaries of our service
• Industries
• International Organizations
• Community
• Civic Agencies

Thrust Areas

• Environmental Research
• Natural Resources Management
• Life Cycle Assessment
• EIA, EMP, DMP, Safety Audits
• Solid Wastes Management
• Treatability Studies
• Water Wastewater Characterization
• Air Emission Studies

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BIOLOGICAL SCIENCES

• TOXICOLOGY
• Acute, subacute and inhalation toxicology
• Supplementary toxicology
• Dermatological toxicology
• Reproduction toxicology
• Mutagenicity studies
• Carcinogenicity
• Eco-toxicity

• MICROBIOLOGY
• Drugs Pharmaceuticals
• Food and Water
• Disinfectants
• Cosmetics
• Water filter cum purifiers

• PHARMACOLOGY
• Pyrogen test
• Lal test
• Bioassay
• Oxytocic activity

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SPECIALIZED SERVICES

• APPLIED RADIATION CENTER
• Irradiation of medical products
• Irradiation of food products
• Irradiation of pharmaceutical products
• Co60 ? irradiator capacity 500 Kci (Licensed for
  800 Kci)
• QUALITY ASSURANCE
• Certified for ISO9001
• Accredited by NABL in the fields of
• Chemicals
• Mechanical
• Biological
• Calibration
• Proficiency testing
• Internal audits
• Handling of complaints
• Internal quality check

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RESEARCH AND TRAINING

• Research development for industrial products
• Imparting industrial training to students from
  various universities and technical institutions
• Up-gradation of qualifications
• Organizing seminars, conferences and workshops

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MATERIAL SCIENCE DIVISION

• MAJOR THRUST AREAS
• Polymers Plastics
• Biomedical Healthcare
• Composites
• Resins Coatings
• Adhesives
• Waste Renewable Resource Utilization
• Biodegradable polymers
• Polymer processing and recycling technologies
• Green Technologies
• Food Preservation
• Specialty Chemicals
• Consultancy Services

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MAJOR ON-GOING PROJECTS

• High performance epoxy glass composites
• Bio-absorbable synthetic sutures
• Mesta fibre PP composites
• Disposable speculum for gynecological application
• Reduction of polyaromatic hydrocarbon in coal tar
  pitch
• Metal containing polymers for optical
  applications
• High performance e-beam curable wood coatings
• Remediation of PCBs in oil and paints by
  radiolysis
• Lip seal for transfer of radioactive material
• Photo-resist coating for printed circuit board
• Pellets from plastic waste

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NATIONAL / INTERNATIONAL CONFERENCES / WORKSHOPS
ORGANIZED DURING 1999-2004

• Application of radioisotopes radiation
  technology in food processing and healthcare
  products
• Performance enhancing additives for polymeric
  materials
• Reference materials - A mandatory requirement
  under quality systems
• Recent trends in instrument techniques for
  quality assessment
• Environment pollution prevention control
  strategies in new millennium
• Plastic waste management environment
• Plastics Environment opportunities challenges
• Awareness of gamma radiation processing of food,
  spices, animal feed and healthcare products
• NABL awareness programme on measurement
  uncertainty

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II. CONTRIBUTIONS OF SRI
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SCIENCE TECHNOLOGY CHALLENGES

• Areas of Focus
• Indigenous technologies
• Health safety
• Food safety
• Energy
• Environment
• Rural upliftment
• Novel materials

• Areas of Challenges
• Patent regime
• Hygiene, Nourishment and Medical care
• Quality food, food processing and preservation
  and Bio-safety issues for GM foods
• Alternate fuels
• Green Technologies, Waste Management, GHG
  emissions
• Infrastructure
• Cost-effective Technologies
• Advanced Applications
• Import substitute items of strategic application

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FOOD PROCESSING

• Increase/enhancement of shelf life of apples by
  gamma irradiation.
• To enable farmers to preserve their produce from
  damages
• To avoid dumping of imported apples during
  off-season
• Control of aflatoxin in groundnuts
• To exploit the export-potential
• To avoid health hazards
• Development of rodent repellent packaging and
  storage material for food grains
• To avoid losses due to rodents
• PATH FORWARD
• To enhance PFA list by inclusion of various
  fruits and vegetables for irradiation.
• To set up irradiation facilities in different
  regions of India

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FOOD FARM PRODUCTS

• Development of methods for low detection limits
  of various residual pesticides
• Export of farm products e.g. Honey, Egg powder,
  Gherkins, Grapes Marine products.
• Capability building in the area of residue
  analysis in the wake of WTO
• Development of methods with very low levels of
  detection of adulterants in food products
• PATH FORWARD
• Setting up of a centre of excellence in the area
  of residue analysis for various food products.
• Fixing of Maximum Residue Limit (MRL) by risk
  assessment studies for various residues.

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BIO-TECHNOLOGY

• Bio-safety evaluation of various Genetically
  Modified products
• for registration and certification
• for bio-safety
• Mycotoxins in various food products
• Rapid immuno analysis
• According to EU norms using sophisticated
  equipments
• PATH FORWARD
• Setting up of state-of-the-art GLP compliant
  toxicology facility for bio-safety evaluation of
  all types of GM products.
• Framing protocols for bio-safety evaluation of GM
  products.
• Bio-remediation of various environmental
  pollutants.

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NOVEL MATERIALS

• Booting
• Radiation protective garments for robotic arms
  for nuclear applications
• E-beam Composites
• High performance composites for aerospace and
  automobile applications
• PATH FORWARD
• Commercialisation of Booting
• Working on the development of other strategic
  materials

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WASTE TO WEALTH

• PEF FUEL from plastics
• Substitute of coal
• High calorific value
• Road construction using plastics
• Better durability
• Cost effective
• Use of non-recyclable plastics for value added
  products
• Substitute of wood
• Avoids land filling of valuable resource
• PATH FORWARD
• Adoption of plastics for road making by way of
  demonstration at various places.
• Use of PEF in various industries as an
  environment friendly fuel.

• Solves problem of plastic waste
• Low emissions

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Health Hygiene

• Development of Low Cost Sanitary Napkins
• For rural women
• Biodegradable
• Employment generation
• Disposable Vaginal Speculum
• Better Hygiene for gynae applications
• Cost effective
• Bio-absorbable sutures
• Blood Bag
• Products for Dental Application
• High Refractive Index Material (HRIM)
• PATH FORWARD
• Taking Napkin technology to masses
• Commercializing Speculum Technology
• Commercialization of HRIMs

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ENVIRONMENT

• Hygiene index of Yamuna water in collaboration
  with Japan Development Authority under Yamuna
  Action Plan-II
• Monitoring of Ganga water under Ganga Action
  Plan-II
• Mapping of Arsenic in ground water in the border
  areas of Eastern India
• Mapping of Floride in ground water in Rajasthan
  and Madhya Pradesh
• Pollution monitoring of Delhi at Different time
  periods
• PATH FORWARD
• Phytoremediation of Arsenic

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ACKNOWLEDGEMENT

• My sincere thanks to the management of SRI for
  giving me this opportunity for presenting my work
  at this forum.
• I wish to extend my thanks to the Director, Dr.
  R.K. Khandal and senior management for their
  guidance and support.
• My sincere thanks to the Department of Science
  and Technology for sponsoring the work

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ACKNOWLEDGEMENT

• I wish to acknowledge my team for their
  continuous efforts to make this technology a
  success
• Mr. Vinay Tyagi
• Mr. Amit Pandey
• Mr. Parveen Gogia
• Mr. Amit Kumar
• Mr Bhupesh Sharma

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THANK YOU