PAINT MANUFACTURING
[CODE NO.3788]
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.
COST ESTIMATION
Plant Capacity 12 Ton/Day
Land & Building (4000 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
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 (SOLVENT BASED)
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%):-
COMPOSITION:-
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:-
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 FOR THINNER
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
RESIN PRODUCTION AND COOKING
EQUIPMENT SELECTION
PIGMENT GRINDING OR MILLING
ROLLER MILLS
BALL AND PEBBLE MILLS
ATTRITORS
SAND MILLS
HIGH-SPEED STONE AND COLLOID MILLS
HIGH-SPEED DISK DISPERSERS
HIGH-SPEED IMPINGEMENT MILLS
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
FILTER PRESS
STORAGE VESSELS
PLANT LAYOUT
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)
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