PAINT MANUFACTURING
[CODE NO.3765]
Organic coatings are composed of pigments suspended in a vehicle. The vehicle or carrier consists primarily of a resinuous of driers, plasticizers and stabilizers as required. As the paint film dries, these vehicles changes from a liquid to the solid film by one or more of several mechanisms.
1. Evaporation of Solvents.
2. Oxidation (of a drying oil).
3. Polymerization through application of heat, addition of catalyst, or combination of reactive components.
The pigments contribute such properties as inhibitions of a metal surface (red lead & zinc chromate), reinforcement of the film, stabilization against deterioration by sunlight, controlled chalking (titanium oxide) and colour clear coating (varnishes, lacquers & shellac) are not pigmented.
Inorganic coatings such as the zinc silicates also may be though of as a pigment suspended in a vehicle. In this case, the pigment con consists of metallic zinc dust, and the vehicle is a blend of water soluble silicates.
Terminology sometimes is confecesing. "Paint" usually refers to materials applied primarily for their decorative effect and any protection received is of secondary importance. The term coating or "protective coating" on the other hand generally is received for use when protecting is the primary consideration.
The alkyd resins form the largest groups of synthetic resins available to the paint industry. Alkyd finishes in general shows good gloss and gloss retention. These resins are employed in stroving enamels quick drying paints, stoving coatings in conjunction with amino resins, marine paints etc.
Among the resins used, it has been found that 90% of alkyd produced are handled in one of these ways to produce some type of paints varnishes, or lacquer for industrial and home consumption. So the scheme is prepared mainly on the production of the modified alkyd resins though production of phenolic and meleic resins are also considered. Alkyd resins are classified according to the amount of oil and phthalic anhydride present in the alkyd.
Type of oil Oil content % Phthalic anhydride
Short 35-45 More than 73%
Medium 46-55 30-35
Long 56-70 20-30
Very Long 71 up less than 20
The short oil alkyds are of two types:
1. Non-drying type
2. Drying types
The short oil non-drying alkyds contain, coconut, castor oil or similar saturated fatty acids. They are used as plasticizers in cellulose nitrate lacquers and baking enamels combine with amino resins. They find uses for very hard and tough finishes like automobiles refrigerators, washing, machines, home freezers and other metal finishing users.
The short oil drying alkyds contain tall oil, fatty acids like soybean, dehydrated castor and linseeds oils. Alkyds have utility in industrial backing finishes. They are also used as metal primers. Medium oil alkyds are the most versatile of the alkyds family. They have excellent gloss durability and flexibility. The medium oil alkyds find use in air drying of baking enamels, metal decorative coatings, machinery paints furniture finishes, metal primers and also in roller coating finishes.
Long oil alkyds find wide applications in structural steel finishes marine paints, interior and exterior architectural enamels and for oleo-resinous varnishes. Very long oil alkyds dry slowly but have good brushing properties and also durability.
Phenolic and maleic resins, are mainly modified with resins which is an important component in surface coating media. Principal uses for these resins include air drying industrial finishes, floor varnishes and also for hard gloss paint media.
Maleic resins excel in initial colour and colour stability to phenolic resins but inferior to phenolic resins in water alkali resistance.
COST ESTIMATION
Plant Capacity 12 Ton/Day
Land & Building (8000 sq.mt.) Rs. 4.38 Cr
Plant & Machinery Rs. 1.10 Cr
Working Capital for 1 Month Rs. 5.67 Cr
Total Capital Investment Rs. 11.56 Cr
Rate of Return 46%
Break Even Point 39%
INTRODUCTION
THE SHORT OIL ALKYDS ARE OF TWO TYPES:
PROPERTIES
1. PHYSICAL PROPERTIES:-
2. CHEMICAL PROPERTIES:-
OVERVIEW OF GLOBAL PAINT AND COATING INDUSTRY
WORLD ECONOMIC OVERVIEW
AUTOMOTIVE
FIGURE: FOCUSED SPECIALTY CLUSTERS LEAD IN THE CHEMICAL
RANKINGS (MEDIAN TSR %), 2012-2016.
FIGURE: MEDIAN PRETAX RETURN ON INVESTED CAPITAL,
INCLUDING GOODWILL %.
CONSTRUCTION
COMPETITIVE LANDSCAPE
FIGURE: GLOBAL COATINGS – IRR (OPERATING CASH FLOW/ERV),
2005-2017.
FIGURE: TOP 10 GLOBAL PAINT & COATINGS PRODUCERS, BY VALUE
(EUR BILLIONS).
GLOBAL MARKET
ARCHITECTURAL (DECORATIVE) PAINTS
INDUSTRIAL OEM COATINGS
FIGURE: HISTORICAL RAW MATERIAL INDEX AND TIO2 PRICES.
FIGURE: GLOBAL PAINT AND COATINGS INDUSTRY, VOLUME & VALUE
(2017-2020F).
FIGURE: GLOBAL ARCHITECTURAL PAINTS REGIONAL BREAKDOWN,
VOLUME & VALUE (2017).
FIGURE: GLOBAL INDUSTRIAL OEM COATINGS MAJOR MARKET
SUB-SEGMENTATION, VOLUME & VALUE (2017).
RAW MATERIALS
SEQUENCES IN PAINT MANUFACTURE
MAKING THE PASTE
DISPERSING THE PIGMENT
THINNING THE PASTE
CANNING THE PAINT
QUALITY CONTROL
TECHNOLOGICAL DETAILS FOR PAINT MANUFACTURING
EMISSION SOURCES
PRIMARY EMISSION REDUCTION MEASURES
TECHNICAL ASPECTS
PRINCIPLES OF PAINT FORMULATIONS
PAINT FORMULATION:
CHARACTERISTICS OF PIGMENT
CHARACTERISTICS OF SOLVENTS
1. PIGMENT & VEHICLE RATIOS
2. VISCOSITY
3. HIDING POWER
4. SELECTION OF PIGMENTS
5. VEHICLE SELECTION
6. OIL ABSORPTION
7. BULKING VALUE
8. FINENESS OF THE PIGMENT
LIME COLOURS & DRY DISTEMPER
LIME COLOURS
1. BLUE PIGMENT
2. RED PIGMENTS
3. YELLOW PIGMENTS
4. GREEN PIGMENTS
5. BLACK PIGMENTS
FORMATION OF BLUE LIME COLOUR
DRY DISTEMPERS
FORMULATIONS FOR DRY DISTEMPERS:-
1. WHITE DISTEMPER:
2. YELLOW DISTEMPER:
3. GENERAL DRY DISTEMPER:
MANUFACTURING PROCESS
LIME COLORS:-
DRY DISTEMPER:-
OIL BOUND DISTEMPER
SOLUTION A:-
SOLUTION B:-
SOLUTION C:-
GLUE OR CASEIN BASED OIL BOUND DISTEMPER:-
TYPICAL FORMULA FOR SOYBEAN PROTEIN BASED OIL BOUND DISTEMPER
LINSEED OIL CONTAINING (0.02%):-
PLASTIC WALL DISTEMPER FORMULA:-
ENAMEL PAINTS
FORMULATIONS:-
1. SYNTHETIC ENAMEL (ORANGE):-
2. WHITE ALKYD GLASS ENAMELS:
3. BLACK ALKYD GLOSS ENAMEL:-
4. SINGAL RED ALKYD GLOSS ENAMEL:-
5. LIGHT (GREEN ALKYD GLOSS ENAMEL:-
FORMULATION FOR ENAMEL PAINT:-
MANUFACTURE OF ENAMELS:-
RED OXIDE PRIMER
FORMULATION FOR RED OXIDE PRIMERS:-
2. OLEORESINOUS TYPE:-
3. ZINC CHROME PRIMERS:-
4. MANUFACTURED OR NATURAL RED OXIDE:-
MICA BASED PAINT
FORMULATIONS:-
MICA LUSTURE PAINT:-
TYPES & USES OF VARIOUS MICA PAINTS
1. PRIMERS AND ANTI CORROSIVE PAINTS:
2. ALUMINIUM PAINTS, BASED ON MICA:
3. TRAFFIC OR ROAD MARKING PAINTS:
4. EXTERIOR HOUSE PAINTS:
5. FIRE RETARDING PAINTS:
PROCESS OF MANUFACTURERS & FORMULATIONS
THINNER FORMULATIONS FOR BRUSHING LACQUERS:-
LOW-VISCOSITY NITROCELLULOSE:-
HOT SPRAY APPLICATION:-
THINNER FORMULATIONS
OTHER FORMULATIONS:-
PROCESS FLOW SHEET FOR MANUFACTURE OF THINNERS
PROCESS DESCRIPTION FOR PAINT MANUFACTURE
PREASSEMBLY AND PREMIX
RESIN PRODUCTION AND COOKING
EQUIPMENT SELECTION
PIGMENT GRINDING OR MILLING
ROLLER MILLS
BALL AND PEBBLE MILLS
FIGURE: SCHEMATIC DIAGRAM OF A THREE-ROLL MILL
ATTRITORS
SAND MILLS
HIGH-SPEED STONE AND COLLOID MILLS
HIGH-SPEED DISK DISPERSERS
HORIZONTAL MEDIA MILLS
PRODUCT FINISHING
THINNING (LETDOWN)
TINTING
BLENDING
PRODUCT FILLING
FILTERING
MATERIAL TRANSFER
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)