SANDING SEALER, LACQUER, PU WOOD COATING & VARNISH MANUFACTURING WITH FORMULAE
[CODE NO. 3294]
Sanding sealer is a liquid coat that seals wood and prevents the surface from absorbing varnish. It is a hard first coat that seals without obscuring the grain of the wood. It helps woodworkers achieve a smooth, even finish on a wood furniture. By design, sanding sealer serves as a “sandable” sealer, which means it can easily be sanded after application without impacting its effectiveness on the wood .
Sanding sealer is typically very thin, and dries very quickly to condition the wood in order to allow for less lean time. By applying sanding sealer during the finishing process, woodworkers minimize rough textures and create a smooth finish. Sanding sealers are used to eliminate stains. It can be applied over wood stain or bare wood, depending on the desired appearance, but before any protective coating or finish. This stains include those from water and fire damage. The sealer is then applied over the entire surface using a brush or foam pad after the stain is dried. The sealer must then be allowed to dry completely before proceeding to sanding. The surface is then sanded using a sanding paper before subsequent coats are applied. Sealers may be transparent and sometimes act as primers. Some sealers are designed to be left uncoated and thus can also be used as a varnish, however this is not recommended. Sealers are absorbed quickly by spongy woods, and this can prevent the formation of a film on the wood, leading to an effective seal. Sanding sealers contains zinc stearate, which helps it seal soft woods quickly and makes the wood easier to sand. However, if a lacquer finish is intended to be used above the sanding sealer, more than one or two coats should not be applied as a buildup of sealer can cause the lacquer to chip.
In the current market, most sanding sealers which have good drying capability have not been able to meet users’ requirements, prompting the present research study to attempt to calibrate the different qualities of the various available products, to produce sanding sealer of low drying time and also identify the raw materials that could be combined to obtain optimal sanding sealer formulation that would compete with already existing ones.
The modern wax based polishes were first introduced as wax solvent paster in the late nineteenth century up till then floors, furniture and other surfaces were treated by a variety of methods such as scrubbing oiling sanding, varnishing and wood polishing. Waxes such as bees wax had been used long before this for treating wooden surfaces but these had to be labourising applied by rubbering with a block of the material concerned later paster of bees wax is turpentine or emulsions of wax in soda solutions were used but these again required the expenditure or vasts amounts of time and energy to achieve a rates factory surfaces gloss.
From today new manufacturing techniques and the inclusion of additives such as silicone are continually being experimented with to improve the finished product. Although a number of special wax polished have developed for application to specific surfaces such as footwear motor cars, furniture and floors, two principal types of polish can be distinguished . There are other process in which the wax base is dissolved in a non-aqueous solvent (Paste polished) and those in which the wax is in the form of an aqueous emulsion (liquid polish). In both cases the waxes to be used are broken up i.e. crushes in crushing machine and then melted in steam or electrically heated pans.
COST ESTIMATION
Plant Capacity : 2.00 TON/day
land & Building (1500 Sq.mt) : Rs. 1.73 Cr
Plant & Machinery : Rs. 54.00 Lacs
Working Capital for 2 Months : Rs. 1.52 Cr
Total Capital Investment : Rs. 3.86 Cr
Rate of Return : 28%
Break Even Point : 51%
INTRODUCTION
PROPERTIES OF SANDING SEALER
PROPERTIES AND CHARTERISTICS OF POLYURETHANE VARNISH
USES AND APPLICATION OF SANDING SEALER
USES AND APPLICATION OF PU VARNISH
USES AND APPLICATION OF WOOD POLISH
NITROCELLULOSE LACQUER (SOLVENT BASED)
FEATURES OF SANDING SEALER
WOOD VARNISH AND ITS TYPES
TYPES OF LACQUER
OVERVIEW OF WOOD COATINGS
MARKET SURVEY
MANUFACTURERS/SUPPLIERS OF SANDING SEALER
PU WOOD COATING
FORMULATION OF SANDING SEALER
FORMULATION OF SANDING SEALER
HIGH VISCOSITY WOOD SEALER AND LACQUER FORMULATION
FORMULATION OF SOLVENT
FOR LACQUER & SEALER
FORMULATION OF WOOD COATING
(PU BASED) (CLEARED)
FORMULATION POLYURETHANE VARNISH
(SOLVENT BASED)
ACID CATALYZED WOOD COATINGS
ACID CATALYZED ACRYLIC TOPCOAL
PU WOOD COAT GLOSSY CLEAR
WOOD COAT SEALER AND PRIMER
(SOLVENT BORNE SEALER)
FORMULATIONS OF WOOD POLISH
MANUFACTURING PROCESS OF SANDING SEALER
TECHNICAL DATA OF SANDING SEALER
PROCESS OF MANUFACTURE OF WOOD POLISH
PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF WOOD POLISH (NON-ALCOHOLIC)
DETAILED MANUFACTURING PROCESS OF WOOD POLISH
PROCESS FLOW DIAGRAM FOR THE MANUFACTURING OF WOOD POLISH
METHOD OF WOOD FINISHING
FINISHING PROCESS OF NITROCELLULOSE LACQUER
PLANT LAYOUT
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 MACHINERIES
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET