Detailed Project Report on paint production unit

PAINT PRODUCTION

[CODE NO.4130] 

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 pigmens 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.

The alkyd resins form the largest groups of synthetic resins available to the paint industry. Alkyd finishes in general shows good gloss and gloss retention. These resins are employed in stroving enamels quick drying paints, stoving coatings in conjunction with amino resins, marine paints etc.

Among the resins used, it has been found that 90% of alkyd produced are handled in one of these ways to produce some type of paints varnishes, or lacquer for industrial and home consumption. So the scheme is prepared mainly on the production of the modified alkyd resins though production of phenolic and meleic resins are also considered. Alkyd resins are classified according to the amount of oil and phthalic anhydride present in the alkyd.

Enamel paint is paint that air-dries to a hard, usually glossy, finish, used for coating surfaces that are outdoors or otherwise subject to hard wear or variations in temperature; it should not be confused with decorated objects in "painted enamel", where vitreous enamel is applied with brushes and fired in a kiln. The name is something of a misnomer, as in reality, most commercially available enamel paints are significantly softer than either vitreous enamel or stoved synthetic resins, and are totally different in composition; vitreous enamel is applied as a powder or paste and then fired at high temperature. There is no generally accepted definition or standard for use of the term enamel paint, and not all enamel-type paints may use it.

Typically the term "enamel paint" is used to describe oil-based covering products, usually with a significant amount of gloss in them, however recently many latex or water-based paints have adopted the term as well. The term today means "hard surfaced paint" and usually is in reference to paint brands of higher quality, floor coatings of a high gloss finish, or spray paints. Most enamel paints are alkyd resin based. Some enamel paints have been made by adding varnish to oil-based paint.

Although "enamels" and "painted enamel" in art normally refer to vitreous enamel, in the 20th century some artists used commercial enamel paints in art, including Pablo Picasso (mixing it with oil paint), Hermann-Paul, Jackson Pollock, and Sidney Nolan. The Trial (1947) is one of a number of works by Nolan to use enamel paint, usually Ripolin, a commercial paint not intended for art, also Picasso's usual brand. Some "enamel paints" are now produced specifically for artists.

The short oil alkyds are of two types:

1.   Non-drying type

2.   Drying types

The short oil non-drying alkyds contain, coconut, castor oil or similar saturated fatty acids. They are used as plasticizers in cellulose nitrate lacquers and baking enamels combine with amino resins. They find uses for very hard and tough finishes like automobiles refrigerators, washing, machines, home freezers and other metal finishing users.

The short oil drying alkyds contain tall oil, fatty acids like soybean, dehydrated castor and linseeds oils. Alkyds have utility in industrial backing finishes. They are also used as metal primers. Medium oil alkyds are the most versatile of the alkyds family. They have excellent gloss durability and flexibility. The medium oil alkyds find use in air drying of baking enamels, metal decorative coatings, machinery paints furniture finishes, metal primers and also in roller coating finishes.

Long oil alkyds find wide applications in structural steel finishes marine paints, interior and exterior architectural enamels and for oleo-resinous varnishes. Very long oil alkyds dry slowly but have good brushing properties and also durability.

Phenolic and maleic resins, are mainly modified with resins which is an important component in surface coating media. Principal uses for these resins include air drying industrial finishes, floor varnishes and also for hard gloss paint media.

Maleic resins excel in initial colour and colour stability to phenolic resins but inferior to phenolic resins in water alkali resistance.

COST ESTIMATION

Plant Capacity                           6 Ton/Day

Land & Building (4000 sq.mt.)  Rs. 1.87 Cr

Plant & Machinery                        Rs. 2.16 Cr

Working Capital for 1 Month    Rs. 3.23 Cr

Total Capital Investment             Rs. 7.43 Cr

Rate of Return                              29%

Break Even Point                          50%

• INTRODUCTION
  
• PROPERTIES
• CHEMICAL PROPERTIES
• COMPONENT IN PAINT MANUFACTURE
• USES AND CATEGORIES OF ENAMEL PAINT
• MARKET OVERVIEW OF PAINTS AND COATING IN AFRICA
• OVERVIEW OF GLOBAL PAINT AND COATING INDUSTRY
• COMPETITIVE LANDSCAPE
• GLOBAL MARKET
• ARCHITECTURAL (DECORATIVE) PAINTS
• INDUSTRIAL OEM COATINGS
• RAW MATERIALS
• TECHNOLOGICAL DETAILS FOR PAINT MANUFACTURING
• EMISSION SOURCES
• PRIMARY EMISSION REDUCTION MEASURES
• Technical Aspects
• PAINT MANUFACTURING PROCESS
• FORMULATIONS OF PAINTS
• Flat Black Baking Enamel
• White Enamel
• Formulation of Emulsion Paints
• SEQUENCES IN PAINT MANUFACTURE
• MAKING THE PASTE
• DISPERSING THE PIGMENT
• THINNING THE PASTE
• CANNING THE PAINT
• 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 OF LIME COLOUR AND DRY DISTEMPER
• LIME COLORS
• DRY DISTEMPER
• OIL BOUND DISTEMPER
• Glue or Casein Based Oil Bound Distemper:-
• Composition:-
• Plastic Wall Distemper Formula:-
• DETAILS OF ENAMEL PAINTS MANUFACTURE
• 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
• 1.  Oil type
• 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
• 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
• PREASSEMBLY AND PREMIX
• 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
• STORAGE LAYOUT
• EQUIPMENT LAYOUT
• SAFETY
• PLANT EXPANSION
• FLOOR SPACE
• UTILITIES SERVICING
• BUILDING
• MATERIAL-HANDLING EQUIPMENT
• RAILROADS AND ROADS
• PLANT LOCATION FACTORS
• 
  
• PRIMARY FACTORS
• 1.   Raw-material supply:
• 2.   Markets:
• 3.   Power And Fuel Supply:
• 4.   Water Supply:
• 5.   Climate:
• 6.   Transportation:
• 7.   Waste Disposal:
• 8.   Labor:
• 9.   Regulatory Laws:
• 10.  Taxes:
• 11.  Site Characteristics:
• 12.  Community Factors:
• 13.  Vulnerability To Wartime Attack:
• 14.  Flood And Fire Control:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF PLANT AND MACHINERY
• FILTER PRESS
• STORAGE VESSELS

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)