Detailed Project Report on paint manufacturing

PAINT MANUFACTURING
[CODE NO.3765]  


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.


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.



Type of oil                       Oil content %           Phthalic anhydride


Short                        35-45                        More than 73%
Medium                       46-55                        30-35
Long                         56-70                        20-30
Very Long                    71 up                        less than 20


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            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%                


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 – 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)