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DAYANANDA SAGAR COLLEGE OF ENGINEERING KUMARASWAMY LAYOUT, BENGALURU DEPARTMENT OF CHEMICAL ENGINEERING IN-PLANT TRAINING AT KANSAI NEROLAC PAINTS LIMITED , JAINPUR ON ANALYSIS OF LOSSES INVOLVED DURING PACKAGING OF PRODUCT & COMPARISON AND ANALYSIS OF EFFICIENCY OF DIFFERENT GRINDING MILLS PRESENTED BY: Karan Duseja 1DS12CH015 22-March-16 1

Nerolac paints internship

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Page 1: Nerolac paints internship

DAYANANDA SAGAR COLLEGE OF ENGINEERINGKUMARASWAMY LAYOUT, BENGALURU

DEPARTMENT OF CHEMICAL ENGINEERING

IN-PLANT TRAINING AT

KANSAI NEROLAC PAINTS LIMITED , JAINPUR

ONANALYSIS OF LOSSES INVOLVED DURING PACKAGING OF PRODUCT

&COMPARISON AND ANALYSIS OF EFFICIENCY OF DIFFERENT GRINDING MILLS

PRESENTED BY:Karan Duseja1DS12CH015

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COMPANY PROFILE

• It started it’s journey as Gahagan Paints and Varnish Co. Ltd. at Lower Parel in Mumbai.

• Then it grew popular as Goodlass Nerolac Paints (Pvt.) Ltd. Also, it went public and established itself as Goodlass Nerolac Paints Ltd.

• Goodlass Nerolac Paints Ltd. strengthened itself by entering in technical collaboration agreements with Kansai Paint Co. Ltd., Japan.

• On the 11th July2006, Goodlass Paints Ltd. name has been changed to Kansai Nerolac Paints Ltd.

• It is one of the top ten coating companies in the world.

• It is the second largest coating company in India and market leader in Industrial Coatings.

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PRODUCT LINE

• Enamel

• Gen Industrial

• HPC

• Cement Plus

• Emulsion

• Distemper

• Automotive

• Marine Paints

• Powder Coatings

ENAMEL

GEN IN

DUSTRIAL

HPC

CEMEN

T PLU

S

EMULSI

ON

DISTEM

PER

AUTOMOTIV

E

MARINE PAINTS

POWDER

COATINGS

05

101520253035404550

Product Share

%Product

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INTRODUCTION

• Paint is any liquid, liquefiable, or mastic composition which after application to a substrate in a thin layer is converted to an opaque solid film.

• Paint is used to protect, preserve, decorate, or add functionality to an object or surface by covering it with a pigmented coating.

• An example of protection is to retard corrosion of metal. An example of decoration is to add festive trim to a room's interior.

• Major Divisions :

• Industrial Paints - Major Supply to Automobiles companies

• Decorative Paints – Interior and exterior paint applications

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COMPOSITION OF PAINT

• Pigments :- Pigments provide the paint its color and finish. Apart from this , it also protect the surface underneath from corrosion and weathering as well as helping to hold the paint together

• Binders :- The binder exists to hold the pigment to the surface. It imparts adhesion and strongly influences properties such as gloss, durability, flexibility, and toughness. The binder is a polymeric substance, and is either dissolved in the paint or suspended in it by emulsifiers such as drying oils, alkyd resins, epoxy resins etc.

• Solvent :- A solvent is nothing more then a medium in which binder is soluble and the binder should not be so much soluble in solvent that it won’t polymerize. The main purposes of the diluent are to dissolve the polymer and adjust the viscosity of the paint. It is volatile and does not become part of the paint film. Eg-MTO(Mineral Turpentine Oil)

• Additives :- An additive is a compound which provides additional properties to the paint such as resistance to corrosion, heat, water etc. Eg- The titanium dioxide used in most paints today is often coated with silica/alumina/zirconium for various reasons, such as better exterior durability.

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EQUIPMENTS/MACHINES USED IN PAINT INDUSTRY

• Premixer :- In premixers raw materials are mixed in an early stage in the manufacturing and distribution process.

• Sand Mill :- Sand mill is used for grinding purposes and also for proper blending/mixing of pigments and solvent, raisin. Apart from paint industry, sand mill is also used in Inks, Pigments, Foodstuff, Dyestuffs, Cosmetic, Electric industry...etc. mid-viscosity liquid grinding.

• Ball Mill :- A ball mill is a type of grinder used to grind materials into extremely fine powder for use in mineral dressing processes, paints, pyrotechnics, ceramics and selective laser sintering.

• Cartridge Filtration :- Cartridge filtration is a type of sediments filters, which is to say it reduce the amount of sediments transported by the fluid trough filtration.

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FLOW SHEET OF PAINT PRODUCTION

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GRINDING

• Grinding is a method to reduce (something) to small particles or powder by crushing it by a Mill or Machine.

• Paint basically consists of two components: pigment and Binder. Pigment particles do not dissolve in the paint Binder, but are suspended in the liquid.

• Making paint simply means mixing a solid and liquid component together into a smooth paste.

• Although a powdered pigment may appear very fine, it is composed of aggregates of pigment particles.

• The aggregates clump together to form larger agglomerates and settle during storage in the paint Binder.

• Grinding breaks up agglomerates of pigment particles and evenly disperses them in the paint Binder, thereby wetting particle surfaces more thoroughly.

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COMPARISION BETWEEN DIFFERENT SAND MILLS

LME DYNO-AP10 IEC

Glycol is pumped with the pressure of Air.

Glycol is pumped with the pressure of Air.

Glycol is pumped with the pressure Created by pump.

Least Efficient Grinding Mill

Most Efficient Grinding Mill

More Efficient than LME and Less Efficient than Dyno

Shell Volume is about 60 Litres

Shell Volume is about 10 Litres

Shell Volume is about 30 Litres

Works on Lesser Flow Rate

Works on Greater Flow rate

Works on less flow rate than dyno but Greater Flow rate than Lme

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TESTS PERFORMED IN QUALITY CONTROL LAB

• HG :- A Hegman gauge, sometimes referred to as a grind gauge or grindometer, is a device used to determine how finely ground the particles of pigment (or other solid) dispersed in a sample of paint (or other liquid) are.

• ER :- ER means electrical resistance. It is useful in finding out the electrical resistance of paint. It is found out by help of millimeters and a ER measuring device.

• Viscosity Test :- Viscosity is perceived as ‘thickness’ or resistance to pouring, but there is more to viscosity than this. All fluids have an internal friction between molecules, which determines how well the fluid flows. Due to this internal friction, energy is required to move the liquid and the viscosity is the measure of the resistance to the flow

• Hardness test:- Hardness test is used to find out whether the paint is hard enough to resist all the scratches and dents and it does not get ripped off very easily if something sharp is applied and something blunt is pressed hard.

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PACKAGING OF PAINT

The action or process of filling of the paint in container so that they can be moved to the market and purchased by customers. 

There are Different machines Used for packaging

• Fully Automatic Machine

• Semi-Automatic Machine

• Manually Filling Machine

Placing of Containers on Conveyor

Filling of paint in Container to the Set volume

Placing and Pressing of lid on the Container to Air-tight the container

Printing Of MRP , Colour , Batch no. , Manufacture date, exp Date , etc

Placing Of Container in Cartoon Box

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DEFECTS IN PACKAGING

• Printing of shade name out of the shade window.

• Overlap printing of net weight, MRP, Batch no. , etc

• Inappropriate closing of cans.

• Dripping /Splashing of paint on Top/Side of container.

• Rusting and Leakage of cans passed without taken into notice

• Volume set In Machine Should be Exact (Excess or Less Give away should be Controlled)

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PAINT DEFECTS

• Sagging :- Incorrect spraying viscosity, spraying technique, flash-off times between coats, and film thickness.

• Solvent Popping :- Insufficient drying of primer filler in corners, edges, rebates and below decorative strips.

• Matting/Gloss :- Film thickness or air humidity too high or substrate too sensitive to solvents

• Poor Opacity :- Substrate not uniform (Effect finishes) or top coat film build too low or coating over thinned

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Basic Operation• Premixing of slurry• Grinding

Role of Engineers• Analysis of Quality

Safety• Fire extinguishers• No use of mobile phones n electronic devices

CONCLUSION

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LEARNINGS

• Manufacturing of paints

• Quality Analysis of product

• Packaging of product

• Safety Parameters

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Thank You

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