Project Report On Production and Operations Of "Paint"

Treating Wastages

 A recent regulation concerning the emission (release) of volatile organic
compounds (VOCs) affects the paint industry, especially manufacturers of
industrial oil-based paints. It is estimated that all coatings, including stains
and varnishes, are responsible for 1.8 percent of the 2.3 million metric tons
of VOCs released per year.

 A manufacturer has an in-house wastewater treatment facility that treats all
liquids generated on-site, even storm water run-off. The facility is monitored
24 hours a day, and the Environmental Protection Agency (EPA) does
periodic records and systems check of all paint facilities. The liquid portion
of the waste is treated on-site to the standards of the local publicly owned
wastewater treatment facility; it can be used to make low-quality paint. Latex
sludge can be retrieved and used as fillers in other industrial products. Waste
solvents can be recovered and used as fuels for other industries. A clean
paint container can be reused or sent to the local landfill.

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OUTPUT

Types of products:

Alpha Paints Pvt. Ltd. produces three types of paints, which can be presented in
the below diagram.

Oil paint Water Powder
based Paint
paint

Types
of

paints

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1) Oil Paint:

 This type of paint is most often used to paint the outside of the house
because it dries very hard and withstands harsh weather conditions for a long
time. Sometimes people may use oil-based paint indoors in areas that have a
lot of moisture such as in kitchens and bathrooms.

 The solids in the oil-based paint are kept suspended by a number of
chemicals that are organic solvents. The solvents commonly used in oil-
based paints include mineral spirits (naphtha), toluene, xylene, and other
petroleum distillate solvents. Oil-based paints are sometimes called Alkyd
paints. "Alkyd" refers to the resin type that is used in the paint.

 Advantages of Oil-based Paints

a) Attractive surface shine.

b) Good "leveling" (brush strokes fill themselves in to create a smooth
finish)

c) Hard, durable finish

The majority of wall paint sold today is water-based, but oil-based paint
remains popular for glossy woodwork, doors, and furniture, as well as
demanding surfaces such as floors.

What health and safety precautions do you need to think about with oil
based paint?

Oil-based paint contains organic solvents that can be irritating to eyes and skin,
and can cause cracking of skin. Inhaling paint fumes can result in headaches,
nausea, dizziness, and make you very tired (fatigued) if you breathe in the
fumes for too long without good air circulation. Most of these symptoms will go
away if you remove yourself from the area being painted into fresh air. Let an
adult know if you continue not to feel well. If you are exposed to the chemicals
in these types of products often you may experience other longer term problems
such as kidney, liver or blood effects. Breathing in paint fumes from cans of
spray paint on purpose is a very bad idea. It can lead to non-reversible brain
damage and death even after the first time.

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2) Water based paint:

Water-based paints are formulated with resins which have a different chemical
composition than those used in conventional (solvent-based) paint.

Water-based paints are water thinned. These paints are often selected because
clean-up can be done with soap water. These paints are also durable, easy to
apply and retain color well with time. These paints also emit low amounts of
Volatile Organic Compounds (VOCs), which is good for the environment.

The consequence of this is that water-based paints last longer, look better and
save money in the long term.

 The major qualities which have made water-based paints so popular are:

1) Easy Application: They brush or roll on very easily.

2) Easy Clean Up: Simply clean equipment in water.

3) Quick Drying: Touch dry in 30 minutes and usually recoatable in two
hours.

4) Flexibility: Water-based paints actually stretch and contract so that
normal climatic conditions affecting timber and other surfaces will not
crack the paint.

5) Water-based paints can also ‘breathe’ allowing water vapour out instead
of blistering. On the other hand, they won’t allow water in so the surface
remains waterproof.

6) A Choice of Finishes: Water-based paints are available in a wide range of
colours and several finishes ranging from flat to high gloss. Although the
gloss finish is not as full as oil-based enamel, the gloss level is retained
much better.

7) Water-based paints are water thinned. These paints are often selected
because clean-up can be done with soap water. These paints are also
durable, easy to apply and retain colour well with time. These paints also
emit low amounts of Volatile Organic Compounds (VOCs), which is
good for the environment.

Today’s water-based paints are available in primers, undercoats and finishing
coats for both exterior and interior use. Most surfaces, properly prepared, can be
painted with water-based paints, ie, brick, stone, fibro, masonry and timber.

Exterior water-based paints are mould resistant, have good adhesive qualities,
low odor and are color fast. In addition, they are non-yellowing and chalking is
almost non-existent.

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3) Powder paint:

Powder paints are dry paint formulations which are prepared by mixing them
with water shortly before application. They are used for both interior and
exterior applications.

Powder paints are one of the new developments in the paints sector and
currently only account for a small market share.
 Advantages of Powder Paints

They have a number of environmental and economical advantages such as
a. Free from solvents and preservatives
b. Reduced weight and packaging volume
c. Low-cost packaging
d. Stability against cold during storage.
e. An improved processing consistency.

Powder paint is a type of paint that is applied as a free-flowing, dry powder.
The main difference between a conventional liquid paint and powder paint is
that the powder paint does not require a solvent to keep the binder and filler
parts in a liquid suspension form.

It is usually used to create a hard finish that is tougher than conventional paint.

 Powder paint is mainly used for paint of metals, such as

i. Household

ii. Aluminum extrusions

iii. Drum hardware,

iv. Automobile and bicycle parts.

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Packaging:

After the paint has been manufactured, the next process comprises of packaging
of these paints. This packaging process is manual.

First of all the paint is fed in the company’s own tin cans of different volumes.
The cans are available for 1 liter, 5 liter and 10 liter.

Then, the cans are sealed with the caps with the help of machinery, which can
be seen in the above images.

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Storage:
After the packaging process the product is stored. For that there is a godown
reserved, inside the manufacturing plant for storing the finished goods. There
are two security guards are engaged for taking care of the finished goods.

This area covers 1/4th of the manufacturing plant.

There are two security guards engaged in taking care of the godown and the
finished products.

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CONCLUSION

“Experience is the comb which nature gives us when we are bald”
As the above quotation suggests that experience is the most effective, useful and
positive thing we learn slowly and gradually in our life.
The project on “Productions & Operations” has provided nice experience and
has been proved effective to us. The main objective of the project that is to
know the practicality of the production process is satisfied.
We have studied all the aspects of Alpha Paints Pvt. Ltd. and have learnt the
formation of production including the concepts of raw materials, machineries
used in company, manpower, manufacturing process, and final product,
throughout the whole project.

“One can get more knowledge by traveling, than reading of 100 books”
We have indeed realized the actual scenario of production and operations of
color, after visiting Alpha Paints Pvt. Ltd.
Finally, we may add up that the theoretical aspects which are taught to us, now
we have understood very nicely.

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BIBLIOGRAPHY

We have referred of the following books for the understanding of the concepts
of production.

 Management Principles By
P.C Tripathi & P.N Reddy
Publisher -Tata Mcgraw hill
Edition -4th

 Production and Operation Management
K. Aswathappa & K. Shridhara Bhatt
Publisher- Himalaya Publishing House

 Management
BY James A.F Stonner
R. Edward Freeman
Daniel R. Gilbert Jr
Publisher-Pearson
Edition-6th

WEBOGRAPHY

We have taken the use of following websites for the detailed information.

 http://www.essentialcolorindustry.org
 http://www.madehow.com
 http://manufacturing.stanford.edu

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