PRODUCTIONS & OPERATIONS OF COLOR

A PROJECT ONPRODUCTIONS AND OPERATIONSOFPAINT

Group Name: L

First Year B.B.A2014-2015

Submitted to:K.S. School of Business ManagementGujarat UniversityAhmedabad-380009

Project ProfileObjectivesProduction & Operation Management StudyTeam MembersProject Guide Yesha PatelAssistant Professor

Presentation Contents

IntroductionHistory of CompanyInputProcessOutputConclusionExit

Introduction:Legal requirementsTop 10 companies of industry

Legal requirements:Statutory Requirements

Regulatory Requirements:IdentityPhysical, chemical & biological propertiesChemical SpecificationsManufacturing process description

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Top 10 companies of industry:Asian PaintsKansai Nerolac Paints LtdBerger Paints India LimitedShalimar paintsJenson & Nicholson (I) LtdSnowcem PaintsBritish paintsSheenlacDulux PaintsNippon PaintsBack

History of Alpha Paints Pvt. Ltd.:

Nature and type: Paint manufacturing for industrial use

Year of establishment: Established in the year 1971 by the owners 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

Annual turnover: Rs 4crore

Working hours: 8:30 to 5:30

Input:LandMachineryFurniture & Office EquipmentsRaw MaterialsMan Power

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: Clerical office, Manufacturing plant & Storage sectionAdvantages of location:All the facilities such as, electricity supply, water supply, disposal facility of wastage etc. is good in this location.There are also complementary industries, which can fulfill the need of spare parts or any other supportive items.As it is reserved industrial area, the advantages provided by the state government can easily be taken.

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Machinery:Back

Ball Mill:

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.

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Bead Mill:

Thisbead millsare 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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Mixer:

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.

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Furniture & Office Equipments:Vehicles for transportation: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:Back

Pigment:

Apigmentis a material that changes thecolorof reflected or transmittedlightas the result ofwavelength-selective absorption. This physical process differs fromfluorescence,phosphorescence, and other forms ofluminescence, in which a material emits light.

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Binder: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.

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Solvent:

Asolventis a substance that dissolves a solute (a chemically different liquid, solid or gas), resulting in asolution. 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 withtemperature.

Common uses fororganicsolvents are indry cleaning, aspaint thinners, as nail polish removers and glue solvents, in spot removers, in detergents and inperfumes. Solvents find various applications in chemical,pharmaceutical, oil and gas industries, including in chemical syntheses and purification processes.

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Man Power:Detailed organization structureDescription of WorkNumber of employeesProcedure of recruitmentTraining and development of worker Working hoursPayment of salary Other facilities Motivation

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Process:Preassembly & PremixDispersing the pigmentThinningthe pasteQualityControl BlendingTintingTreatingWastages

Explanation

1) Preassembly & 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. At this stage, the particles 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 dispersion.Then it is sent to grinding operations.

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2) Dispersing the pigment:

This process occurs in three stages (i.e., wetting, grinding, and dispersion)

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.The goal of pigment grinding is to achieve fine, uniformly-ground, and smooth, round pigment particles which are permanently separated from other pigment particles.

Step 3

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3) Thinning the paste: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 and serviceable film that is easily applied to the surface.

The volume of the paint may increase significantly at this point depending on the final product specifications.

Step 4

4) 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.

Step 5

5) 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. Step 6

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6) Quality Control:

a) Examining Viscosity:

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.

b) Examining Consistency:

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.

Ford cupHegment gaugeStep 7

7) Treating Wastages: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. 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:ProductsPackagingStorage

Products:OilpaintWater basedpaintPowderpaintOutput

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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 companys 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.Finally, the sealed cans are kept in the boxes.

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Storage:Back

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.

Oil Paint:This type of paint is most often used to paint the outside of the house and indoors in areas that have a lot of moisture such as in kitchens and bathrooms because it dries very hard and resist harsh weather conditions for a long time.The solids in the oil-based paint are kept suspended by a number of chemicals that are organic 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:Attractive surface shine.Good "leveling" (brush strokes fill themselves in to create a smooth finish)Hard, durable finish

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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.

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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:Free from solvents and preservativesReduced weight and packaging volumeLow-cost packaging Stability against cold during storage. An improved processing consistency.

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Conclusion:Experience is the comb which nature gives us when we are bald

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.

Finally, we may add up that the theoretical aspects which are taught to us, now we have understood very nicely.

Thank You...