Reduction in batch cycle time of TSD and productivity improvement

Submitted by:-
Kopparapu S.V.B.N.S Rohith Kumar (Y18CH025)

R.V.R&J.C COLLEGE OF ENGINEERING

AT

Gollapuram , Hindupur,
Anantapuram dist , Andhra Pradesh 515211, India

EXTERNAL GUIDE INTERNAL GUIDE

Mr.M.R.Suresh Prof.K.SivaPrasad
British Paints Department of Chemical Engg.
Hindupur-515211
 CERTIFICATE

This is to certify that Mr.S.V.B.N.S ROHITHKUMAR S/O KOPPARAPU

SRINIVASARAO pursuing IV/IV B.Tech Chemical Engineering from R.V.R&J.C
College Of Engineering,Guntur had done three months internship in BRITISH PAINTS
PVT.LTD,Gollapuram,Hindupur,Ananthapuram,AP.

During his internship he worked from 1/01/2022 to 31/03/2022

His performance during the internship is satisfactory.

We wish him success in all his future endeavours.

INDUSTRIAL GUIDE

Mr.M.R.Suresh

Senior Manager of Production

British Paints-Hindhupur.

Mr.Kishan Kumar

DY.Manager of Production

British Paints-Hindupur
 R.V.R&J.C COLLEGE OF ENGINEERING

CERTIFICATE

This is to certify that the dissertation “Reduction in batch cycle time of TSD and
productivity improvement” is a bona fide record of the project work carried out by
Mr.KOPPARAPU S.V.B.N.S ROHITHKUMAR in under the guidance of
Mr.M.R.SURESH,British paints pvt ltd, Hindhupur. The dissertation has been
submitted as a partial fulfilment of the requirement for the award of the degree of
Bachelor of Technology, R.V.R&J.C College of Engineering,Guntur and is a bona fide
record of the work carried out by him for the duration from January 2022 to April 2022.
The work presented in this dissertation has not been submitted for any other degree or
diploma earlier.

Place:

Date: Head of the Department

 ACKNOWLEDGEMENT

This is a formal piece of acknowledgement is an attempt to

express the feeling of gratitude towards people for their supervision and
guidance to complete successful training. I am also thankful to people who
helped me and supported me.

I would like to express my respect to my Prof. K.Siva Prasad,

Prof.Dr.C.V.Subhramanyam (HOD) ,K.Ramesh Chandra, T.Rohini Kumar,
D.N.V.Satyanarayana R.V.R&J.C college Guntur Andhra Pradesh giving to
me opportunity to go for Industrial training at British Paints Pvt. Limited.
This report is based on my practical work that I had done in the company.
I would also like to be thankful to Mr.M.R.Suresh(Senior manager
of Production) & Mr.Kishan Kumar(Deputy Manager), for giving me
opportunity to carry out my Industrial training in British Paints Pvt. Limited.

I am also grateful to Mr. Narendra Varma,Mr.Doddana, Mr.

HariPrakhash and Mr.VijayKumar all other working personals for their
valuable help during my training period.

I am also thankful to all the color team and other supporting staff
for their help, care and concern.

I am also thankful to my parents for their valuable advice and

acknowledge their blessings.

I also express thanks to all my classmates and friends who helped

me during my project period.

Lastly I also thankful to all those who helped me in any way to

complete my training.

Regards
KOPPARAPU S.V.B.N.S ROHITH KUMAR
CONTENTS

Chapter-1 objectives

Chapter-2 literature review

Chapter -3 Introduction

 Role of chemical engineers in paints industry

 Binder or Resin
 Acrylic resin
 Types of emulsion polymer
 Emulsion for paint application
 Acrylic emulsion advantages
 Effect of various monomer of polymer film
properties
 Pvc (pigment volume concentration)& cpvc
(critical pigment volume concentration)
 Pigments
 Organic pigments
 Inorganic pigments
 Extenders

 calcium carbonate
 china clay
 talc
 barytes
 silica
  mica

 Additives
 Thickners or rheology modifiers
 Surfactants
 Biocides
 Defoamers
 Wetting and dispersing agent
 Rheological additives
 Co – solvent
 Solvents

 Equipment involving in paint industries

3.1 Dispersers
3.1.1 Twin Shaft Disperser
3.1.2 High Speed Disperser

3.2 Pug Mill or Pug Mixer

3.3 Bead Mill

3.4 Sand Mill

3.4.1 Vertical Sand Mill

3.4.2 Horizontal Sand Mill

3.5 Mixing Tank

Chapter -4 production of water based paints

4.1 Emulsion Paint

4.2 Texture Paints

4.3 Stainers

4.4 Colouralts

Chapter- 5 Batch Cycle time of wall masta paint in TSD 8&9

5.1 TSD 8&9

 5.2 TSD 1&2

Chapter -6 Reduction in batch cycle time of TSD and productivity

improvement

Chapter -7 Quality control for manufactured products

Chapter-8 Conclusions

Chapter-9 References

LIST OF NOTATIONS
EXT : Extender
GU : Gloss Unit

HSD : High Speed Disperser

PVC : Pigment volume concentration

IRC : International Research Centre

ISO : International Organization for Standardization
NSS : Neutral Salt Spray
NVM : Non Volatile Material
OEM : Original Equipment Manufacturer
PCM : Pre-Coated Metal
PU : Polyurethane
About British paints

The Colourful History

British Paint advent in India dates back to 1947, though its genesis was in 1919 in Britain.
As a Paint Manufacturer we gained huge popularity in India due to our wide and vivid
range of Industrial and Architectural coatings, post which we were renamed Berger Paints
in 1983.

The initial brand name was however, reintroduced as an SBU of Berger Paints India
Limited in 2009. Headquartered in Delhi, we have served varied project verticals both in
the industrial and retail sectors. For statutory details, please see www.bergerpaints.com.
With 50+ branch offices and 12,000 channel partners spread over the length and breadth
of the country, British Paints offers a wide palette of decorative and generic industrial
paints and coatings, manufactured at dedicated units located in Uttar Pradesh, Jammu &
Kashmir, Andhra Pradesh and Assam.

Ranging from decorative paints like texture and enamel paints or waterproofing solutions
like British Waterproofing, British Paints has a solution to all home surface problems like
wall care, maintenance and industrial solutions like Epoxy Coatings too. Glo Advanced,
Expa Cool, Shingar Advanced, British Emulsion, Master Blaster, Acri-silk are a few of
the many well-known products of our brand. Backed by a dedicated team of professionals
with rich and valued experience, we bring to its customers top notch coating solutions.

Besides being acknowledge as one of the leading paint companies in the country, we are
also known for our impeccable painting solutions provided to businesses like Hospitals,
Institutions, Corporates and the like. In fact, our experts also provide painting guidelines
and tips for beautiful home interiors through our website. Essentially, quality products
combined with expert solutions has helped make British Paints, one of the most preferred
brand in the Paint Industry
Objectives

1. Overall review of equipment used in British paints .

2. How the TSD and HSD and Pug mixer works .

3. Different types of additives,resigns,pigments.

4. How we can reduce the batch cycle time of TSD and productivity
improvement.

5. Other equipment used for production of paints and process.

6. Techniques used for reduction in batch cycle time of TSD.

7. Productivity improvement ways

LITERATURE REVIEW

 Understanding Batch Process Management

By Chandrashekhar Limaye

ABSTRACT:

 For example, a paint manufacturing plant manufactures 20 different types of

paints with the same set of equipment, but each product will have its own recipe
and operating procedure
 Traditionally, these products were being manufactured manually. Their
requirement for instrumentation was only a pressure gauge, temperature gauge,
weighing scale and a lab for testing the quality.
 With increasing scale, complexity of process, multi-locational manufacturing,
regulatory compliances, paucity of skilled and experienced manpower,
competition, they felt the need for automating their operations

Evolution of Batch Process Management

 During the initial period, automation involved transfer and charging of liquid raw
materials and solvents from respective storage tanks to the batching tanks, mixers
or reactors, remote monitoring of parameters like temperature, pressure, level and
flow and remote operation of valves and motors.
 It was easy to achieve this using the available PLC/SCADA systems or DCS.
Automatic temperature control of batch reactors was attempted using the
conventional PID control techniques, without much success.
 Heavy investment in the automation system, field instrumentation and upgrading
the manpower did not yield the desired results.
 The quality of the product, batch cycle time, productivity still depended on the
knowledge and skills of the operator.
  Less than half of the process operations could be automated, and the rest
continued to be manual.
 An operator was required to carry out field operations as well as go to the control
room for carrying out the automated operations.

Controlling the viscosity of paints-by traditional way

By Robert Shafoe

ABSTRACT:

 Viscosity plays a critical role in the end-use performance. Some paints should
make a thick protective layer, others a fine glossy surface.
 Some paints are made for brushing or rolling, others for spraying or even dip
coating. The viscosity determines how the paint is to work with and it influences
parameters such as film build, color match, voids, and chemical resistance.
 And even before the paint gets to the end-user, the viscosity and yield stress
determines if the paint is stable during storage.
 Correct paint viscosity is, therefore, the key to good paint quality. There is no way
around it: The viscosity must be carefully controlled.
 There are many ways to do this, but they all have in common that after mixing a
batch of paint a sample must be taken out and measured with a device.
 Traditional devices include flow cups and more or less sophisticated viscometers
or rheometers located on the factory floor or in the QC lab.
 Such a measurement takes time and resources. In practice, this means that the
paint is finished, then it is controlled, and if it “passes the test” (the viscosity is
within the acceptance limits), the batch may be filled.
 Now, if the batch is not right the first time, it must be corrected to higher or lower
viscosity, mixed well, and then a new sample is taken and measured.
Temple C. Patton is the author of Paint Flow and Pigment Dispersion: A
Rheological Approach to Coating and Ink Technology, 2nd Edition,
published by Wiley.

ABSTRACT:

 Mainly pigment dispersion is also one of most important thing for reduction of
batch cycle time.
 While paint manufacturing in TSD , with proper dispersion of pigment tends to
increase the whiteness of paint product and role of pigment and extenders is very
important . Every batch there must be some time allocated for pigment dispersion.
 Critical pigment volume concentration (CPVC) refers to a scientific property used
to describe the volumetric point at which there is precisely enough polymer to
provide moisture to the finely ground particles of pigment that are used to make
paint.

Zoga, Christ, "Dispersion and Milling Methods to Increase Plant

Productivity," reprinted from Modern Paint and Coatings, by Premier
Mill Corporation, New York, NY. May 198

ABSTRACT:

 By different milling methods and dispersion techniques we can reduce batch cycle
time
 The dispersion process in paintsand coatings can be incredibly complex. Each
component adds its own variables to the mix, and their potential interaction
demands scientific know-how.
 Particle sizes can affect attributes ranging from color, hiding power, and level of
gloss in paints to the coefficient of friction in industrial coatings. So tight control
over milling and dispersion processes is an absolute must for consistent quality.
 Grinding and blending processes need to address characteristics that range from
abrasiveness to viscosity to temperature sensitivity and more.
 In addition to achieving target particle sizes, grinding is indispensable for
blending and dispersion. This is true whether the product is a liquid dispersion
(such as solvent- or water-based paint) or a powdered solid (as in heat-cured
coatings used in metal finishing).
 CHAPTER—3

Introduction to Paint
Paint is homogeneous mixture of pigment, resin, solvent and additives or Paint is any
liquid, liquefiable, or mastic composition which, after application to a substrate in a thin
layer, is converted to a solid film. It is most commonly used to protect, colour or provide
texture to objects. Paint is essentially a mixture of a binder, which sticks the paint to the
surface, pigments, to give colour, make it opaque and occasionally to prevent corrosion
and solvents to make the paint spreadable.

Water based paint

 Due to growing environmental awareness and the resulting resulting restrictions to use
of solvents, paint industry all over the world is shifting from solvent based to water
based system in which organic solvents are replaced by water contentaining dispersed
polymer particles.
 The purpose of this paper is giving the paint formulator a clear picture of the water
based paint technology, so that we may make an confirmed decision on the various raw
materials being used by us while formulating water based paints.
 Science the emulsion is the backbone on the water based paint system, it will be vital for
the paint formulator to have a clear understanding of the various polymer types it is
likely to encounter.

Binder or Resin:
It’s a sticky, flammable, insoluble in water, organic compound, making by plants and
seeds.
o Gloss of the paint film
o Gives flexibility and hardness to the paint film
o Adhesion between paint & substrate surface

Acrylic Resin:
Acrylic resins are a group of related thermoplastic or thermosetting plastic substances
derived from acrylic acid, methacrylic acid or other related compounds. Poly (methyl
acrylate) is an acrylic resin used in an emulsified form for lacquer, textile finishes,
adhesives and, when mixed with clay, to gloss paper. Another acrylic resin is poly methyl
methacrylate, which is used to make hard plastics with various light transmitting
properties. It is used for the materials which need some light transmitting properties,
because it is transparent as glass, some amount of titanium dioxide can be added for a
translucent effect. examples given shown below,

Styrene Methacrylic acid Acrylonitrile

Structure 4: acrylic polymers

Properties of acrylic resin:

o Good chemical and photo chemical resistance
o Good weather resistance
o Physically drying at room temperature
o Friendly with environment
 o Non-toxic

Types of emulsion polymers

The past decade, advancements in emulsion polymerization technology coupled with
development of newer monomers has lead to availability of emulsion polymers with
improved performance capability.
Shows the various types of emulsion polymers available to the paint formulator.
EMULSIONS FOR PAINT APPLCATION
Emulsion type Properties Uses

Polyvinyl acetate polymers Film is hard and brittle. Not suitable for alkaline
Plasticizer is required. surfaces like cement and
Plasticizer loss gives poor asbestos. To be used only for
flexibility. interior application.
Vinyl acetate – acrylic co-
polymers Better binding, more flexible Not suitable for highly alkaline
film plasticizer is not required. surfaces. suitable for interior
application only.
Vinyl acetate veova co- Excellent water and alkali Suitable for exterior and
polymers resistance, gives a tough film. interior applications.

High pigment binding, excellent

Pure acrylic polymer alkali and water resistance and Suitable for exterior and
abrasion resistance. interior applications.

High pigment loading

properties, good water and
Styrene-acrylic co-polymers
alkali resistance and gives a Suitable for interior and
tough film. Excellent exterior applications.
washability.

Acrylic emulsions have a number of advantages.

 They have excellent hardness.

 Impact strength and durability.
  They also have high gloss, outstanding clarity and excellent ultraviolet light,
water and chemical resistance.

Most acrylic emulsions are characterized by a very fine particle size and low viscosity.
Emulsion manufacturers are continuing to strive to develop newer grades of emulsions
which can gives good performance at low cast.
Chemists have since successfully copolymerized acrylates monomers with styrene and
developed emulsions with very fine particle size of about 0.1 micron.
A higher pigment loading capacity than any of the other emulsions.
The styrene acrylic emulsions are very versatile and can be used in all types of interior
paints, matt and gloss and also in high PVC exterior paints.
The veova 10 contributed in giving polyvinyl acetate copolymer alkali resistance, these
copolymers when used in formulating high PVC paints [PVC between 60-85% had
limitations.
Styrene acrylic of the advantages
Higher pigment binding power and are ideal for formulating high PVC paints for interiors
and exterior.
In addition they are less susceptible to chalking, have excellent scrub and chemical
resistance.
Styrene acrylic emulsions are ideal for combining performance with economy in wide
range of decorative paints.
It is for this reason that they represent the largest group of polymer emulsions used in
the developed world.

TYPES OF EMULSION POLYMERS

Continuous advancements in emulsion technology have lead to availability of polymers
with improved performance capability. It is important for the paint manufacturer to know
the different types of polymers available for paint applications to enable a proper
selection for the specific application. The different types of polymers are as under:
1. Vinyl Acetate homopolymers: These produce hard and brittle films which need
plasticisation.They cannot be used on exterior, alkaline surfaces as vinyl acetate has a
tendency to hydrolyse and ultimately disintegrate in the presence of water. These are,
therefore, no longer in use.
2. Vinyl acetate – Acrylic copolymers: These are internally plasticised and hence, have
better flexibility than pure vinyl acetate homopolymers but these are still not
recommended for highly alkaline surfaces.
3. Vinyl acetate – Veova copolymers: When adequate proportion of Veova is used in
these polymers, they produce a tough film which has excellent water and alkali resistance.
But such a polymer can be prohibitively expensive as Veova is a costly monomer which
has to be imported into the country.
4. Pure Acrylic copolymers: Paints based on pure acrylic emulsions are a standard in
performance as they have very good pigment binding capacity, excellent water and alkali
resistance and form a tough clear film which gives gloss as well as abrasion resistance.
These too, are quite expensive and can only be justified in better quality paints.
5. Styrene- Acrylic copolymers: These combine performance with economy due to their
high pigment loading properties, good water and alkali resistance and find application in a
wide range of paints for both interior and exterior applications. Polymers of this kind
represent more than half of the total consumption of polymers used by the developed
world.
Important Properties Of Emulsion Polymers

After knowing the different kinds of polymers, it is also important to differentiate the
various polymers by their properties so that it is possible to identify the most appropriate
emulsion for the desired end application. The important properties are listed below:
1. SOLIDS: The solids or polymer content of an emulsion should not be viewed in
isolation as the performance is governed not just by solids, but also by its chemical
composition as well as particle size.
2. pH: The pH of emulsion can be either acidic or alkaline.
3. VISCOSITY: In emulsion paints, there is no direct co relation between the viscosity of
the emulsion and the viscosity of the final paint.
This is so because the paint viscosity is also largely influenced by the thickener and
extender combinations as well as particle size and chemical composition of the emulsion.
4. PARTICLE SIZE: Particle size of emulsions for paint applications ranges from 0.1 to
1.5 microns. The particle size has a direct influence on pigment binding, gloss,
coalescence and the flow properties of the final paint.
Finer particle size emulsions import better pigment binding, gloss and coalescence to the
final paint. The flow properties of such emulsions need to be improved by a proper
formulation to take full advantage of their other good properties.
5. GLASS TRANSITION TEMPERATURE (Tg): The minimum film forming
temperature (MFFT) of a polymer is closely related to its Tg.
This temperature is derived from the combination of monomers used in the polymer.
This is the minimum temperature at which the paint emulsion will form a continuous
film.
The flexibility, adhesion, and mechanical resistance of the final paint will be depend upon
the Tg of the monomers used.

6. CHEMICAL COMPOSITION: The chemical composition is determined by the

monomers used in its production and this composition, influences the resistance
properties of a paint.
As vinyl acetate monomer is susceptible to hydrolysis in the presence of water and alkali,
all copolymers of vinyl acetate monomer are water sensitive.
 Vam -Veova emulsions, too will remain susceptible to hydrolysis, unless they contain at
least 20-25% Veova, which will make them unviable in price.
Pure acrylic and styrene acrylic are the most resistant to hydrolysis, due to the
hydrophobicity of side chains of acrylic esters and the styrene ring.

7. From the foregoing, it is clear that for interior applications, the particle size and glass
transition temperature need to be considered, while for exterior paints, the chemical
composition also needs to be taken into account.
Thus, for interior high PVC paints, the styrene acrylic emulsions are the best and
most economical, while pure acrylics may be used for interior sheen/semi-gloss
paints.
For high PVC exterior paints, good quality styrene acrylics can be safely used, and
for lower PVC exterior paints, pure acrylic or Vam-Veova emulsions with at least
20-25% Veova content should be used.
Popular Types Of Water Based Paints
Architectural water based paints can be broadly classified into interior and paints which
are further categorised as under on the basis of their PVC (Pigment volume
concentration)

INTERIOR PAINT PVC % Emulsion by WT

POUCH DISTEMPER 87-92 5-7

ACRYLIC DISTEMPER 80-85 7-10

PLASTIC EMULSION PAINT 73-77 12-14

ACRYLIC EMULSION 67-72 14-16

PAINT

SATIN EMULSION PAINT 32-35 35-45

SEMIGLOSS EMULSION 18-22 55-60

PAINT

CEMENT PRIMER 73-77 12-14

WALL PUTTY 93-95 3-4

INTERIOR PAINT

TEXTURED COATING 73-78 14-16

 ACRLIC EMULSION PAINT 67-72 14-16

TEX PAINT 62-67 22-25

100% ACRYLIC EMULSION 47-50 30-35

PAINT

ELASTOMERIC COATINGS 30-34 49-52

PVC and CPVC

PVC is the ratio of the pigment to the total composition by volume, where pigment also
includes the extenders.

PVC = Pigment volume +extender volume

Pigment volume +extender volume+ binder volume

=*100%
Basic ingredients of an emulsion paint
A paint mainly consists of a continuous phase, the binder and a discontinuous phase, the
pigment, extenders and additives.
The two primer functions of paint are decoration and protection. The requirements of a
paint intended for exterior use are more stringent than those intended for interior
application .

Pigments
durability and protection are concerned, whereas, interior sheen and gloss paints require
more careful formulation with respect to visual appeal and feel.
According to the end use and the decorative effect desired different ingredients at
varying concentrations are incorporated in the paint formulation.
Following are the ingredients of an emulsion paint ;
To provide color hiding and control gloss.
Pigments are insoluble fine particle size material which gives colour and opacity. Pigment
gives colour component to reflection or transmission of light.
o Hiding
o Provide a colour
o Improve the strength of the paint film
o Improve the adhesion of the paint film
o Its importance of opacity
Pigments are classified into two types:

Organic pigments:
These are some natural pigments like cadmium, cobalt, earth colours etc. Carbon chains
and carbon rings are always present in the molecules of the Organic pigments. Organic
pigments are transparent. Examples given shown below,
o Poly cyclic pigments
o Azo pigments
o Anthraquino pigments
o Trial carbonium pigments
1.2.2.2 Inorganic pigments:-

Those pigments that are made up of mineral compounds as known as to inorganic

pigments. These pigments created in the laboratory and included the pthalocyanides,
dioxazine, naptol etc. Most inorganic pigments are opaque. Examples given below,
o Titanium dioxide
o Zinc oxide
o Antimony oxide
o White lead
o Lead sulphate

In this paper we shall only be discussing the most popular white pigment titanium
dioxide.
Its combination of high opacity and chemical inertness makes titanium dioxide the sole
white pigment which can be used for all applications.
Two forms are available with different crystalline structure.
They are anatase, with somewhat open structure and rutile, which mole compact.
As indicated in the table below, the rutile pigment has a higher refractive index than the
anatase pigment and hence greater hiding power.
When replacing anatase for rutile the amount of pigment has to be increased by about 30,
percent by weight in order to attain the same opacity.
Anatase pigments have a certain photo activity they can adversely affect the binder in the
presence of light, oxygen and induce chalking [a powdering of the surface which
ultimately leads to the destruction of the film].
The rutile pigment on the other hand, provides protection against light by absorbing the
UV-rays and thus preventing the degradation of the organic binder.
For this reason and also on account of the low hiding and lightening powers, the use of
anatase is restricted to interior applications.
Rutile anatase
Specific gravity 4.2 3.9
Refractive index 2.71 2.53
Mhro’s hardness 6.7 5.56
The pigments are very costly so in order to minimize their proportion and attain adequate
properties, optimized mixture of extenders is used.

Extenders
This are cheaper and used for increase the quantity of paint and also give a property to
paint such as flatting, reduce gloss, ant settling, reduced cost.

Figure 2 : extenders

Role of extenders:

o Gives matt finish

o Reduces the cost
o Provides functional properties to paint
The purpose of extender is to increase the volume of paints and to improve their technical
and optical properties.
Properties which can be directly influenced by the extenders are the
CPVC weathering resistance, scrub resistance, gloss reduction, rheology, settling
behavior.
Cracking and film tension, to name but a few.
Extender like talc with lamellar structure contribute in raising the CPVC, as they
distribute very well & give a close packing.
The CPVC decreases when the particle size of the extenders decreases.
Extenders exert an indirect effect on the pigment distribution.
The pigment distribution is improves as the particle size of the extenders decerases.
Lamellar extenders like talc and china clay distribution better than nodular extenders, like
calcium carbonate even if they are coarser than nodular extenders.
Extenders are important raw material In the manufacture of emulsions paints.
The principal classes of extenders are;
 Calcium carbonate
 China clay
 Talc
 Barytes
 silica
 mica

calcium carbonate
calcium carbonate ; [ natural ; calcite, whiting , chalk.
Synthetic ; precipitated cao3]
Fine particle types of calcite are most suited to improving the
pigment distribution, and have a high degree of brightness.
Though synthetic calcium carbonate has the highest brightness
it should be avoided as it affects the storage stability of paint.
Calcium carbonate has good leveling properties and can be incorporated in interior and
exterior paints.
Calcium Carbonate also called ground lime stone, whiting, or chalk is the most widely
used extender mineral in coatings applications. It is very bright and comes in a wide range
of particle size distributions. Finally, it is the most economical of all common filler.

China clay
Natural ; kaolin
Synthetic ; precipitated aluminiu msilicate [Al2Si2O5(OH)4]
China clay gives good pigment distribution and gives the maximum dry hiding effect
above the CPVC.
Its disadvantages is that it a dirty colour to the paint, reduces the scrub resistance and
also has a tendency to crack.

China Clay / Kaolin Clay

Chemical Name: Aluminium Silicate (Al2O3, 2SiO2, 2H2O)China Clay / Kaolin Clay is
naturally occurring hydrated Aluminium Silicate. It mainly has oil
absorbing properties, reduced shine and translucent properties. It
also provides hiding effect and reduces the usage of TiO2 to a
great extent.

Industrial Applications

.Paint Industry: China Clay forms the basic raw material as an extender for Water
based decorative paints.
Solvent based decorative paints.
Protective and OEM coatings;
domestic appliance finishes;
electrophoresis coatings.
coil coatings; traffic markings; printing ink

We offer China Clay of different grades as follows:

–          Kaolin Clay Micro White Powder

–          Kaolin Clay Levigated Ultrafine Powder

–          China Clay Super White Powder

–          China Clay 300,400 & 500 Mesh Powder

–          China Clay Crude Powder / China Clay Ordinary Powder

Talc [magnesium silicate ]

Talc is a hydrated magnesium silicate.

Talc is one of the most widely used extender minerals in paint. Its platy structure
hydrophilic structure and inert chemistry helps in the formation of coatings that provide a
real moisture barrier. The platy structure also promotes a strong, flexible film.
There are many types of talc and each ore body has its own features, its own geology,
formed many millions of years ago.

As a natural ore, talc is always found in combination with at least one other mineral. The
most common of these is chlorite, a chemically and structurally similar ore.

Other associated minerals often found with talc include dolomite and magnesite.

It has a lamellar plate like structure, hence increases the CPVC of the paint by forming a
compact closely packed film.

Talk which has virtually zero hiding power below the CPVC develops exceptionally high
hiding power above this level. It is recommended in interior and exterior paint for
mulations.

Talc in Paint

Most paints are suspensions of mineral particles in a liquid. The liquid portion of the paint
facilitates application, but after the liquid evaporates, the mineral particles remain on the
wall. Talc is used as an extender and filler in paints. The platy shape of talc particles
improves the suspension of solids in the can and helps the liquid paint adhere to a wall
without sagging.

Powdered talc is a very bright white color. This makes talc an excellent filler in paint
because it simultaneously serves to whiten and brighten the paint. Talc's low hardness is
valued because it causes less abrasion damage on spray nozzles and other equipment
when paint is applied. In 2011, about 16% of the talc consumed in the United States was
used to make paint.

Physical properties

Softest mineral on earth (1 on Mohs’ scale)

Platy, lamellar 

 Hydrophobic 
 Oleophilic (natural affinity with oils)
 Relatively inert 
 Properties vary from one deposit to another depending on associated minerals

Physical Properties of Talc

Chemical Silicate
Classification
Color Green, white, gray, brown, colorless
Streak White to pale green
Luster Pearly
 Diaphaneity Translucent
Cleavage Perfect
Mohs Hardness 1
Specific Gravity 2.7 to 2.8
Diagnostic Feel, color, softness, cleavage
Properties
Chemical Mg3Si4O10(OH)2
Composition
Crystal System Monoclinic
Uses Used as a filler and anti-stick coating in plastics, ceramics,
paint, paper, roofing, rubber, cosmetic

Effects and benefits:

 1. Extension of durability through
 2. Improves the resistance and prevents cracking and peel of.
 3. Water-repellent effect .
 4. Increases the viscosity and facilitate dispersion .
 5.Improves the weather and UV resistance .
 6. Reduction of solvents – decrease VOC .
 7. Improves the adhesion of the coating film

Barium sulphate
Natural; barytes syntactic;
balance fixes
Barium sulfate (or sulphate) is
the inorganic compound with the chemical formula BaSO4.
It is a white crystalline solid that is odorless and insoluble in water.
It occurs as the mineral barite, which is the main commercial source of barium and
materials prepared from it.
The white opaque appearance and its high density are exploited in its main
applications.
barytes gives abrasion resistance to the paint film.

it is highly resistance to weathering, gives good gloss and bright ness and also causes an increases in the specific gravity of the paint.

can be used in interior and exterior paints but in low properties.

Baryte (BaSO4) is a colorless or white inorganic mineral having high hardness and
chemical resistance. It is used as a reinforcing additive
barium sulfate BaSO4 used in paint
Barium sulphate is widely used in powder coating (powdr paint), paint, marine paint,
industrial paint, decorative paint, automotive paint, water-based paint, oil-based paint,
rubber, plastic, masterbatch, filler masterbatch, color masterbatch, oil drilling, lead-acid
battery, etc. 

Silica

natural ; quartz, diatomaceous silica kieselguhr

silica have high hiding power, so titanium dioxide pigment can be reduced to a certain extent, without losing
opacity, when these are include in the grind. they also increase the toughness of the paint film, improving its
scrub resistance.

the maim disadvantage of using silica is greater dirt pick up. these are incorporated in high build textured coating and en exterior tex paints.

Transparent, tasteless crystals found in nature as agate, amethyst, chalcedony,

cristobalite, flint, sand, QUARTZ, and tridymite. The compound is insoluble in water
or acids except hydrofluoric acid.

Molecular Formula: (SiO2)n or SiO2 or O2Si

Mica[potassium aluminium silicate]

It is incorporated in small proportions in order to prevent cracking of the film.
In exterior paints its use should be restricted as it detracts from weathering.
It is usually included in putty, textured coating and tex paint formulation.
Paint Industry: To make good anti-corrosive paint, primer, undercoat, water-based
paints exterior coating, chemical resistant coating
Marine paints and aluminum paints

Chemical Composition:
 All these grades are available in different mesh size & the particle size
would be in mesh or Microns as per customer requirement.
 Price range may vary from Rs 9 to 30/-kg as per quality specification
 Sodiam aluminium silicate: zeolex323: is a synthetic, amorphous, precipitated
silicate. It is chemically synthesized using state-of-the art manufacturing
 technology. Zeolex® 323 is a titanium dioxide (TiO2) extender and gloss sheen
control agent. Zeolex® 323 also improves light scattering and increases opacity
when used in paints over CPVC where air is present in the paint film. Zeolex®
323 can reduce the cost of your interior architectural formulations while
maintaining the opacity, whiteness, brightness, flattening, and scrub resistance.
 ZEOLEX® 323 is a synthetic amorphous precipitated sodium aluminosilicate
powder. Acts as a titanium dioxide extender and gloss sheen control agent.
Exhibits high brightness, good scrub resistance, low influence on viscosity, easy
dispersion and outstanding sheen control. Improves light scattering and increases
opacity over CPVC (where air is present). It has a dual function - scatters light and
spaces titanium dioxide. It is stable and non-reactive under normal conditions.
ZEOLEX® 323 is suitable for interior architectural paints and coatings. It is listed
in U.S. EPA TSCA invory list.

Additives
Additives are defined as low-level ingredients that provide specific paint properties such
as mildew resistance, defoaming, and good flow and leveling.

A list of additives used in the manufacture of latex paints includes:

 Thickeners or Rheology Modifiers

Thickeners influence a range of properties such as viscosity, consistency, open time

leveling, sag resistance, setting behavior, strong stability, water resistance, brush drag,
and scrub resistance.

• Rheology is the science of how a liquid tends to flow. These additives provide adequate
viscosity so the paint may be applied proerly, and they impact how thick the paint goes
on, and how well it flows when apply.

• Modern rheology modifiers help latex paints resist splattering, flow out smoothly and
resist spoilage.

 Example of thickners ;cellulosic, acrylic, CMC, HEC, etc.

Surfactants

• These specialized soaps stabilize the paint so that it will not separate or become too
thick to use.

• Keep pigments dispersed for maximum gloss and hiding.

• Help “wet” the surface being painted so the paint won’t move about when it is applied.

• Provide compatibility with tinting colorants so that the correct color will be obtained.

Biocides  –

Paint both in liquid form and as a coating after application, are subject to the constant
attack of microorganisms.

Organic thickners protective colloids.

Emulsifiers, defoamers serve as breeding grounds for microorganisms.

Two types are used in latex paints:

• Preservative - keeps bacteria from growing in the paint.

Preservative are compatibility long term stability, PH range and water solubility.

These preservative are add at 0.2-0.5%level.

• Mildewcide - discourages mildew from growing on the surface of the paint after it has
been applied.

Usually only in can preservative are included in interior paint applications. Film
preservative are necessary in exterior paints.

Defoamers

Additives that break bubbles as they are formed in the paint when the paint is mixed in a
factory, stirred or applied to a surface.

The defoamer is added mill base. The amount to added are in the region of 0.1-0.5%based
on the loading of the finished paint

The combination of hydrophobic very fine particles or droplets [hydrophobic silicone

derivatives, waxes, fatty acid derivatives] in carrier liquid [mineral oil, glycols].

Wetting and dispersing agent:

Several types of additives can be used in the dispersion process in which solid particles,
like pigments and fillers, are distributed and stabilized in a liquid.

Figure 3 : Mechanism of wetting and dispersing additive

Two categories of additives are wetting agent and dispersants are mentioned in one
breath. However, the two materials differ strongly with respect to the role they play in the
system and with respect to chemical composition and morphology of the molecules they
are composed.

o Wetting agents:

Wetting is the first step in the dispersion process. The air that surrounds the solid
particles in agglomerate must be substituted by liquid. Wetting will take place
when the surface tension of the liquid is low compared to the surface energy of
the solid particles. Wetting will not occur when the surface tension of the liquid is
too high. In that case, the surface tension of the liquid can be lowered by adding a
wetting agent. A wetting agent does its job because the molecules adsorb and
orient on the liquid-air interface.

Figure 4: Wetting and dispersing Agent micelle

 Dispersants:
Solid particles attract each other for this reason, energy is needed to separate the
particles from each other in the second step of the dispersion process. Also, solid
particles must be stabilized after they have been separated from each other. The
particles will move to each other and glue together again when particle-particle
repulsion is insufficient. The spontaneous process of gluing together of solid
particles in a liquid is called flocculation. The functionality of a dispersant is to
prevent flocculation. Dispersants do their job because the molecules adsorb on the
solid-liquid interface and assure repulsion between dispersant molecules adsorbed
on the interface of a solid particle and liquid.

Rheological Additives:
Rheology the study of the flow of matter primarily in a liquid state, but also as soft solids
or solids under conditions in which they respond with plastic flow rather than deforming
elastically in response to an applied force. Newtonian can be characterized by a single
coefficient of viscosity for a specific temperature. Although this viscosity will change
with temperature, it does not change with the strain rate. Only a small group of fluids
exhibit such constant viscosity. The large classes of fluids whose viscosity changes with
the strain rate (the relative flow velocity) are called Non-Newtonian fluids. By using
rheology additives, the application properties of the most varied of systems can be
significantly improved.
De-foaming Agent:

De-foaming agent effective antifoam in paint foaming materials due to its unique comb
tri-merized to form the iso cyanate ring initiation of low surface tension, inertness. The
primary selection criteria are the insolubility in the foaming system, the working
temperature, and the

Polydimethylsiloxane: ease of handling. E.g. Polydimethylsiloxane

Fluids are widely used during paint production and ink operations for foam control.
Extremely small addition levels of fluid effectively control foam in many non-aqueous
processing operations. Due to their unique combination of chemical and physical
properties, these Polydimethylsiloxane are the most effective antifoams for paint
applications.

Applications:
o Anti-corrosion through water repellence
o Low temperature mechanical fluid

Co-Solvents (Most co-solvents are volatile organic compounds)

o • Additional liquids, other than water, that aid the binder in forming a good film
when applied down to the minimum application temperature.
o • Help the liquid paint resist damage if frozen.
o • Enhance brushing properties, including flow and the time the paint can be
applied and worked before it sets up, known as “open time.”
o Other additives produce certain desired characteristics in paint, such as the
thixotropic agents that give paint its smooth texture, driers, anti-settling agents,
anti-skinning agents, defoamers, and others that enable paint to cover well and
endure.
o Additives can also include anti floating agents, antimicrobial agents, antioxidants,
catalysts, flame retardants, friction reducers, plasticizers and thickeners.

Solvent

It helps to reduce the viscosity of paint to render applicability. When the production is in
progress during premixing & grinding, solvent or Thinners are added to maintain the
consistency of the mill base. Remaining part of the solvent in the formulation is added at
the time of viscosity adjustment.

The main functions of thinners or solvents

o To make the coating liquid enough to be easily & evenly applied

o To evaporate completely form the coating which is applied on the substrate
o This helps in the various methods of application, such as brush, roller,
conventional spray, airless spray, etc
o After application; the solvent evaporates and plays no further part in the final
paint film
Solvents are of three types:

o True solvent - A liquid which will dissolve the binder and is completely
compatible with it
o Latent solvent- A liquid which is not a true solvent. However, when mixed with a
true solvent, the mix has stronger dissolving properties than the true solvent alone
o Diluent solvent - A liquid which is not a true solvent. Normally used as a blend
with true solvent/latent solvent mixes to reduce the cost. Binder will tolerate a limited
quantity of diluents
Role of chemical engineering in paint industry
Chemical Engineers translate processes developed in the lab into practical
applications for the commercial production of products and then work to maintain and
improve those processes. They rely on the main foundations of engineering: math,
physics, and chemistry (though biology is playing an increasing role). The main role
of chemical engineers is to design and troubleshoot processes for the production of
chemicals, fuels, foods, pharmaceuticals, and biologicals, just to name a few. They are
most often employed by large-scale manufacturing plants to maximize productivity
and product quality while minimizing costs.
Chemical engineers utilizes the skills by what type of equipment we should used and
how new products should develop and many of chemical engineering techniques
should be applied . Process Engineers at plants for troubleshooting, operations etc.

Equipment used in British paints

In British paints they are manufacturing of two types of paint
1. Water based paints
2. Solvent based paints
Equipment used in water based paints .
1. Twin shaft disperser (TSD).
2. High shaft disperser (HSD).
3. Pug mixer
4. Bead mills
5. Ball mills
6.Mixing tanks
 Dispersers

Dispersers certainly serve a very important role in many industries. This includes
applications in food, cosmetics, and pharmaceutical industries. A disperser is a
type of mixer that is used to rapidly break lumps that are generally formed in
powdery materials, uniformly distributing them and wetting them in a liquid. It is
also used to dissolve soluble solids in liquids. They are available in different types
depending on the shafts: single speed, double speed, and variable speed mixing
shafts.

Twin shaft disperser(TSD)

 Twin Shaft Disperser used for manufacturing of materials of high viscosity

such as sealants, polyester putties, coatings etc.
 The machine consists of a centrally located shaft fitted with a butterfly
blade that moves and mixes the mass around the vessels.
 A second variable speed disperser shaft with a cowless impeller blade
operates in short intervals. The mixers are also designed to operate under
vacuum, heating arrangement for vessels is also provided

High Speed Disperser

 A high speed disperser is another type of industrial mixer that makes use
of the blade which is disc-shaped and is mounted at the end of the shaft.
 The blades and the mixing shafts come in different sizes according to the
requirements of the industry they are used in. They find
  To attain high speed dispersion, the dispersion blade should rotate on
optimal speeds so as to achieve the flow pattern and the consistency which
is needed in the mixing vessel.
 The correct amount of dispersion will be entirely dependent on the size of
the vessel and the materials you want to mix in the disperser.

3.1.3 Pug Mixer

 Pug mixer is used in various industries to mix a dry powdered material with a
liquid material to generate a extrude wet mass.
 Pug mixers come with a variable speed drive to adjust the speed of propeller and
shafts. They are extensively used in many industries. We can custom design Pug
mixers as per customer's need
 Operating Principle
 Pug mixer inner walls are constructed of SS or MS sheets. The mixer consists of a
centre shaft of appropriate diameter and is either made of S.S or M.S materiaI.
The centre shaft is fitted with specially designed agitator blades in order to
provide contraflow action. Contraflow ensures constant circulation of mix/blend
ingredients from one end to another to homogenise the batch.Both the ends of the
vessel are provided with stuffing boxes on the shaft. Blend ingredients are
prevented from leaking and entering into bearings by the stuffing box.
3.1.4 Bead Mill
 Bead mill is an apparatus that agitates grinding media (beads) in a cylindrical
vessel to grind or disperse minute particles in slurry.
 The rotor of the mill generates bead motion, which induces intense shear force and
impact on the particles. The bead mill is applied to a wide range of applications,
such as grinding relatively large particles and dispersing nanoparticles.
 Particles of the size of microns or submicron are effectively reduced into finer
particles as fine as tens of nanometers.
 Energy and impact force that materialize the best condition for each material are
adjusted by optimizing the media size, rotor speed, and type of the roto
 bead size is the most important factor for milling practices.
 Large beads, bigger than 0.5 mm, are adequate for grinding micron-size particles
into submicron-size ones. Small beads, 0.3 mm or finer, are applied to grinding or
dispersing submicron- or nanometer-size particles. For dispersing, a large impact
is not necessarily required, and, in addition, smaller beads provide faster
processing rates since frequency of contact between a bead and a particle
increases. In particular:
 1) The adequate impact energy for milling, which is controlled by the bead size,
rotor speed, and mass of the beads charged in the mill, is determined according to
the target size and hardness of the particles.
 2) The frequency of the impact between a bead and a particle, which is controlled

by the rotor speed and bead size, affects the processing rate.
3.15 Ball Mill

 A ball mill is a type of grinder used to grind or blend materials for use in mineral
dressing processes, paints, pyrotechnics, ceramics, and selective laser sintering. It
works on the principle of impact and attrition: size reduction is done by impact as
the balls drop from near the top of the shell.
 A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of
the shell may be either horizontal or at a small angle to the horizontal. It is
partially filled with balls. The grinding media are the balls, which may be made of
steel (chrome steel), stainless steel, ceramic, or rubber. The inner surface of the
cylindrical shell is usually lined with an abrasion-resistant material such as
manganese steel or rubber lining. Less wear takes place in rubber lined mills. The
length of the mill is approximately equal to its diameter.

Sand Mills

 Sand mills are vertical bead mills which are used for particle size reduction and
dispersing of pigments in liquids in the paint, ink & coating industries. Particle
size reduction up-to 2 microns is possible in a single pass. The material to be
processed is pumped from the bottom of the mill into the milling chamber which
is filled with grinding media.
 The media is agitated by a shaft fitted with numerous discs along its length. As the
material moves upwards it is subjected to high hydraulic & shearing forces which
results in fine grinding of the material. The material then passes through the
screen which separates the media from the mill base.
Horizontal Sand Mill

 HE series horizontal disk mill is a high efficiency mill designed for automotive
coating, CED coating, epoxy coating, plastic coating, flexo ink, gravure ink and
other demanding grinding requirement.
 HE series has been field tested and proven over the years for :-
- Narrow particle size distribution.
- High colour strength development.
- Higher flowrate.
 Grinding Disk Peripheral Speed : 11 ~ 16m/s
 Suitable for circulation or passing grinding.
 Engineered beads separation screen which permits higher flowrate.
 High heat transfer rate between chill water and the mill base.
 Highly instrumented for safe, user friendly and unmanned operation.
 Designed for Hazardous Area or Safe Area application.
 The delivery pump circulates the materials in the tank and the materials in the
grinding chamber. The discs drive the grinding medium inside the grinding
chamber to do irregular movements in all direction to put the materials under the
action of constant collision and friction. At same time, the materials are separated
from the grinding medium by the sieve and keep circulating from the tank to the
grinding chamber to obtain smaller particle size, narrower particle size range.
 Chapter—4

Production of paint

For manufacturing of paint the main raw materials Required are

1. Additive

2. Extenders

3. Binders

4. Pigments

Water base section:-

1. First we should clean the TSD with water then after removing the water .

2. We can prepare the solution by adding water and some other raw materials according
to the data . Then after 15 min solution is preapared .

2. After that we have to add some chemicals.

3. After 5 min we have to add Powders and machine can be operating at high speed .

4. After that we have to add water ( flushing) ,then leave the disperser for 1hr for proper
dispersion of materials .

5. Then we have to take a little bit product from disperser for checking the finish of
paint ,if the finish is ok we proceed further or otherwise we can leave the disperser for 10
more minutes.

6. Then by adding chemicals and mixing for 20 min .

7 . Then after thinning can be started ( emulsion added to the disperser ).

Manufacturing of stainers and colourants in Bead mill .

1. In manufacturing of stainers or colourants first we have add powders and chemicals

into bead mill.

2 . Were in bead milks consists of bead which can be used to mixing the raw materials ,
beads sizes are also one important factor.

3 . The by slowly adding the chemicals and pigments we run the machine for 4 or 5 hours
4 . Then total completion of adding chemicals by proper mixing should be done .

5 . Then we have to take one vortex ,then their is one valve in bead mill where we collect
the finished product .

6 . Then we have to check Herman gauge scale in that it should be 7.

7. Then all the product is fine then we have to put the vortex containing paint under the
sand mill for 1 hr .

Pug mixer

1. Distemper and texture like products are manufactured in pug mixer .

2. Here first we have to make solution for 15 min .

3 .After that we have to charge the pug mill and then leave for dispersion.

4 . It containing of two blades one rotates clock wise and other rotate anti clockwise.

5 . then after dispersion we have check finish and after chemicals added and take the
sample.
Chapter—5

Batch Cycle time of TSD

1. Reduction in batch cycle time.

Batch cycle time - It is the time taken for manufacturing of paint from starting to transfer
it to mixing tanks.

2. Batch cycle time mainly depends upon -

 Volume of TSD
 Manpower
 Volume of paint manufacturing.
 Transfer of paint to mixing tanks.

Volume of TSD

 Volume of TSD means , in our site we have TSD 8 &9 of 5kL and TSD 1&2 of
3.5 kL . According to the Batch sheet we have to know about what disperser we
have used by converting of kg to kL .
 Mainly batch cycle depends upon the volume of paint manufacturing . If more
volume is done then batch cycle time increases.

Man Power

Man power required:

1. It is the one of most important criteria for manufacturing of paint.

2 .If we are doing a 5 kL production . We definitely required of 2 manpower for TSD 8

and two for TSD 9 .

3 . Based upon the knowledge of manpower, we have to reduce some what lf batch cycle
time.

4 . How to handle of chemicals should be known to manpower which it can be reduce

batch cycle time .
5. For TSD 1 &2 of 3.5 kL it should take manpower of 2 .

Batch Cycle time of TSD 8&9(5KL)

TSD 8&9 of 5KL

Product formation stages Time

Solution 15min

Charging (7000kg batch ). 45min to 1hr

Dispersion 1 hr

Flushing 10 min

Thinning (mixing tanks) 15 to 20 min

Stabilization (chemicals addition) 20 min

Tranfering( mixing tanks) 30to 45 min

Mixing in mixing tanks with emulsion 10min

3.5 hr

*Then overall Time taken for TSD 8&9 is 3 .5 hours for completion of one batch.

* Manpower Required for production is 2.

Batch Cycle time of TSD 1&2(3.5KL)

TSD 1 & 2 3.5 KL

Product formation Time

Solution 15 min

Charging 30 min

Flushing 5 min

Dispersion 45 min

Stabilization 10 min

Thinning 45 min (both)

 Transfer 30 min

* Overall time taken for TSD 1&2 is 3 hr . Manpower is 2 .

*So based upon about data for completion of one batch it tkaes 3.5 hours . Manpower
should be 2 for all dispersers.

*But the only dependence is how the manpower can effectively do the work and the main
thing is for both 2 manpower is working , but volume of paint Making is large so that
here we are increasing the productivity.

Volume of paint

Volume of paint manufacturing is one the factor for reduction in batch cycle time.

For small production of 1.5 kL, we can manufacture in two hours . So that here we can
understand volume of production may directly depends on batch cycle time .if the volume
of batch increased then batch cycle time also increses.

REDUCTION IN BATCH CYCLE TIME OF TSD AND

PRODUCTIVITY IMPROVEMENT

TS PROD VOLU OLD DATA NEW DATA No.of Reduc Volu

D UCT ME Man tion in me
NO. Before No.o Before
NAME (KL) powe time redu
of f
comple comple
r ced
man man
tion tion
redu
powe powe
ced
r at r
start
At
ing
start
ing

8 Walma 5kl 2 2 1 2 1 30min

stha
To 40
min
1 walmas 3.5kl 1 2 2 2 1 25min
tha to 30
min

PRODUCTIVITY IMPROVEMENT

 Quality of the product is also the one the important factor for
productivity improvement
 Effective planning and designing of manufacturing processes and
equipment helps in achieving optimum productivity through maximum
utilization of the resources available leading to least possible industrial
wastage thus resulting low production cost.
 The aim of this paper is to study the implementation of industrial
engineering tools in a paint industry.
 This study started with observing the standard operation procedures
and understanding the existing process flow.
 At the same time, observations at the production line were made to
identify problems and areas of possible improvements.
 The packaging method used was conventional and time consuming
which was simplified.
 There were suggestions proposed how redesigning of the process flow
and efficient material handling could save idle time for machines, how
replacing the old packaging method with use of zip ties would require
less manpower and could help mitigate the non-value added activities,
thereby resulting in improved productivity of the industry.
 Because If the paint we are manufacturing is good for customers, then
there would be best marketing and production also increases
 Effective planning and designing of manufacturing processes and
equipment helps in achieving optimum productivity through maximum
utilization of the resources available leading to least possible industrial
wastage thus resulting in low production cost.
 The aim of this paper is to study the implementation of industrial
engineering tools in a paint
industry.
 This study started with observing the standard operation procedures
and understanding the existing process flow.
 At the same time, observations at the production line were made to
identify problems and areas of possible improvements. Time study,
method study and layout study techniques formed an integrated
platform to help identify and rectify the time lost in unnecessary
movements of labor and tools which resulted in long machine idle
time.
 The packaging method used was conventional and time consuming
which was simplified. There were suggestions proposed how
redesigning of the process flow and efficient material handling could
save idle time for machines, how replacing the old packaging method
with use of zip ties would require less manpower and could help
mitigate the non-value added activities, thereby resulting in improved
productivity of the industry.
Chapter—7

Quality Control

1 .After giving sample to Qc then they check the viscosity and specific gravity .

2. After that they check the NVM(non volatile matter ) and chalking .

3 . For base products we have to check strength .

4 . After that we have to check contrast ratio and whiteness of the paint.

5 .If all the specifications are ok ,then they release filling note ,then they started filling .

6. It all process take 2 hr .

So that from starting of paint manufacturing to filling of it takes 5 hr approximately.

Chapter-8

Conclusions

From the foregoing one can conclude that:

 Reduction in batch cycle time concept reveals that the time it takes to
produce a unit product is directly proportional to the number of
production stages involved and tine spent at each of the production
stages.
 We can learn how the equipment in the paint industry are used and
what are specifications used for machines in manufacturing the paints .
 In the above discussion we can conclude how the paint is
manufacturing and the batch cycle time for manufacturing the paint at
every stage is also the most important thing in reduction of batch cycle
time .
 For better dispersion ,what are the different types of additives and
resins and binders are used which it can reduce the dispersion time .

We can conclude that productivity improvement techniques:

 Productivity Analysis is conducted to identify areas for potential

productivity improvement projects based on statistical data collected
during the analysis. The analysis also pinpoints areas of delays and
interruptions that cause loss of productivity.
Chapter—9

References

 Global journal of engineering Research vol.7(1) 2008:pp .15-19

by AO Odior
 Temple C. Patton is the author of Paint Flow and Pigment Dispersion:
A Rheological Approach to Coating and Ink Technology, 2nd Edition,
published by Wiley.
 Understanding Batch Process Management by Chandrashekhar Limaye
 Zoga, Christ, "Dispersion and Milling Methods to Increase Plant
Productivity," reprinted from Modern Paint and Coatings, by Premier
Mill Corporation, New York, NY. May 198
 Heaton, Noel. Outlines of Paint Technology.Glasgow: J.b
Lippincott,1940
 Controlling the viscosity of paints-by traditional way By Robert
Shafoe