Detailed Project Report (DPR) on sanding sealer,lacquer, pu wood coating & varnish manufacturing with formulae

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