Report on my Pre-final year Internship Program in Excel India Protective Paints Pvt Ltd

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By
Ankur Omprakash Pandey
Roll No. : 114CH0459
(III year B.Tech. in
Chemical Engineering,
NIT Rourkela)
A Report on the
8 weeks Internship Program in
Excel India Protective Paints

2. CONTENTS :
1. Introduction to Company
1.1. Company Profile
1.2. Safety and Health Policy Statement
1.3. Safety and Health Goals
2. Introduction to Paint
2.1. Definition and Applications
2.2. Components of Paint and their Purpose
2.2.1. Pigments
2.2.2. Resins/Binders
2.2.3. Solvents
2.2.4. Additives
3. Format of the Internship Program
3.1. Week 1: Orientaion
3.2. Week 2-Week 4: Raw Materials Testing Lab
3.3. Week 5-Week 6: R&D Lab
3.4. Week 6-Week 7: Quality Control Lab
3.5. Week 8: Production Plant
4. List of Lab Instruments in the R&D and QC Departments
5. Batch Production of Products
5.1. EXLThane 570 – Base – PU – Top Coat
5.2. EXLGUARD 247 Base Black
1. Introduction to Company
1.1. Company Profile:
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3.  One of the leading paint manufacturers in India producing
Paints/Coatings for corrosion protection in industrial and marine
environments
 Started as a backward integration and to provide complete coating
solution under one roof began its operations in 2006
 Company has got experienced and qualified paint technologists,
mainly from the ICT, having over 20 years of experience in the
coatings industry
 Factory is situated in the industrial zone at Badlapur on the
outskirts of Mumbai city
1.2. Safety & Health Policy Statement:
Excel India Protective Paints Pvt. Ltd. believes
“NO JOB OR TASK IS MORE IMPORTANT THAN EMPLOYEE’S
HEALTH AND SAFETY”.
1.3. Safety and Health Goals:
 Every employee is entitled to a safe and healthy place to work.
 To provide workers/trainee with a safe work environment.
 To provide Personal Protective Equipment.
 To develop and implement safe work procedures and rules.
 To enforce safety rules and appropriate discipline.
2. Introduction to Paint
2.1. Definition and Applications:
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4.  Any liquid or liquefiable composition that, after application to a
substrate in a thin layer, converts to a solid film.
 It is used to protect and/or color.
2.2. Components of Paint and their Purpose:
2.2.1. Pigments:
 Pigments are finely ground solids of different shades, which
give color, durability and consistency.
 They are the costliest out of all the ingredients and are of two
types: True pigments (2-5µ size) and Extenders (upto 10µ
size).
 Pigments can be of organic, inorganic or metallic nature.
2.2.2. Resins/Binders:
 They are the oils and resins that give protective properties.
 They have the function of binding pigments and assist in film
formation.
 They determine the transfer and applicable consistency of the
paint.
2.2.3. Solvents:
 VOCs used to dissolve, suspend or change the physical
properties are known as solvents.
 Their main role is in adjusting the % of non-volatile matter
present in the paint and its viscosity.
 Around 70-75% of paint liquid is constituted by it and it
escapes into atmosphere when the fluid dries.
2.2.4. Additives:
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5.  Additives are the components that are used in small
quantities to increase the performance of paint by
deflocculating the pigments.
 The properties such as Surface Tension and drying are
determined by them.
3. Format of the Internship Program:
3.1. Week 1:
Orientation:
 Company History/Introduction
 Introduction with other members /guide in company
 Time schedule in company (entry time, lunch time, tea-break,
exit time)
 Responsibility in company
 Safety Education/Training
 Personal Protective Equipment
 Tool & Equipment Use
 Introduction of equipments/ Raw materials
 Products manufactured in company
 Recent project in R& D lab
 Emergency Action
3.2. Week 2 – Week 4:
Raw Materials Testing Laboratory: The
Raw Materials Testing Laboratory analyzes
samples of all classes for purity, properties,
impurities, and more. The objective of material
characterization is often to understand the
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6. chemistry of the major and minor components in a substance. I had to
study properties and testing of raw materials.
The table given below shows some testings of the raw materials:
Raw
Materials
Testing Resins Pigments Extender Additives Solvent
Colour - - - - -
Appearanc
e
- - - - -
Specific
Gravity
- - - - -
Viscosity - - -
Non
Volatile
Matter (%)
- -
Particle
Size
- -
Moisture
Absorption
(%)
- -
Tinting
Strength
-
Oil - -
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7. Absorption
Drying
Time
-
Pot life -
Distillation
Range
-
3.3. Week 5 – Week 6:
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8. Research and
Development
lab:Excel paints
R&D Division is
fully equipped
with Modern
paint testing
equipment. The
R&D activities
include business
segments
encompassing
high
performance
protective
coatings, floor coatings, industrial paints, heat resistant coatings and
marine paints. The R&D lab’s Guide explained the procedure to make
paints using various Binders/Curatives combination at High Speed
Disperser /Bead mill and what sequence should be followed while
adding raw materials as well as to observe the processing at room
temperature; time required for recommended gauge with speed of
stirring.
I had to perform maximum of the tests given below in the R&D Lab:
Paint
Properties
Application
Details
Dry Paint Film
Properties
1 Specific
gravity at
30 cᵒ
1 Application
Temperature
1 Gloss
(20 ,60 )angleᵒ ᵒ
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9. (Base,
Hardener
,Mix)
2 Viscosity at
30 cᵒ
(Base,
Hardener,
Mix)
2 Application
viscosity
2 Adhesion test
3 % NVM at
120 c /1 hrᵒ
(Base,
Hardener,
Mix)
3 Application
method
3 Impact
Resistance test
(Direct, Reverse)
4 Induction
time (Mix)
4 Substrate used 4 Scratch
Hardness test
5 Drying time
(Surface dry,
Tack free,
Hard dry)
5 Recommended
(Dry Film
Thickness) in
micron
5 Solvent Rub
test
(Solvent used ,
No. of passes)
6 Pot life (Mix) 6 Wet Film
Thickness for
desired DFT in
micron
6 Acid /Alkali test
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10. 7 Fineness of
grinding
7 Volume Solids 7 Pull of strength
8 Volatile Organic
Component
8 Water resistance
test
9 Pigment Volume
Concentration
9 Engine/Gear oil
Test
1
0
Pigment/Binder
ratio
10 Detergent test
3.4. Week 6 – Week 7:
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11. Quality Control
Department:
In the Quality Control
department, I carried out
operational techniques and
activities that sustain the
quality of the products to
satisfy the given
requirements. It consists of quality planning, data collection, data
analysis, and implementation, and is applicable to all phases of the
product life cycle: design, development, manufacturing, delivery and
installation, and operation and maintenance. Manufacturers, product data
sheets; measuring prevailing ambient conditions and surface
temperature; mixing, thinning and application procedures; calculation
and measurement of wet film thickness; dry film thickness measurement
of each coating layer; and a host of post-application quality control
procedures, including cure/hardness testing, holiday/pinhole detection,
adhesion evaluation, and identification of application defects.
3.5. Week 8:
Production plant: The production
plant consists of developed paint
manufacturing machines such as
ball mill, sand mill, basket mill and
high speed disperser etc. The plant
manufactures Epoxy resin
(Solid/Liquid) based, Epoxy
Phenolic /Ester based, Polyurethane resin based, polyurethane acrylic
based, alkyd resin based, resin VAGH based, Bitumen based, coal tar
(Epoxy/PU) based and so on paints/coatings with different shades
according to the customer requirements.
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12. 4. List of Lab Instruments in the R&D and QC Departments:-
4.1. Digital Coating Thickness Gauge : used to measure the DFT
4.2. Scratch Hardness Tester : used to test the scratch hardness
4.3. Hegman Gauge : used to observe the fineness of grind
4.4. Ford and Din Cups : used to find the viscosity of sample
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13. 4.5. WPL Cup : used to find out the specific gravity of the given
sample
4.6. Impact Tester : used to test on impact of panel
4.7. Hot Air Oven (300
- 2500
C) : used for heating
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14. 4.8. Muffle Furnace (2000
-10000
C) : used to heat at high temperature
4.9. Digital balances (max 1000 gm and max 3000 gm) : used to find
out the weight
4.10. Salt Spray Tester : used in the Salt Spray Test
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15. 4.11. Humidity Tester : used to test the humidity resistance
4.12. Digital Glossometer : used to find out the gloss of the specimen
4.13. Shade Card RAL K5 Classic : used for shade matching
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16. 4.14. High Speed Stirrer : used to stir the sample at high speed
4.15. Bead Mill : used for grinding
5. Batch Production of Products
5.1. EXLThane 570 – Base – PU – Top Coat
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17. Base
Sr.No. Raw Material
Code
no. PBW A
Charge 1,2 in clean pot & add 3,4,5 &6 in the
pot at medium speed in High Speed Stirrer
1 Butyl Acetate 8817 1.72
2 MIX Xylene 8400 3.43
3 PU-resin-60% 1504 17.15
4 Castor oil pale grade 4604 2.86
5 W&D agent-RDU MAK 4915 0.34
6 Air release agent-Afcona 200 4213 0.06
Add 7 in this mix, run the mill at high speed for
15 min. Check clarity ofsolution on glass plate
7 10% BP 186 Jelly in Xylene 634 4.57
Mix 8 at high speedfor 5 minutes then transfer this mix
to bead/sand mill for dispersion and grinding 15-20 mic
8 TiO2 2811 25.16
Wash solution with 9
9 MIX Xylene 8400 0.57
MILL BASE 55.86
Stabilise batch with 10
10 PU-resin-60% 1504 22.87
Use 11 to flush & wash the mill
11 MIX Xylene 8400 0.23
Use 12 to discharge the mill, adjust other parameters
12 PU-resin-60% 1504 16.7
Add 13-15 at low speed, run for 15 minutes
13 UV Stabiliser 4991 0.21
14 Levelling agent - BUK 399 4613 0.11
15 1% DBTL sol. In Butyl acetate 646 0.06
Mix 16 at low speed
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18. 16 Butyl acetate 8817 2.34
Adjust solid & viscosity with 17, sample to QC & filter
through 100 µ cloth
17 MIX Xylene 8400 1.72
17 TOTAL 100
Hardener
Raw Material
Code
No. PBW
Fill Isocyanate in clean & dry container, purge nitrogen
in empty containe
1 PUH Isocyante 5216 93.6
2 Butyl acetate 8017 6.3
TOTAL 10
Test parameters
Sr. No. Test method Standard Observed
WET PAINT
PROPERTIES:
BASE
1 Mill base PBWT 55.86 55.8
2 Mill base Volume 38.52 37.8
3 Mill base specific gravity 1.45 1.47
4
Mill base
viscosity
120-140
sec 124
5 Grinding HG in µ 20 20
6 Specific gravity @ 30 C 1.21+-0.03 1.24
7 Viscosity @ 30 C FC 4 Cup
100-130
sec 109
8 %NVM 62+-2 63.2
9 Thinner ET500 ET500
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19. HARDENER
10 Finish clear clear
11 Specific gravity @ 30 C 1.04+-0.02 1.05
12 Viscosity @ 30 C FC 4 Cup 50-55 sec 54
13 %NVM 70-71% 71.3
MIX PAINT
14 Specific gravity @ 30 C 1.17+-0.02 1.16
15 Viscosity @ 30 C FC 4 Cup
130+-10
sec 126
16 %NVM 63+-2% 61.4
17 Pot life 2 hrs 2 hrs
18 Application, rec spray|brush|roller spray spray
19 Application viscosity 30-40 sec 38
20 Thinner reqd ET 500 ET 500
21 VS% 57+-3% 54.5
Dry Film Test (after 24
hrs)
22 REC DFT 50µ 60µ
23 REC WFT 114µ 120µ
24 SD @30 C 1 hr 1 hr
25 TF @30 C 3 hrs 3 hrs
26 HD @30 C 24 hrs 24 hrs
27 Gloss @60 min 90 90
28 Impact test, 50 cm ID of probe 1000 gm PASS
29
Adhesion test x cut (2x2 mm
100/100) PASS
30 Scratch hardness test (min 1500 gm) PASS
31
Flexibility
Mandril PASS
32 SST 500 hrs 750 hrs, PASS
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20. 5.2. EXLGUARD 247 Base
black
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21. Base
Sr.
No. Raw Material
Code
No. PBW
Actual
wt
Use jacketed tank/mill for water circulation to
control temperature. Do not disturb raw
material
addition sequence. Use proper filter cloth.
Mix 1,2,3,4 @ 600 RPM for 10 minutes.
Make clear solution.
1 Epoxy thinner ET 307 9.681 9.5
2 Epoxy resin - 75% 1328 22.39 22
3 BUT - 60% 1001 1.447 1.5
Add 4 & 5 at high speed
4 W & D agent - RDU MAK 4915 0.412 0.4
5 10% BP - 186 jelly in xylene 634 16.96 17
Grind 6 & 7 to get 40 µ
6 Zinc phosphate 2851 14.53 14.6
7 Carbon black HF grade 2602 2.067 2
Stabilise batch with 8 & 9; discharge then add
10
8 Epoxy resin - 75% 1328 27.25 27.5
9 Epoxy thinner ET 307 4.851 4.9
10 Adhesion promoter 60 40 silane 4200 0.413 0.4
TOTAL 100 99.8
Hardener
Sr.
No.
Raw
Material
Code
No. PBW
Actual
wt
Add 1 & 2 at low speed for 10 minutes then
filter
through 100µ cloth
1 EH polamide ADDT 280x 75% 5104 46.72 46.8
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22. 2
Epoxy
thinner ET 307 53.28 53.2
TOTAL 100 100
Test parameters
Sr.
No. Test method Standard Observed
1 Mill base PBWT 89.21 88.7
2 Mill base vol 56.82 55.9
3 Mill base specific gravity 1.57 1.59
4 Mill base viscosity 100-110 kU 104
5 Grinding, HG 40µ 40
6
specific gravity
BASE 1.47+-0.03 1.45
7
specific gravity
HARDENER 0.92+-0.02 0.92
8 specific gravity MIX 1.35+-0.03 1.31
9 viscosity BASE 80-95 kU 98
10 viscosity HARDENER 30-40 sec 32
11 viscosity MIX 80-90 kU 87
12 %NVM BASE 71-72% 70.38
13
%NVM
HARDENER 35-36% 36.83
14 %NVM MIX 66-67% 66.25
15 Thinner used ET 307 ET 307
16 Application REC B|S|R Spray
17 Application viscosity 40-50 sec 48
18
Thinner reqd by vol
% 2-5% 3
19 REC DFT 50-60µ 50
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23. 20 REC WFT 104-115µ 113
21 Pot lie MIX @30 C 3 hrs 3 hrs
22 SD @30 C 30 min 30 min
23 TF @30 C 80 min 90 min
24 HD @30 C 6-8 hrs 6 hrs
25 Gloss @60 8-10 unit
12-15
unit
26 VS % 48+-2% 46.5
27 Impact test @50 cm actual PASS
28 Adhesion test x cut (2x2mm) PASS
29 Flash point 24 C 25 C
30
Flexibility - 6.25 mm,
MANDRIL PASS
31 Scratch hardness test PASS
32 Solvent rub test PASS
33 SST 500 hrs PASS
34 Humidity test 200 hrs PASS
ET 307 - EXL Epoxy Thinner for BFL 247 Black
Sr. No. Raw Material Code No. PBW Actual
1 MIX Xylene 8400 35
2 Solvent 110 ARIOSOL ISO 7202 35
3 PI ALCOHOL acetone 7800 10
4 N-Butanol 8301 20
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