This document provides a summary of Archit Yadav's industrial training at Orient Electric Limited in Faridabad, Haryana, India. It describes the various processes involved in ceiling fan production, including fabrication of parts like blades and covers, pretreatment, powder coating and liquid coating. Defects in coating processes are also discussed along with corrective measures. The training helped Archit gain valuable insights into industrial painting, quality control and teamwork.

1. OBSERVATIONS & LEARNINGS FROM INDUSTRIAL TRAINING
Name: Archit Yadav
Roll No: 20BME072
Course: B. Tech (Final Year, Mechanical Engg)
Subject: Industrial Training Presentation
Sub code: ME-418
Place of Training: Orient Electric Limited, Faridabad, Haryana.

2. CONTENTS
 INTRODUCTION
 PAINT SHOP
 FABRICATION OF TOP COVER AND BOTTOM COVER
 FABRICATION OF BLADES
 POWDER COATING
 LIQUID COATING
 MECHANICAL TESTING
 REFERENCES
 CERTIFICATE OF COMPLETION

3. ORIENT ELECTRIC LIMITED
 Orient Electric Limited (OEL) is part of the
diversified USD 2.4 billion Indian conglomerate
CK Birla Group.
 It is one of the leading consumer electrical
brands in India with a diverse portfolio of fans,
lighting, home appliances and switchgears.
 Orient Electric today is the largest manufacturer
and exporter of fans from India with more than
60% share in exports and a dominating
presence in more than 35 international markets.

4. CEILING FAN
 A ceiling fan is a mechanical fan mounted on the
ceiling of a room or space, usually electrically
powered, that uses hub-mounted rotating blades to
circulate air.
 It’s used for conventional cooling. They only
introduce movement to the air through their
rotating paddles or blades.
 The rotation mechanism of the ceiling fan is built
in way so as to attract the warm air upwards. As the
hot air rises up, the blades of the fan slice this air
and push it down. This being a continuous process
causes the air in the room to circulate in the entire
room.
 Thus, a ceiling fan only moves the air around.
Contrary to the common belief, fans do not exactly
cool. Rather they speed up the process of
evaporation of sweat on our body, which naturally
makes us feel ‘cool’.

5. PARTS OF A CEILING FAN
 Mounting
 Down rod
 Top and bottom covers
 Top and bottom canopies
 Ball bearings
 Electric motor
 Blades bracket
 Blades

6. PAINT SHOP
 Paint shop is the well maintained and
systematically arranged area where
various processes ranging from
chemical testing, pre-treatment, IR
drying, coating followed by baking and
cooling to a finished good take place.
There are three lines in paint shop viz.
 Pre-treatment line
 Powder coating line
 Liquid coating line

7. FABRICATION OF TOPAND BOTTOM COVER
 Motor covers of ceiling fan will be formed with
die casting process.
 Further formed metal parts polishing and panting
will be done in the paint shop.
Steps involved in fabrication of top and bottom covers
are:
 Melting of metal
 Die casting
 Machining
 Pre-treatment
 Coating
 Baking
 Testing

8. PRETREATMENT OF TOPAND
BOTTOM COVER
 Optimally, the coating will also chemically bond
to the metal. While there are various pre-
treatments available to the modern custom paint
shop, from legacy phosphates to modern silane
polymers and zirconium nano-coatings.
 There is 8- tank process utilized for the pre-
treatment of covers in which a bunch of covers
is dipped in different tanks for respective time
period.
 Out of these tanks some tanks contain
demineralized water for rinsing and rest contain
different chemicals for degreasing, derusting and
to avoid oxidation.
 Fluid in these tanks is fluidized by the flow of
compressed air from the bottom.
 After eight tank process top and bottom covers
are dried in Infrared (IR) heater and ready for
coating.

9. FABRICATION OF BLADES
Steps involved are:
 Decoiling
 Straightening
 Shearing
 Punching
 Blanking
 Forming
 Buffing
 Riveting
 Pre-treatment
 Coating
 Baking
 Testing

10. PRETREATMENT OF BLADES
 In pre-treatment of blades there is almost
same procedure for both powder coating and
liquid coating i.e., 8-tank process but there is
slight difference in the process of performing
the action on the blades.
 For powder coating, various pre-treatment
processes are carried out by spraying the
chemicals over conveyorized blades through
sprayers in a closed chamber. These chemicals
are stored in their respective tanks and
pumped to the sprayers by pumps installed
near the tanks.
 For liquid coating, pre-treatment processes
are carried out by simply dipping a bunch of
blades into different tanks for respective time
period.
 Chemicals used for different processes like
degreasing, derusting, rinsing and nanocoating
are same for both the cases.

11. POWDER COATING
 Powder coating is a dry finishing process
that has become extremely popular since its
introduction in North America over in the
1960s. More and more companies specify
powder coatings for a high-quality, durable
finish, allowing for maximized production,
improved efficiencies, and simplified
environmental compliance.
 Powder coatings are based on polymer resin
systems, combined with curatives, pigments,
leveling agents, flow modifiers, and other
additives. These ingredients are melt mixed,
cooled, and ground into a uniform powder
similar to baking flour.
 Powder coatings are used as functional
(protective) and decorative finishes.

12. WORKING PRINCIPLE
OF POWDER COATING
 A process called electrostatic spray
deposition (ESD) is typically used to achieve
the application of the powder coating to a
metal substrate.
 This application method uses a spray gun,
which applies an electrostatic charge to the
powder particles, which are then attracted to
the grounded part.
 After application of the powder coating, the
parts enter a curing oven where, with the
addition of heat, the coating chemically
reacts to produce long molecular chains,
resulting in high cross-link density.
 These molecular chains are very resistant to
breakdown. This type of application is the
most common method of applying powders.

13. THE POWDER CIRCUIT
Components are:
 Booth
 Cyclone separator
 Sieve
 Dense Phase Conveyor
 After Filter
 Refuse Container
 OptiCenter
 Automatic guns

14. ADVANTAGES OF POWDER COATING
 Powder coatings emit zero or near zero volatile organic compounds
(VOC).
 Powder coatings can produce much thicker coatings than conventional
liquid coatings without running or sagging.
 Powder coating overspray can be recycled and thus it is possible to
achieve nearly 100% use of the coating.
 Powder coating production lines produce less hazardous waste than
conventional liquid coatings.

15. DEFECTS, CAUSES AND REMEDIES

16. LIQUID COATING
 Liquid paint is a process of coating metal which is carried out using a spray
gun. The coating is sprayed onto the metal surface in one or more layers,
depending on the type of liquid paint used and the purpose of the coating
(primer, finish, intermediate layer).
 This paint can be applied to all types of metallic materials. It has a good
elastic resistance to wear and impact, as well as to chemical attack, fire (for
certain types of paint) and corrosion.
 The basic raw materials comprising a liquid coating are additives, carriers,
pigments, and resins. Additives make up the smallest portion of any liquid
coating composition, but they impart special characteristics on the overall
finish.

17. STEPS IN LIQUID COATING
 Cleaning (Tag-Rag & Cotton Gloves)
 Primer Coating
 Base Coat Painting
 Laquor Coating
 Paint Curing Oven
 Unloading & Inspection

18. ADVANTAGES OF LIQUID COATING
 Liquid coatings can be applied at lower film builds, which means
less coating is required, which can be an economic advantage.
 Ambient cure is an option in some liquid paint technologies, so no
oven is required.
 A wide variety of substrates can be painted with conventional liquid
paints and the substrates do not need to be conductive for the
majority of applications.

19. DEFECTS, CAUSES AND REMEDIES

20. MECHANICAL TESTING
 Bearing Vibration Test
 Spring Load Test
 Spindle Test
 Blade Testing
 Cover Testing

21. CONCLUSION
In conclusion, my training experience at Orient Electric Limited has been both
educational and rewarding. Over the course of my time here, I have gained valuable
insights into the world of industrial painting processes, quality control, and
teamwork. I have had the opportunity to work alongside skilled professionals who
have generously shared their knowledge and expertise with me. I have learned about
the various types of paints and coatings used in the industry, as well as the meticulous
preparation and application techniques required to achieve a flawless finish.
Moreover, I have developed a deep appreciation for the importance of quality control
measures in ensuring that the finished products meet the highest standards.
Throughout this internship, I have also honed my teamwork and
communication skills, as effective collaboration is essential in a fast-paced
and detail-oriented environment like the paint shop. I have learned to adapt to
challenges, troubleshoot issues, and maintain a strong commitment to safety
and environmental regulations.

22. REFERENCES
 Mr. Somesh sir, Industrial Head, OEL, Faridabad.
 Mr. Rajesh Raghuvanshi sir, HR Head, OEL, Faridabad.
 Paint shop of OEL Manufacturing plant, Faridabad.
 Mechanical testing lab, OEL.
 https://www.sugawaralabs.co.jp/en/bearings/anderon/bearing_vibration_tester_ander on_meter
 https://fillopainting.com/blog/harmful-effects-of-painting-on-the-environment/
 https://www.orientelectric.com/
 https://www.gemapowdercoating.com/fileadmin/documents/User_Manuals/English/B
 https://www.ppcoatings.co.uk/wp-content/uploads/2016/06/Coating-Failure-Defects.pdf
 https://www.tcipowder.com/media/2593/final-troubleshooting-poster-english-2019-18-by-24.pdf

24. THANKYOU!