Project Report On Production and Operations Of "Paint"

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LEGAL REQUIREMENTS FOR COLOR INDUSTRY

 Statutory Requirements

Section 201(t) of the Act defines color additive to mean:

"a material which ... is a dye, pigment, or other substance made by a process
of synthesis or similar artifice, or extracted, isolated, or otherwise derived,
with or without intermediate or final change of identity, from a vegetable,
animal, mineral, or other source, and ... [that] when added or applied to a
food, drug, or cosmetic, or to the human body or any part thereof, is capable
(alone or through reaction with [an]other substance) of imparting color
thereto ... The term 'color' includes black, white, and intermediate grays..."

Food (section 402(c) of the Act), drugs and devices (section 501(a)(4) of the
Act), and cosmetics (section 601(e) of the Act) are deemed to be adulterated
if they contain a color additive that is unsafe within the meaning of section
721(a) of the Act.

Section 721(a) of the Act defines conditions under which a color additive is
deemed unsafe. Briefly, a color additive used in or on a food, drug, cosmetic
or medical device shall be deemed unsafe unless (1) there is a regulation
listing such color additive, (2) the regulation allows that particular use, and
(3) the color additive and its use conform to the regulation. A color additive
for use in or on a device shall be subject to this section only if the color
additive comes in direct contact with the body of man or other animal for a
significant period of time.

Coal-tar hair dyes are cosmetic products that have a limited exemption,
under section 601(a) of the Act, from the color additive regulation
requirements (section 721(a) of the Act). Coal-tar dyes are organic dyes
formerly synthesized from coal tar but now synthesized from petroleum or
coal sources. Coal-tar dyes used for coloring the hair are not required to be
pre-approved by the FDA. Under section 601(a) of the Act, hair coloring
products containing unapproved coal-tar dyes are not considered to be
adulterated if the products bear a specified caution statement and adequate
directions for a preliminary patch test. Section 601(a) of the Act also
stipulates that the term "hair dye" does not include eyelash or eyebrow dyes.
Currently no color additives are approved for use in dyeing the eyelashes or
eyebrows.

Section 721(b) of the Act describes the statutory requirements for the listing
of color additives. Briefly, when the FDA evaluates safety data, there are
four general areas of consideration.

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 Regulatory Requirements

The chemical and technological data that are appropriate for the evaluation
of a color additive petition are described in 21 CFR 71.1(c) sections A., B.,
C., E., F., and G. as discussed below. The data must be submitted in the
manner described in 21 CFR 71.1(f). Sections D., H., I., and J. are not
covered by these recommendations.

 Identity

The petition must include the name and all pertinent information concerning
the color additive, including chemical identity and composition and a
description of the chemical and physical tests relied upon to identify the
color additive. (21 CFR 71.1(c) A.)

Information identifying the proposed color additive should be as complete
as possible and generally includes (as appropriate):

a) The common or usual name of the color additive.
b) Formal names, such as Chemical Abstracts Service (CAS) or IUPAC

names, of the components that significantly contribute to the color
imparted by the color additive. Colored substances that are not included
in the identity may be considered impurities for which specifications may
be proposed as described in the Chemical Specifications section.
c) Synonyms, other common names, or trade names for the color additive.
d) Chemical formulae, structures, and molecular weights for all color
components included in the identity.
e) CAS Registry Numbers of the color additive and of color components
included in the identity, if available. CAS Registry Numbers for new
compounds may be obtained from CAS upon written request.
f) For a color additive derived from plant or animal sources, a complete
description of its source -- i.e., segment of plant or animal, common
name, genus, and species, and any subclassification.
g) Descriptions of chemical, physical, and biological tests and the resulting
data that establish the identity of the color additive (for example, NMR
and mass spectra, elemental analysis, photograph of biological source).
h) If the petition includes the use of lakes of a color additive, a description
of the color additive lakes should be included (see 21 CFR 74.340(a)(3),
74.1340(a)(3), and 74.2340(a)(2) for examples). The description should
include the identity (including composition) of the substrata and the
precipitant, as well as the anticipated range of total color incorporated in
the lakes. Under current listings, (1) lakes that are certified for use in
coloring food, drugs, and cosmetics may contain only alumina as a
substratum and only aluminum or calcium as lake cations.

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 Physical, Chemical, and Biological Properties

The petition must include information on physical, chemical, and biological
properties. (21 CFR 71.1(c) A.)

Information on the properties of representative batches of the proposed
color additive and, if available, of the main color component (s) generally
includes (as appropriate):

i. Physical properties -- A complete physical description such as physical
appearance, melting and boiling range (where applicable), solubility in
various common solvents, odor, etc.

ii. Chemical and spectrometric properties -- A description of the (1)
chemical properties of the color additive, such as the effects of air, water,
light, acid, base, and temperature and (2) spectrometric properties of the
color additive such as ultraviolet/visible spectra (in appropriate solvents
and pH). The infrared, NMR, or mass spectra of certain color additives
may be appropriate.

iii. If the particle size is important for the color additive to achieve its
intended technical effect, such that the color additive is produced or
processed using techniques or tools that manipulate the particle size and
may contain altered particles that are formed as manufacturing by-
products, data on the size (average and distribution), shape, surface area
(average and distribution), surface charge (zeta potential), and
morphology of the particles, as well as any other size-dependent
properties (e.g., agglomeration, aggregation, dispersion) should be
included, as appropriate.

 Chemical Specifications

The petition must include specifications prescribing the color additive
component(s) and identifying and limiting the reaction byproducts and other
impurities. (21 CFR 71.1(c) A.)

Recommendations concerning chemical specifications for the proposed
color additive are as follows:

A. The petitioner should propose chemical specifications that, together with the
identity, define the article of commerce and reflect the composition of the
proposed color additive. The petitioner should unambiguously identify any
individually specified component (e.g., using the common or usual name,
IUPAC or CAS name, and CAS Registry Number, where possible).
Proposed chemical specifications should closely reflect the composition of
representative batches of color additive used in performing the safety tests
for the color additive. Justification is generally needed if a proposed
specification greatly differs from the amount of that component found in
representative batches. Separate specifications should be included for any

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lake(s). Examples of chemical specifications for listed color additives are
available in existing regulations in 21 CFR Parts 73, 74, and 82. Chemical
specifications generally consist of the following aspects of color additive
composition (as appropriate):

1) Volatile matter (specify conditions, maximum percentage).
2) Soluble, extractable or insoluble matter (specify solvent or conditions,

percentage).
3) Residual salts (identity, maximum percentage).
4) Soluble impurity (identity, specify solvent or conditions, maximum

mg/kg (ppm)).
5) Unreacted intermediates and related compounds (identity, maximum

percentage, mg/kg (ppm) or μg/kg (ppb)).
6) Subsidiary colors (identity, maximum percentage) (subsidiary colors

are colored substances that are not included in the identity of the color
additive but are structurally similar to the main color component(s)).
7) Individual components that are included in the identity of the color
additive (identity, minimum or maximum percentage).
8) Pesticide residues (maximum mg/kg (ppm)).
9) Solvent residues (identity, maximum percentage or mg/kg (ppm)).
10) Ash (maximum percentage).
11) Heavy metals (identity, maximum mg/kg (ppm)).
12) Total color content (assay, minimum percentage). This may
include contributions from the identified color components and
subsidiary colors.
13) Parameters related to the particle size, shape, and surface properties
of the color additive, as appropriate, if particle size is important for the
identity and functionality of the color additive.
B. The petitioner should submit analyses for several batches of the proposed
color additive manufactured according to the process(es) included in the
petition to demonstrate conformance with and suitability of specifications.
Analyses of five or more batches, including batches used for safety testing,
are recommended unless the petitioner provides a valid justification for a
different sampling scheme. The analytical methods used should be those
provided by the petitioner as discussed below.
C. The petitioner should consider that impurities of specific toxicological
concern (e.g. chemical carcinogens) may be present in the proposed color
additive. The petitioner should review the manufacturing process, the
chemical literature on the proposed color additive and related compounds,
and the specifications of listed related color additives. If carcinogens (e.g.
unsulfonated aromatic amines such as 4-aminobiphenyl, aniline, and
benzidine), compounds that may degrade to carcinogens (e.g. 1,3-
diphenyltriazene), or compounds that may be metabolized to carcinogens.

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 Manufacturing Process Description

The petition must include a full description of the methods used in, and the
facilities and controls used for, the production of the color additive. These
shall establish that it is a substance of reproducible composition. Alternative
methods and controls and variations in methods and controls, within
reasonable limits, that do not affect the characteristics of the substance or
the reliability of the controls may be specified.

The petition shall supply a list of all substances used in the synthesis,
extraction, or other method of preparation of any straight color, regardless
of whether they undergo chemical change in the process. Each substance
should be identified by its common or usual name and its complete
chemical name, using structural formulas when necessary for specific
identification. If any proprietary preparation is used as a component, the
proprietary name should be followed by a complete quantitative statement
of composition. Reasonable alternatives for any listed substance may be
specified.

If the petitioner does not himself perform all the manufacturing, processing,
and packing operations for a color additive, the petitioner shall identify each
person who will perform a part of such operations and designate the part (21
CFR 71.1(c) A.).

Recommendations concerning manufacturing process descriptions for
petitioned color additives are as follows:

A description of the manufacturing process generally includes (as
appropriate) conditions for reactions (reagents and how they are combined
and mixed, temperature, time, solvent, pH, atmosphere) and for
concentration, isolation, and purification of intermediate and final products.
The production controls that are employed to assure purity, conformance
with specifications, and uniformity of product (such as specifications,
source, and purity of reagents; assay, analyses, chromatography, spectra,
and other tests of reagents, reaction mixtures, and products) should be
described. If the color additive is manufactured by extraction from plant or
animal sources, a complete description of all conditions including solvents
employed, processing aids, and processes for removing residual solvents
should be submitted. If the color additive is produced by tissue, bacterial or
yeast culture, or fermentation, an analogous description of the
manufacturing process and controls should be submitted. These descriptions
should show that the manufacturing process and controls yield a product of
specific identity.

Alternative manufacturing methods not employed by the petitioner but
known to the petitioner should also be identified.

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TOP 10 COLOR COMPANIES OF INDUSTRY

1 | Asian Paints

Corporate office - Mumbai, Maharashtra | Establishment – 1942 |
Business – Paint & Chemicals | Website - www.asianpaints.com|
Asian Paints is a leading industrial paint and decorative paint manufacturing
company based in Mumbai and has 24 paint manufacturing plants operating in
17 countries. The Decorative paint products include exterior wall finishes,
interior wall & wood finishes and enamels. Asian Paints has always been a front
runner in introducing new ideas like Kids’ World, Color Worlds, Color Next
and Home Solutions.

Since its foundation in 1942, Asian Paints has come a long way to become
India’s largest and Asia’s third largest paint company, with a turnover of Rs.
127.15 billion. Asian Paints operates in 17 countries and has 23 paint
manufacturing facilities in the world servicing consumers in over 65 countries.
Asian Paints has always been a leader in the paint industry, pushing new
concepts in India like Colour Worlds, Home Solutions, Colour Next, and Kids’
World.

Vision

“Clear goals for a clear future”
Asian Paints aims to become one of the top five decorative coatings companies
world-wide by leveraging its expertise in the higher growth emerging markets.
Simultaneously, the company intends to build long term value in the industrial
coatings business through alliances with established global partners.

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2 | Kansai Nerolac Paints Ltd

Corporate office - Mumbai, Maharashtra | Establishment – 1920 |

Business – Paint | Website - www.nerolac.com |

Among the top paint companies in India, Kansai Nerolac Paints Ltd is a

subsidiary of Kansai nerolac paints, JAPAN which was established in the year

1920. Nerolac Paints manufactures a wide range of paints for decorative and

industrial use and is the second largest coating company in India.

Vision, Values and Culture
1) Responsive
2) Innovation
3) Team Orientation
4) Entrepreneurial
5) Simplicity

These are the values that form the foundation of our business and provide the
blueprint that sets us in the right direction, each time.
In today's dynamic business environment, no organization can afford to
survive without a thoughtful vision, a dynamic set of guidelines and the ability
to leverage global technology, as and when needed.

CORPORATE SOCIAL RESPONSIBILITY

The bigger an organization becomes, the bigger is its responsibility to society.
That's what Nerolac firmly believes and following this, we have involved
ourselves with innumerable ventures over the years.

Actively involving ourselves in the rehabilitation of Tsunami victims,
organizing contests and celebrations for the children of BMC workers and
painting Mumbai to make it a brighter place to live in, these are just some of
the ventures we believe in and have associated with so far. We also partner
with NGOs in social outreach programmes spanning the areas of healthcare,
education, conservation and community development.

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3 |Berger Paints India Limited

Corporate office - Kolkata, West Bengal | Establishment – 1923 |

Business – Paint | Website - www.bergerpaints.com |

Berger Paints is the fastest growing paint company headquartered in Kolkata.

It is the second best paint company in India which has a global presence.

Berger is the only supplier of protective coatings to nuclear power plants and

has completed many prestigious projects which includes Cognizant, Chennai;

Hotel Le Meridien, Delhi; Teen Kanya, Kolkata; Akshardham Temple, Delhi

and more.

Vision
To be the most admired Indian paint and coating solutions company with
globally recognised competencies.

Mission
To maximise shareholder value by developing and delivering innovative and
best solutions for our customers, consistently outperforming our peers and
providing a dynamic and challenging work environment for our employees.

"Innovation, customer-focus, contemporary and responsible products"
The driving forces of Berger Paints - reflect the very spirit of its founder Lewis
Berger - who laid the foundations of brand Berger way back in 1760 in the
UK. With modest beginnings in India in 1923, today, Berger Paints India
Limited is the second largest paint company in the country with a consistent
track record of being one of the fastest growing paint company, quarter on
quarter, for the past few years.

Undergoing a number of changes in ownership and nomenclature in its 88 year
old history in India, the company has come a long way. Starting out as
Hadfield's (India) Limited, it had just one factory in Howrah, West Bengal. By
the close of 1947, Hadfield's was acquired by British Paints (Holdings)
Limited, UK and came to be known as British Paints (India) Limited. In 1983,
the name of the Company was changed to Berger Paints India Limited.
Currently, the majority stake is with the Delhi based Dhingra brothers. Berger
Paints has established itself through a long course of time.

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4 |Shalimar paints

Corporate office - Mumbai, Maharashtra | Establishment – 1902 |

Business – Paint | Website - www.shalimarpaints.com |

Incorporated in 1902, Shalimar paints is having three manufacturing units and

more than 54 branches and depots accross the country. The Company is
engaged in architectural, decorative and industrial segments. Company’s

landmark projects includes Rashtrapati Bhavan Delhi, saltLake stadium

Kolkata, vidyasagar setu Kolkata, Malankara Orthodox Church, Kerala etc.

With a heritage of 112 years, Shalimar Paints is India’s iconic paint-maker.
Established in 1902, the country’s oldest paint company is a pioneer in the field

of paints and coatings.

At Shalimar Paints, ‘Art & Science’ co-exist in perfect harmony to create
superior quality durable paints. Shalimar Paints have perfected this art of
blending aesthetics and chemistry over the last 112 years, to give beautiful, rich
finishes in every imaginable shade with its roots firmly based on performance.
From the mining of best quality pigments to packaging and sealing of cans,
Shalimar’s inventive DNA of Art & Science, empowers every drop of paint,
ensuring that it is handcrafted with precision and care to provide the best of both
the worlds, in equal measure - beauty and innovation, brilliance and protection,
craft and technique.
In tune with this legacy, and to make The Art & Science of Paints work for you,
desirous minds at Shalimar are constantly striving to create superior quality
paints that don't just protect surfaces, but also transform everyday objects into
works of enduring beauty.

R&D

Shalimar Paints believes in paint innovations that protect infrastructure and
assets, and enrich consumers' home lives. The company pioneered industrial
coatings technology in India with several industry firsts such as high build zinc
coatings, radiation resistant coatings for nuclear power plants, polyurethane
paint for fighter aircraft and railway coaches, among others.

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5 | Jenson & Nicholson (I) Ltd

Corporate office - Gurgaon, Haryana | Establishment – 1922 |

Business – Paint | Website - www.jnpaints.com |

Second oldest and among the top paint companies in India J&N was launched in

India in 1973. Jenson and Nicholson has successfully completed many

renowned projects including Birla Mandir, Birla Museum Bhopal, Common

Wealth Games Village Delhi, St. Pauls Seminary Shillong and many more.

Incorporated in 1922, Jenson & Nicholson (I) Ltd., or J&N as it is popularly
known, is India’s second oldest paint company. Roots trace back to a business

established in 1821 in London, which eventually became a partnership between

John Jenson and Wilfred Nicholson. In 1973, Jenson & Nicholson (I) Ltd.

emerged as an independent company and is a major player in the Indian market.

J&N pioneering efforts have been providing consumers, trade, and professionals
with world class products using the latest technology and have introduced path
breaking concepts to the Indian paint industry. Its innovations in products,
delivery, and concepts have set major trends followed by the industry.

In 1955, it launched India’s first plastic emulsion paint under the brand

Robbialac. It ventured into the powder coatings market in 1986, becoming the

first company in the organized sector to offer this durable and environment

friendly coating technology.

In 1996, unfazed by industry skepticism, J&N introduced InstaColor in-shop
tinting system. For the first time the Indian customer had the possibility to select
among 5000+ shades instantaneously and create his/her own shade. The concept

has revolutionized the industry.

The culture to seek out and implement concepts that create and deliver value
encompasses all processes of the company. J&N had an in-house developed
email system and was networked with all branches and factories well before the
internet came to being. Recognizing the importance of the partnership with the
distribution channel, J&N was the first paint company to start international
dealer trip schemes. It’s oft repeated and mimicked advertising slogan –
“Whenever you see colour, think of us” created a paradigm

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6 |Snowcem Paints

Corporate office - Mumbai, Maharashtra | Establishment – 1959 |

Business – Paint | Website - |www.snowcempaints.com|

Established in the year 1959, Snowcem Paints is a leading manufacturer of

cement paints, textured paints, primers, liquid paints, surface preparation

products and construction admixture.

Snowcem is a generic name today, has been the first choice for consumers and
painters for over 50 years. This internationally renowned brand launched in
Mumbai in 1959 in collaboration with George Lillington (UK), making high
quality cement paints meeting the specific needs of the vast majority of
Indians.Snowcem paints consistently deliver on their promise of long lasting
protection combined with beauty, season after season.

Always standing for higher value, Snowcem has emerged as the most trusted
brand over time.
With our high performing quality paints, Less is always more than enough!

Research & Development

Research and Development Center plays an important role in innovating and

developing new products.Product up-gradations and applications of new

technology are some of the important activities undertaken here.Our strong team
of qualified technologists & scientists support the company’s business plan and

marketing needs.

Our R&D laboratories are fully equipped with state-of-the-art scientific
instruments, sophisticated testing and analytical instruments, color matching
softwares, automatic dispensing machines, accelerated weathering equipment
for developing, standardizing and testing our products.
Apart from this, R&D extends valuable support to other functions like
manufacturing, sourcing in terms of process standardizations, product trainings,
raw material efficacy amongst many.

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7 |British paints

Corporate office - New Delhi | Establishment – 1947 |

Business – Paint | Website - www.britishpaints.in |

Internationally recognized brand British Paints stepped in India in 1947.

British Paints a SBU of Berger Paints India Ltd. is based in New Delhi. Their

varied product range includes decorative paints, industrial coating,

waterproofing and wall putty.

British Paint’s advent in India dates back to 1947, though its genesis was in
1919 in Britain. As a Paint Manufacturer we gained huge popularity in India
due to our wide and vivid range of industrial and architectural coatings, post
which we were renamed Berger Paints in 1983.

The initial brand name was however, reintroduced as an SBU of Berger Paints
India Limited in 2009. Headquartered in Delhi, we have served varied project
verticals both in the industrial and retail sectors. With 45 branch offices and
12000 channel partners spread over the length and breadth of the country,
British Paints offers a wide palette of decorative and generic industrial paints
and coatings, manufactured at dedicated units located in Uttar Pradesh and
Jammu & Kashmir.

Ranging from decorative paints like texture and enamel paints or
waterproofing solutions like Dr Seal-It, British Paints has a solution to all
home surface problems like wall care, maintenance and industrial solutions
like Epoxy Coatings too. Glo, Expa Cool, Shingar, British Master Blaster,
Acri-silk are a few of the many well known products of our brand. Backed by
a dedicated team of professionals with rich and valued experience, we bring to
its customers top notch coating solutions.

Besides being acknowledge as one of the leading paint companies in the
country, we are also known for our impeccable painting solutions provided to
businesses like Hospitals, Institutions, Corporates and the like. In fact, our
experts also provide painting guidelines and tips for beautiful home interiors
through our website. Essentially, quality products combined with expert
solutions has helped make British Paints, the most preferred brand in the Paint
Industry.

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8 | Sheenlac

Corporate office - Chennai, Tamil Nadu | Establishment – 1962 |

Business – Paint | Website - site.sheenlac.in |

Founded by Mr. John Peter in 1962 Sheenlac Paints has diversified range of

products which includes wood finishes, auto finishes, industrial finishes and

decorative finishes.

The R&D department gives training to sales staff since the products involved
require application knowledge. Apart from detailed induction programs, there
is a criterion of minimum number of training programs that a sales person
needs to undergo to get job promotions.
R&D also offers training to Polishers & Dealers periodically whenever a new
product is introduced. A case in point was the launch of specialty wood
coatings. When a new product like water-based coatings was introduced,
elaborate training was offered to help polishers understand & appreciate the
concept. A new initiative to sustain this external training is the creation of a
new cadre in the sales force called TSO, ie Technical Sales Officers. These
officers who were once Sales Officers are now being groomed to offer support
on the field to such R&D initiatives.

Interior painting is one of the few home improvement projects that can
instantly transform a space. simply adding a coat of fresh paint you can turn a
distressed space into a clean and consistent finish or even turn a dark dreary
space into a lively and bright one. Further more, by using a fresh coat of high-
quality interior paint you are making your surfaces easier to wash and more
abrasion-resistant.

Several things should be taken into consideration before painting the interior
of your home. You need to select the proper interior paint for each room,
decide on what interior wall surface you want, figure out how much paint will
be needed, and make sure your home is ready for a professional painter to
perform the job. Of course We at the Sheenlac Paints can give it to you our
proffesional advice and guide you throgh the process and that's it all free of
charge. Last but not least, before the painting begin is to prepare the work area.
This requires to move all furniture away from walls and make sure to protect
furniture and other items with a cloth of some sort.

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9 | Dulux Paints

Corporate office - Gurgaon, Haryana | Establishment – 1932 |
Business – Paint, chemical and stratch.| Website - www.dulux.in|
Produced by AkzoNobel India, Dulux is one of the world’ top paint companies
manufacturing wide range of products for home, house painting, wall painting
etc.
Present in India for over 100 years and a significant player in the Paints
industry.Over the years, it witnessed sustained expansion, growth and
transformation. In 2008, AkzoNobel N.V. became owner of the entire equity
share capital of Imperial Chemical Industries Ltd., by virtue of which the
Company became a member of the AkzoNobel Group.

AkzoNobel India manufactures and markets paints, coatings and specialty
chemicals.

Dulux is its most popular brand of its Decorative coatings business while the
Performance Coatings business provides solutions to many industries and
sectors including automotive, consumer electronics, power, aviation, shipping
& leisure craft, construction, oil & gas, water & waste water, food &
beverages, etc.

Its chemicals business in India sells more than 30 products grouped under
organic peroxides, metal alkyls and Polymer additives to pharmaceutical
companies, polymer producers, composite & rubber industry. Every year we
try and introduce new products in India to further strengthen our position as an
innovative specialty chemicals company.

With employee strength of close to 1,800, AkzoNobel India has manufacturing
sites, offices and distribution network spread across the country.

All its five manufacturing facilities have an ISO 14001 certification for
environmental management system.Its commitment to Health, Safety,
Environment & Security (HSE&S) has been amongst the best in class globally,
with due care being taken to protect the people and the environment.

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10 | Nippon Paints

Corporate office - Japan | Establishment – 1881 |
Business – Paint
| Website - www.nipponpaint.com |

A leading player in the paint and coating industry Nippon has more than 100

years of experience in paint industry. Its innovative and eco-friendly product

range includes decorative paints, Marine coatings, Industrial coatings,

automotive coatings and fine chemicals.

Durable and weather-resistant, Nippon Paints' high quality finish enhances the
aesthetics of our structures, creating a vibrant and beautiful urban landscape
while providing protection for years to come.The role of Nippon Paint in
modern architecture is crucial. We respond to critical architectural needs with
advanced end-to-end coating solutions and provide comprehensive customer
service.

Nippon Paint's range of coatings for cement-based surfaces feature many
innovative qualities.Walkleen's line of acrylic coatings has anti-algae, anti-
fungi and anti-carbonation properties that make the paint extremely durable
and easy to apply.

Durasil is a product in silicone resin emulsion paint that provides excellent
durability in protecting exterior walls against the effects of water, pollutants
and chemical attacks while preserving the initial coated state.Super Matex
Emulsion is a cost-effective paint solution that provides lasting coats for
internal walls.

W300 Watershield is an invisible system used extensively on bricks and other
porous surfaces for waterproofing protection. It helps to retain the original
look of the surface, while effectively repelling water and moisture.Speedseal is
a water-based wall sealer system product that effectively cuts down plaster
surface curing time by up to 16 days and reduces plaster cracks and stains.
This significantly reduces occurrence of efflorescence.

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HISTORY

 Name of the firm: Alpha Paints Pvt. Ltd.
 Nature and type: Paint manufacturing for industrial use
 Owner of the firm: Bhaumik B Shah
 Partners: It is a partnership firm and the partners are owner’s

mother and wife.
 Year of establishment: Established in the year 1971 by the

owner’s father
 Investment: They found investment from personal resources
 Motto and goal: To increase the profit and value in the market.
 Mission: Mission is to manufacture paints that are used in

industries which prevents corrosion of metals
 Administrative office: GIDC estate, Odhav, Ahmedabad
 Factory name: Alpha paints
 Main head office: GIDC estate, Odhav Ahmedabad
 Annual turnover: Rs 4crore
 Project margin: 1800 square meter

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 Branches:
No branches yet but it includes all the departments like production,
selling, administrative etc

 Product manufactured:
They are producing many types of paints such as ‘superlite’
industrial paints, ‘synthetic enemac’ in different colors

 Banker:
There is no banker and they have been using personal resources for
finance.

 Number of people working in the firm:
Around 8 to 10 workers are required in the company and they have
also hired 4 clerical employees.

 Area covered: The land area is around 1800sq,yards/meter

 Supervision method:
There are around 12 to 13 cctv cameras for direct supervision. The
owner has not recruited any supervisor because they are using
direct advanced supervision techniques.

 Weakness:
The weakness of the company is that it is not located in proper
market and customers seldom come into contact with the company.

 Working hours: 8:30 to 5:30

 Organization structure: The organization runs from top to
bottom.

 Competition: The competition for them is quite high. Page | 19

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LAND

 Location with details:
The head office and manufacturing plant of ‘Alpha Paints Pvt. Ltd. is
situated at- C1/9 GIDC Estate, Opp. Ambikanagar, Odhav, Ahmedabad,
Gujarat-382415.

 Land area covered in area:
The factory has covered 1800 square meters of the land.

 Division of land area:
The whole land area is divided into 3 sections
1. Clerical office
2. Manufacturing plant
3. Storage section

 Reason for location:
The main reason of the company to have plant in the above mentioned
location is to be benefited with the advantages of healthy completion and
to take the benefits provided by government as it is situated in the
industrial area.

 Advantages of location:
There are several advantages of having location in the Odhav, GIDC area
which are mentioned as under:
1. All the facilities such as, electricity supply, water supply, disposal
facility of wastage etc. is good in this location.
2. There are also complementary industries, which can fulfill the need
of spare parts or any other supportive items.
3. As it is reserved industrial area, the advantages provided by the
state government can easily be taken.

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MACHINERY

There are mainly three machines involved in manufacturing process, which are
presented in the diagram as under.

Mixer

Bead
Mill

Ball Mill

Number of machines:
There are total 20 machines installed in production house, which includes 5 Ball
Mills, 7 Bead Mills and 8 Blenders.

Capacity:

Each of the above mentioned machines have capacity of working up to 72-74
hours continuously.

Mobility:
All the machines are immovable as they are fixed at their particular places.

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Persons required for handling:

Each of the machine is required only one or two persons for handling and
operating.

Life expectancy:

The machines involved in manufacturing process have a long term life
expectancy of 8 to 10 years. So it is considerable that the depreciation cost and
maintenance cost of machinery is comparatively.

Installation:

All the machines are installed in a systematic and chronological order. So, there
are very less chances of wastage of time. Moreover, there is less material
handling cost. If there is any breakdown in any machine, it can be identified and
solved as quickly as possible.

Insurance:

The manufacturer has insurance for all the machines installed in his plant so that
the undesirable and unfortunate accidents can be faced.

Power:

In manufacturing plant all the machines are utilized by electric power. Though,
there is 24 hours electricity available in the manufacturing plant, there is also an
alternative source of generator is presented.

Water Consumption:

As earlier said that the machines require only electricity to be operated, there is
no use of water or say, very less use of water in utilizing the machines.

Environmental effects:

These machines are not producing any kind of harmful elements for
environment as well as for human beings. Thus, it can be said that all the
machines are eco-friendly.

Wastage:

The machines involved in manufacturing plant are of high quality and are
maintained very well that leads to minimum wastage.

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Ball Mill

Description

A ball mill, a type of grinder, is a cylindrical device used in grinding (or
mixing) materials like ores, chemicals, ceramic raw materials and paints. Ball
mills rotate around a horizontal axis, partially filled with the material to be
ground plus the grinding medium.

Different materials are used as media, including ceramic balls, flint pebbles
and stainless steel balls. An internal cascading effect reduces the material to a
fine powder. Industrial ball mills can operate continuously, fed at one end and
discharged at the other end. Large to medium-sized ball mills are mechanically
rotated on their axis, but small ones normally consist of a cylindrical capped
container that sits on two drive shafts (pulleys and belts are used to transmit
rotary motion). A rock tumbler functions on the same principle. Ball mills are
also used in pyrotechnics and the manufacture of black powder, but cannot be
used in the preparation of some pyrotechnic mixtures such as flash
powder because of their sensitivity to impact. High-quality ball mills are
potentially expensive and can grind mixture particles to as small as 5 nm,
enormously increasing surface area and reaction rates. The grinding works on
the principle of critical speed. The critical speed can be understood as that speed
after which the steel balls (which are responsible for the grinding of particles)
start rotating along the direction of the cylindrical device; thus causing no
further grinding.

Ball mills are used extensively in the mechanical alloying process in which they
are not only used for grinding but for cold welding as well, with the purpose of
producing alloys from powders.

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Principle

A ball mill works on the principle of impact: size reduction is done by impact as
the balls drop from near the top of the shell.

Construction

A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis
of the shell may be either horizontal or at a small angle to the horizontal. it is
partially filled with balls.

The grinding media is the balls, which may be made of steel (chrome steel),
stainless steel or rubber. The inner surface of the cylindrical shell is usually
lined with an abrasion-resistant material such as manganese steel or rubber.
Less wear takes place in rubber lined mills, such as the Sepro tyre drive
Grinding Mill. The length of the mill is approximately equal to its diameter.

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Working

In case of continuously operated ball mill, the ceramic balls are fed up to 1/3rd
portion of its volume.
As the shell rotates, the balls are lifted up on the rising side of the shell and then
they cascade down (or drop down on to the feed), from near the top of the shell.
In doing so, the solid particles in between the balls are ground and reduced in
size by impact.

Applications

The ball mill is used for grinding materials such as coal, pigments, and felspar
for pottery. Grinding can be carried out either wet or dry but the former is
carried at low speed.

Bench top ball mill Laboratory scale ball mill

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Lead antimony grinding media with aluminium powder

The ball mill is a key piece of equipment for grinding crushed materials, and it
is widely used in production lines for powders such as cement, silicates,
refractory material, fertilizer, glass ceramics, etc. as well as for ore dressing of
both ferrous and non-ferrous metals. The ball mill can grind various ores and
other materials either wet or dry. There are two kinds of ball mill, grate type and
overfall type due to different ways of discharging material. There are many
types of grinding media suitable for use in a ball mill, each material having its
own specific properties and advantages. Key properties of grinding media are
size, density, hardness, and composition.

 Size: The smaller the media particles, the smaller the particle size of the
final product. At the same time, the grinding media particles should be
substantially larger than the largest pieces of material to be ground.

 Density: The media should be denser than the material being ground. It
becomes a problem if the grinding media floats on top of the material to
be ground.

 Hardness: The grinding media needs to be durable enough to grind the
material, but where possible should not be so tough that it also wears
down the tumbler at a fast pace.

 Composition: Various grinding applications have special requirements.
Some of these requirements are based on the fact that some of the
grinding media will be in the finished product. Others are based in how
the media will react with the material being ground.

a) Where the color of the finished product is important, the color and
material of the grinding media must be considered.

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b) Where low contamination is important, the grinding media may be
selected for ease of separation from the finished product (i.e.: steel
dust produced from stainless steel media can be magnetically
separated from non-ferrous products). An alternative to separation
is to use media of the same material as the product being ground.

c) Flammable products have a tendency to become explosive in
powder form. Steel media may spark, becoming an ignition source
for these products. Either wet-grinding, or non-sparking media
such as ceramic or lead must be selected.

d) Some media, such as iron, may react with corrosive materials. For
this reason, stainless steel, ceramic, and flint grinding media may
each be used when corrosive substances are present during
grinding.

The grinding chamber can also be filled with an inert shield gas that does not
react with the material being ground, to prevent oxidation or explosive
reactions that could occur with ambient air inside the mill.

Advantages of the ball mill

Ball milling boasts several advantages over other systems: the cost of
installation, power and grinding medium is low; it is suitable for both batch
and continuous operation, similarly it is suitable for open as well as closed
circuit grinding and is applicable for materials of all degrees of hardness.

Varieties

Aside from common ball mills there is a second type of ball mill called
a planetary ball mill. Planetary ball mills are smaller than common ball mills
and mainly used in laboratories for grinding sample material down to very
small sizes. A planetary ball mill consists of at least one grinding jar which
is arranged eccentrically on a so-called sun wheel. The direction of
movement of the sun wheel is opposite to that of the grinding jars (ratio: 1:-2
or 1:-1 or else). The grinding balls in the grinding jars are subjected to
superimposed rotational movements, the so-called Coriolis forces. The
difference in speeds between the balls and grinding jars produces an
interaction between frictional and impact forces, which releases high
dynamic energies. The interplay between these forces produces the high and
very effective degree of size reduction of the planetary ball mill.

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Bead Mill

Description

Bead Mills are one of the many technologies used for grinding, lysing and
homogenization of laboratory samples. Bead Mills are typically used for
samples that are difficult to disrupt with standard mechanical laboratory
homogenizers. These sample types include tumor, heart, e-coli, yeast, bone,
skin, cartilage, spores, seeds and soil. Bead Mills can also be used to extract
nucleic acids and proteins and can be used with difficult to process cells such as
cyanobacteria, mycobacteria, and microalgae.

Bead Glasses

Bead Mills employ very small glass, ceramic or steel beads. These beads are
placed in a vessel along with the sample media. The vessel, beads and sample
are vigorously agitated by shaking or stirring. Disruption of the sample occurs
as the beads collide rapidly with the cells. A combination of the grinding beads
and rotational effect produces a faster, more reliably effective lysing process for
biological samples. Typically, a higher volume ratio of beads to cells produces a
faster rate of cell disruption. After the processing cycle is complete, the beads
settle by gravity in the vessel and the resulting homogenate is easily removed by
pipette.

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Bead Mills are relatively cross-contamination free because of the disposable

beads and sample tubes they employ. Most shaking-type Bead Mills are

restricted to sample sizes of 3.0mL or less. However, several samples can be

processed at a time. Heat generation can be a problem with Bead Mills, but
many of today’s Bead Mill units are available with optional cooling features and
accessories.

This bead mills are batch process machine for size reduction and dispersing of
paints, inks, coatings etc. The bead mills are widely used in labs for processing
of small daily batches. The bead mill consists of a grinding vessel inside which
rotates a shaft fitted with impeller disc. The grinding media and the charged
material are filled into the vessel and the shaft is run at a very high speed for a
particular time till dispersion is achieved. Vessel with jacket arrangements is
provided as a standard.

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Principle

The bead mill consists of a horizontal grinding chamber, which in turn
houses the shaft and agitator discs. The chamber is filled with zirconium
grinding media and the material leakage is prevented by the double
acting mechanical seal. The material is pumped into the chamber using a
air operated diaphragm pump or screw pump.

Working

The necessary energy for dispersion and grinding is transmitted to the
grinding beads by the agitator discs. The mill is fed continuously by the
pump. The time spent by the material inside the chamber is controlled by
variation of the pump speed.

The retention of the grinding beads inside the chamber is achieved by
means of a cartridge. With optimum utilization of the energy input into
the chamber for dispersion and grinding process, the efficiency of mill is
achieved.

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Construction

Grinding chamber: horizontal position with cooling jacket.
Agitator discs: Specially shaped agitator discs provide good energy input
and prevent packing of beads in one point. The discs are made of wear
resistance steel, Shape and no. of discs are determined according to
product to be processesed The grinding disks are arranged in such a way
to achieve intensive grinding, attached with firm lock fit on shaft and
braced via spacer bushings and end disk. Easily exchangeable.
Agitator shaft with easily exchangeable discs of special 2080 steel or SS
304 , shaft rpm 10-13m/s.

Shaft Seal

Shaft Seal: Double mechanical seal provided. Forced circulating of
sealing liquid is done by means of Thermosyphon system
Grinding beads: spherical grinding beads of different material. The
choice depends on the product to be processesed, filling volume is 80-
85% of chamber volume.
Process control: product pressure, product temperature , seal rinsing
liquid level, pump speed. Temperature control possible for heat sensitive
products

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Varieties

Model Chamber vol (l) Capacity Motor Weight -
L/hr HP Kg
MM 2 1.2 20-50 5 250
MM 5 5 80-100 10 400
MM 10 10 15 600
MM 25 25 180-240 30 900
MM 50 50 500-600
50 1300
900-1100

Bead mills are available in various sizes and configurations from the
Mickle shaker which has a maximum volume of about 40 ml to
continuous process equipment capable of handling up to 200 Kg wet
yeast or 20 Kg wet bacteria each hour. The bead mills that have been
studied in most detail are the Dyno-Mill and the Netsch-Molinex
agitator, both of which consist of a cylindrical vessel containing a motor-
driven central shaft equipped with impellers of different types. Both can
be operated continuously, being equipped with devices which retain the
beads within the milling chamber

.Advantages of the bead mill

Circulation Grinding is a cost-effective solution for grinding large
quantities of material as it allows for a lower cost capital investment in
equipment and grinding media than with many other grinding equipment
options.

Additional benefits of circulation grinding include a narrower particle
size distribution, the ability to continuously monitor the slurry, add
ingredients to the premix tank at any time during the grinding cycle and
control temperature more precisely since the slurry spends only 15-25
seconds in the grinding chamber.

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Mixer(Blender)

Description

Mixer or Blender is a machine which is used for mixing up the
ingredients or materials such as binder and solvent.
There is a small scale high speed mixer installed in manufacturing plant.

Working

Firstly, the prepared mixture of pigment is fed in mixer along with
solvent and binder. Then, the mixer is turned on and it just mixes up the
materials till they get mixed properly.

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FURNITURE & OFFICE EQUIPMENTS

 Vehicles-for transportation:

They are using those kinds of vehicles which can carry the weight of the
packaged boxes of various type of color. They are using 'Tempo’, as well as
‘Trucks’ for transportation.

 Number of vehicles:
They have not bought any of the vehicles for the transportation. They depend
on the local transportation services.

 Small, medium, large:
They use all the sizes of truck or tempo as per the requirement as well as
convenience.

 Owned, hired:-
They do not own any of the vehicles for the purpose of transportation. They
are using hired vehicles for the purpose of transportation of raw materials
and finished product.

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RAW MATERIALS

The materials which are used in manufacturing process, are presented in the
below diagram.

Pigment

Binder Solvent

Suppliers:

All the above mentioned raw materials are supplied by BPCL and Reliance Ltd.

Mode of payment:

Company purchases raw materials in both the ways, credit as well as cash
purchase. But the company does often prefer to purchase on credit base.

Frequency of purchase:

For manufacturing, the raw materials are purchased semi annually. For that they
apply EOQ method so that there would not be any kind of shortage of raw
materials and also would not excess of raw materials.

Unit of measurements:

As there are various raw materials involved in manufacturing process, their unit
of measurements also varies. The pigment is measured in terms of kilogram or
gram, and the liquids- binder and solvent are measured in terms of liter.

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Insurance:

The company has taken joint (combined) insurance for all the raw materials for
facing the problems such as, fire, pilferage, destroy due to any accident occur
etc.

Direct Materials:

All the above described materials- pigment, binder and solvent are utilized
directly for manufacturing color.

Indirect Materials:

There are indirect materials used along with the direct materials that are ceramic
balls and bead glasses used in ball mill and bead mill respectively and various
additives are also used as indirect materials.

Discount on bulk purchase:

As the company does prefer buying the raw materials semi annually, it
purchases in bulk. So, the discount is given by the supplier to the manufacturer
and the terms and conditions for discount are decided after negotiations.

Storage:

 Area:
The company has construcetd a specific area for storing the raw
materials. This storage division is built near by the manufacoring plant so
that the issuing of raw material can be made as easy as possible.

 Security:
To resist the problem of pilfrege, the company has taken care of security
system, too. For that it has appointed two security guards in the storage
godown.

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Pigment

Description

A pigment is a material that changes the color of reflected or transmitted light as
the result of wavelength-selective absorption. This physical process differs
from fluorescence, phosphorescence, and other forms of luminescence, in which
a material emits light.

Many materials selectively absorb certain wavelengths of light. Materials that
humans have chosen and developed for use as pigments usually have special
properties that make them ideal for coloring other materials. A pigment must
have a high tinting strength relative to the materials it colors. It must be stable in
solid form at ambient temperatures.

For industrial applications, as well as in the arts, permanence and stability are
desirable properties. Pigments that are not permanent are called fugitive.
Fugitive pigments fade over time, or with exposure to light, while some
eventually blacken.

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Uses of Pigment

Pigments are used for coloring paint, ink, plastic, fabric, cosmetics, food and
other materials. Most pigments used in manufacturing and the arts are
dry colorants, usually ground into a fine powder. This powder is added to
a binder (or vehicle), a relatively neutral or colorless material that suspends the
pigment and gives the paint its adhesion.

A distinction is usually made between a pigment, which is insoluble in its
vehicle (resulting in a suspension), and a dye, which either is itself a liquid or is
soluble in its vehicle (resulting in a solution). A colorant can act as either a
pigment or a dye depending on the vehicle involved. In some cases, a pigment
can be manufactured from a dye by precipitating a soluble dye with a metallic
salt. The resulting pigment is called a lake pigment. The term biological is used
for all colored substances independent of their solubility.

Types of Pigment

There are mainly two types of pigments:

1. Organic Pigments
2. Inorganic Pigments
Which are mentioned briefly as under…

A. Organic Pigments

1) Yellow
2) Orange
3) Red
4) Violet
5) Blue
6) Green

B. Inorganic Pigments

1) Aluminum Paste, Powder & Pellets
2) Anti-Corrosive
3) Bismuth Vanadate
4) Carbon Black
5) Chromium Oxide Green
6) Chrome Yellow & Moly Orange
7) Complex Inorganic Color Pigments
8) Lanox Iron Oxide & Zinc Ferrite
9) Milori & Ultramarine Blue

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Binder

Description

A Binder or Resin (such as Linseed oil) is what holds the pigment to a surface.
The binder exists to hold the pigment to the surface. The binder is a polymeric
substance, and is either dissolved in the paint or suspended in it by emulsifiers.
A good paint should consist of just paint and binder. Cheap paints contain fillers
to make the manufacturing of the paint cheaper. You can tell by the intensity of
the color whether filler has been used.
Linseed oil dries through the process of oxidation to a strong but flexible
film(coating).
It is the flexible quality of the oil film that allows for its use on canvas.
Cold pressed linseed oil is generally used in paint making though small
proportions of poppy and walnut oils are also used.

Varieties

1. Drying oils
They take a long time to dry and have variable properties as the balance of oils
varies from crop to crop.

2. Alkyd resins
Alkyd resins are the most common resins to be used in solvent-based paints.
They are basically polyesters and are used for both air-drying and heat-cured
paints.

3. Vinyl and acrylic emulsions
These are emulsions in water and are the most common water-based binders for
use in household paint.

4. Epoxy resins
These resins are based on polymers containing the simple organic compound
'oxirane' (ethylene oxide). A variety of other components are added to give a
wide range of properties.

5. Polyurethanes
Polyurethanes are polymers of any ester of carbamic acid, H2N—CO2H.
Polyurethane-based paints are tough, durable films that retain their gloss and are
easy to clean. They are often used for painting aircraft.

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Solvent

Description

A solvent is a substance that dissolves a solute (a chemically different liquid,
solid or gas), resulting in a solution. A solvent is usually a liquid but can also be
a solid or a gas. The quantity of solute that can dissolve in a specific volume of
solvent varies with temperature. Common uses for organic solvents are in dry
cleaning (e.g., tetrachloroethylene), as paint thinners (e.g., toluene, turpentine),
as nail polish removers and glue solvents (acetone, methyl acetate, ethyl
acetate), in spot removers (e.g., hexane, petrol ether), in detergents (citrus
terpenes) and in perfumes (ethanol). Solvents find various applications in
chemical, pharmaceutical, oil and gas industries, including in chemical
syntheses and purification processes.

Uses of Solvent

Solvents are necessary to ensure an even mixing of the paint components and to
make them easy to apply. The solvents used differ with the way in which the
paint will be applied as the drying rate required differs depending on the manner
of application, e.g. the solvents in spray X-Polymers-D-Paints and Pigments-18
Paints need to evaporate much more quickly than those in brush-applied paints.
In general, a blend of solvents is used to produce a paint that will surface and
through dry (i.e. dry throughout) at the correct rate without uneven shrinkage.

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Working

When one substance is dissolved into another, a solution is formed. This is
opposed to the situation when the compounds are insoluble like sand in water.
In a solution, all of the ingredients are uniformly distributed at a molecular level
and no residue remains. A solvent-solute mixture consists of a single phase with
all solute molecules occurring as solvates (solvent-solute complexes), as
opposed to separate continuous phases as in suspensions, emulsions and other
types of non-solution mixtures. The ability of one compound to be dissolved in
another is known as solubility; if this occurs in all proportions, it is
called miscibility.

In addition to mixing, the substances in a solution interact with each other at the
molecular level. When something is dissolved, molecules of the solvent arrange
around molecules of the solute. Heat transfer is involved and entropy is
increased making the solution more thermodynamically stable than the solute
and solvent separately. This arrangement is mediated by the respective chemical
properties of the solvent and solute, such as hydrogen bonding, dipole
moment and polarizability. Solvation does not cause a chemical reaction or
chemical configuration changes in the solute. However, solvation resembles
a coordination complex formation reaction, often with considerable energetics
(heat of solvation and entropy of solvation) and is thus far from a neutral
process.

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MAN POWER

 Detailed organization structure:

 There is flat organization. No delegation of authority is given to employees
to take any kind of decision on their own. Only one boss can give order to
his employees so that unity of command can be seen in this organization.

 Description of Work:

 There is not too much hard work is required in the production process as it is
done automatically through advance machines. Worker fills up the raw
material in the first machine. Then he gets out the output of one machine and
fills it in the next machine. And at last he is required to bring the finished
product. Though, there is no too much work for the workers, the quality of
finished product is much dependent on the accuracy paid by him.

 Number of employees:

 There are total twenty workers are involved in company. From which twelve
workers are involved in manufacturing unit and rest of the workers are
concerned with clerical department. All of them are not so much efficient
regarding to all the activities but, as there is specialization of working in the
organization, they are only concerned with the particular task or work which
is allocated to them.

 Procedure of recruitment:

 In the organization, the recruitment is done based on the technical skills of
workers rather than the educational qualifications. They are selected as per
their working knowledge. Generally, the organization does prefer the local
applicant for recruitment. Moreover, the internal factors of recruitment such
as the relatives or friends of the existing workers are given the first
opportunity for being selected. For that, the loyalty to the organization and
the time period served by existing employees are glimpsed.

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 Training and development of worker :

 The probation period for the workers is of 2-3 months longer. They are given
on the job training during the manufacturing process. In such training, the
workers are instructed by the wide experienced workers of the same
organization. In addition to that, the production made by the trainee is
calculated in real output. In training, as they do practice on the same
machineries which are used in manufacturing, they do not feel any kind of
fear during their job.

 Working hours :

 As the manufacturing process is go on for 24 hours a day, the working hours
are divided into two shifts, day and night. In day shift, the workers are
supposed to work from 8:00 at morning to 6:00 at noon and the hours of
working in night shift are from 8:00 at night to 6:00 at morning. The shifts
are changed according to weeks. The employees are given three breaks
during work for 20 minutes of each. It should be noted that, there is no
facility of canteen but there are food stalls available nearby the organization.

 Payment of salary :

 The workers are given monthly based salaries. The salary for the employees
of the clerical department is higher than the workers of manufacturing unit.
The salary is payed in cash. The employees are given 50% bonus of their
salary in Diwali. Moreover, the employees who do overtime are given extra
bonus as per the extra time they served for their work.

 Other facilities :

 If we look at the other facilities provided by the organization to its
employees, we find that there are several facilities such as, health insurance
policies of workers, counseling for acquiring the knowledge of new and
advanced technology and method, and picnics, which are arranged by
administrative department for all the employees, for one time in a year that is
in April. There are no facilities of hostels or staff quarters and also staff bus
facility is not provided by the enterprise.

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 Motivation :

 Generally, the company does motivate its employees by giving them the
non-financial rewards such as, the reward for best employee of the year. Not
only non-financial but company also gives financial rewards like, extra
bonus is given if the employee completes his task within the standard time,
and commission is payed to those employees who have achieved more than
the target. Moreover, in the organization, the promotion is based on the years
served by the employee for an organization.

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PROCESS

Flow chart:
The flow chart of whole manufacturing process is can be drawn as under.

Preassembly Dispersing the Pigment Thinning
and

Premix

Tinting Blending Quality Control

Treating
wastages

Preassembly and Premix

 The first step in the manufacturing process is preassembly and premix. In
this step, the liquid raw materials (e.g., resins, solvents, oils, alcohols, and/or
water) are "assembled" and mixed in containers to form a viscous material to
which pigments are added.

 The pigment and liquid mixture forms a thicker material, which is then sent
to the grinding operations. At this stage, the particles in the concentrate are
rather large (250 pm) and not consistently mixed. The premix stage results in
the formation of an intermediate product which is referred to as the base or
mill base.

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Dispersing the pigment

 The paste mixer produced in the first step is now routed in a ball mill. The
incorporation of the pigment into the paint to yield fine particle dispersion is
referred to as pigment grinding or milling.

 This process occurs in three stages (i.e., wetting, grinding, and dispersion)
which may overlap in any grinding operation. To wet the pigment particles,
the wetting agent, normally a surfactant, must displace all contaminants (e.g.
air, moisture, and gases) adsorbed on the surface of the pigment particles.
The wetting process actually begins in the premix step, when the pigment is
charged to the liquid vehicle.

 Grinding is the mechanical breakup and separation of the pigment particle
clusters into isolated primary particles. Dispersion is the movement of the
wetted particles into the body of the liquid vehicle to produce a permanent
particle separation.

 The goal of pigment grinding is to achieve fine, uniformly-ground, and
smooth, round pigment particles which are permanently separated from other
pigment particles. The degree to which this is realized determines the coating
effectiveness and permanency of the paint.

Thinning the paste

 Whether created by a ball mill, the paste must now be thinned to produce the

final product.
 Material letdown, or thinning, is the process by which a completed mill base

dispersion is let down or reduced with solvent and binder to give a coating
which is designed to provide a durable, serviceable film that is easily applied
to the substrate. The volume of the paint may increase significantly at this
point depending on the final product specifications.

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Tinting (Shading)

Tinting is the process of adjusting the color of completed mill base dispersions.
Normally, an operator will collect a sample of the paint or ink once it exits the
milling equipment. This sample will be taken to the laboratory and compared to
the desired color standard. Various combinations of pigments, solvents, resins,
and pastes are added to the material to meet the color requirements.
Blending (Mixing)

Blending operations occur once the necessary additions have been made to the
completed mill base dispersion. Blending is the process of incorporating the
additions into the material in order to meet the desired product specifications. In
the case of batch operations, blending may simply consist of additional milling
in a ball mill or added mixing and dispersing in a portable mix tank/high-speed
disperser set-up. In other cases, the mill base dispersion is transferred to fixed
agitated blend tanks or additional mix tank/disperser operations. In each case,
material adjustments for thinning and tinting are added through top openings,
agitated, and gravity fed or pumped out bottom or side spigots for filling
operations.

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Quality Control

 A finished paint is inspected for its density, fineness of grind, dispersion, and
viscosity. Paint is then applied to a surface and studied for bleed resistance,
rate of drying, and texture.

This process involves two steps:

1. Examining Viscosity:

 In this step the thickness of the paint is tested. For that, the equipment used
is called ‘Ford Cup’. For examining the viscosity, the ford cup is fed fully
with the paint. Then, the paint flows from the hole of ford cup. One
experienced observer notices the time limit of the flow of paint. If the paint
flows very quickly than, the paint is thin and it flows slowly than, the paint is
thick.

2. Examining Consistency:

 In this step, the consistency of paint is examined. For that, the tool used is
known as ‘Hegment Gauge’. To test the consistency, the examiner spreads
the paint on hegment gauge. Then, as per the requirement of paint
specifications he detects the steadiness or consistency of the paint.

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