Industry Overview
Organic coatings are composed of pigments dispersed in a vehicle or carrier containing resins, driers, plasticizers, stabilizers, and other required components. During drying, the coating changes from a liquid to a solid film through mechanisms such as solvent evaporation, oxidation of drying oils, or polymerization induced by heat, catalysts, or reactive components. Pigments provide functions including corrosion inhibition, film reinforcement, light stabilization, controlled chalking, and colour development. Inorganic coatings such as zinc silicates similarly use metallic zinc dust with water-soluble silicates as the vehicle.
Alkyd resins constitute a major group of synthetic resins used by the paint industry and are valued for gloss, gloss retention, durability, and flexibility. They are classified according to oil content and phthalic anhydride content into short, medium, long, and very long oil alkyds. Applications include industrial and architectural finishes, automotive and machinery coatings, metal primers, marine paints, enamels, and varnishes. The project also considers modified phenolic and maleic resins, which are used in industrial finishes, floor varnishes, and hard-gloss coating media. The report covers paint and coating formulations, raw materials, manufacturing processes, equipment, quality control, emission reduction, plant layout, utilities, project implementation, and supplier information.
Cost Estimation
| Particulars | Details |
|---|---|
| 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% |
Content Index
- 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
- 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)
Frequently Asked Questions
Organic coatings are protective or decorative coating materials made from pigments dispersed in an organic vehicle or carrier. The vehicle commonly contains resins along with components such as driers, plasticizers, and stabilizers. During application and drying, the liquid coating forms a solid film through solvent evaporation, oxidation, polymerization, or a combination of these mechanisms. Pigments can provide colour, corrosion inhibition, reinforcement, light stability, and other performance characteristics.
Alkyd resins are widely used as binders in paints, enamels, varnishes, primers, and industrial coatings. Their useful characteristics include gloss, gloss retention, durability, and flexibility. Depending on their oil content, different alkyd types can be selected for applications ranging from metal primers and machinery paints to architectural enamels, marine coatings, furniture finishes, and structural steel coatings. The report classifies alkyds as short, medium, long, and very long oil types.
Paint is generally associated with materials applied primarily for decorative purposes, while a protective coating is generally selected when protection of the underlying surface is the principal objective. In practice, many coating products provide both decorative and protective functions. Depending on formulation, coatings may improve corrosion resistance, weather resistance, durability, appearance, or resistance to environmental conditions. The distinction in terminology therefore relates mainly to the primary purpose for which the coating is applied.
The main stages in paint manufacturing include raw material preparation, preassembly and premix, pigment dispersion or grinding, thinning or letdown, tinting, blending, finishing, filtering, and product filling. Resin production and cooking may also be required for manufacturing specific resin systems such as alkyd resins. Equipment selection depends on the formulation and required dispersion quality, with mills and high-speed dispersers used for different processing duties. Quality control is applied to verify the required physical and chemical characteristics of the finished coating.
Paint formulation considers factors such as pigment and vehicle ratios, viscosity, hiding power, pigment selection, vehicle selection, oil absorption, bulking value, and pigment fineness. These factors influence application behaviour, appearance, coverage, drying, durability, and overall coating performance. Solvent characteristics and the compatibility of the selected resin, pigment, additives, and other components are also important. Formulation decisions should therefore be matched to the intended substrate, application method, environmental conditions, and required performance.
Pigment grinding and dispersion can use several types of equipment depending on the formulation and required particle size. The report covers roller mills, ball and pebble mills, attritors, sand mills, high-speed stone and colloid mills, high-speed disk dispersers, and horizontal media mills. Each equipment type provides different levels of shear, grinding action, throughput, and dispersion performance. Selection should consider the coating formulation, pigment characteristics, production scale, desired fineness, process requirements, and compatibility with subsequent finishing operations.
Important factors include plant location, process flow, equipment arrangement, material movement, storage requirements, utilities, safety considerations, emission control, quality control, and provision for future operational needs. A suitable plant layout should support efficient movement of raw materials and finished products while reducing unnecessary handling and maintaining appropriate separation of process areas. The report also addresses plant location factors, principles of plant layout, emission sources, primary emission reduction measures, project implementation schedules, and suppliers of raw materials and plant and machinery.
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