Aniket Dharanakar Report

Deccan Education Society’s
Technical Institute, Pune- 04

A
In-plant Training Report
Conducted at
TUFF COAT POLYMERS PVT LTD
Gat No.108, Village Ranje, TalBhor,Dist. Pune
Submitted for
Partial fulfilment of
Diploma in Surface Coating

Technology
Maharashtra state Board of Technical instituteMumbai – 51
Submitted By
AniketDashrathDharanakar
Semester :- SC 3G
Seat No: - 231344
Deccan Education Society’s Pune- 04 Page 1
TUFF COAT POLYMERS PRIVATE
LIMITED
QUALITY POLICY
WE AT TUFF COAT POLYMERS PVT. LTD, SHALL
PROVIDE COMPLETE SOLUTION TO CUSTOMERS ,
BY PROVIDING QUALITYPAINT SYSTEM ON
TIME WITH BEST ECONOMICS.
WE SHALL ENHANCE CUSTOMER SATISFACTION ,

THROUGH CONTINUAL IMPROVEMENT IN OUR
PRODUCTS AND QUALITY MANAGEMENT SYSTEM.
Mr. SHIRISH PONKSHE Mr. PRASAD PURANDARE

DIRECTOR DIRECTOR

Sr. Objective Measuring Monitoring Target
No parameter responsibility
Quality paint systems No of Customer QC Max.1/month

1. Complaints
2. On time delivery Order not Dispatch Max.5/month

Dispatched on
time
3. Continual Improvement No of Design Max.1/year

in products developments
inproduct /
new products
4. Sales improvement Get customer Sales Min 2/years
with regular
business
TUFF COAT POLYMERS PVTLTD

QUALITY OBJECTIVES

ACKNOWLEDGEMENT
I have great pleasure in submitting this in plant training project report

completed at Tuff Coat Polymer Pvt. Ltd, Ranje. This project report is a
submitted to fulfilment of Diploma In Surface Coating Technology .The main
object of this report is to enlist the work performed during in plant training.
I acknowledge with great regard to our coordinator Mr.R. H. DONGRE SIR.

Who arrange my in plant training in very good organization like Tuff Coat
Polymer Pvt. Ltd and also would like to thanks to, Mr.R. H. DONGRE
SIR .for their kind support and valuable guidance.
I would like to express my sincere thanks to,
Mr. S .D. Ponkshesir&Mr P.D. PurandaresirDirectorsof Tuff CoatPolymer

Pvt. Ltd. for their kindtreatment and co-operation. I also thankful to Mr. Yusuf
sayyad (Q C Department) &SachinJadhav(Jr.Chemist) for their kindly help &
guidance.
Also I am very thankful to, Mr. S. S. Konde and all other employees by whom
I learned educational as well as other valuable thing which may perhaps can
change my life.
I gave best regards to Mr.AnilAmbre(Production Department) who taught me

the apparatus setting and handling of lab scale batches, shade matching and
many techniques to be followed during the processing of paints.
I greatly acknowledge the help of executive and staff of Tuff Coats Polymer
Pvt. Ltd, Ranje.

INDEX
SR.
NO.
TITAL PAGE NO.
1. About Company
2. Production Department
3. Testing of raw material
a. Testing of Resin
b. Testing of solvent
c. Testing of Pigment & Extender
d. Testing of Additives
4. 1. Testing of Paints
2. Testing of Finish Good
3. Instruments used for Testing
5. Material inward, Dispatches,
6. Thinner Manufacturing
7. 1. Spray Gun
2. Phosphating Method
3. Salts Spray Method
8. Customer Complaint Report
9. Project
ABOUT COMPANY

TUFF COAT POLYMERS PVT LTD Is one of the highly
progressive factories among the Indian small scale industries. The
company is having two directors Mr.Ponkshe&Mr.Purandare. Mr.Ponkshe
Sir handling production department & Mr. Purandare Sir deals with the
sales department. This firm is well known for its quality consistency. The
company has a well equipped laboratory furnished with latest testing
instruments like salt spray corrosion resistance chamber with temperature
controller, boiling range apparatus, spray booth with gun for spraying
panels of finished paints etc. All equipment are calibrated on due date.
Annual turnover of the company is about Rs. 10 core.
The various products range of the company is as follows-

1. All types of the Synthetic Enamels and Primers.
2. All types of the Quick Drying Paints and Primers.
3. Epoxy Paints and Primers.
4. PolyurethanePaints and Primers.
5. ChlorinatedRubber and Paints.
6. Stoving Enamels.
7. Coal Tar Epoxy Paints.
8. Hammertone Paints.
9. Wash/Etch Primer.
10. Polychromatic and Metallic Finishes.
11. N.C. Paints.
12. All types of the Thinners.
13. PU/Epoxy Floor Coating.
14. All types of High Performance Anti-Corrosion Coatings.
15. All types of Air Drying &Stoving Varnishes.
16. Water Proofing Compounds.
17. All types of Clear Lacquer.
18. Epoxy Grouting Compounds.
19. LCF EXT PU Luminous Paint.

Production Department:-
RAW MATERIAL SECTION :-
Raw material should be received in good condition. Barrel of solvents &resins should be
proper sealed.Pigment bags should be scaled & are weighed properly before accepting.
For sampling containers are selected at random from bulk .Raw material received should
be used only after approval of quantity control.
A) Sampling :-
In Drawing sample following precautions and directions shall be observed .
i. Sample shall not be taken in an exposed place.
ii. The sampling apparatus shall be clean and dry .
iii. To draw a representivesample, the contents of each container selected for
sampling shall be mixed thoroughly by shaking or stirring or by suitable
means.
iv. Samples shall be placed in clean, dry surface .
v. The sample containers shall be sealed airtight after filing and marked with full
details of sampling ,the date of sampling and month and year of manufacture
of the material .
vi. Samples shall be stored in such a manner that the temperature of the material
does not vary unduly from the normal temperature.
B) Goods Received Report (GRR):-
It is prepared according to the documents of the goods received and should be send
further to Q.C. it is handed over to accounts department.
FINISHED GOODS AND PACKING SECTION :-

Before the sample is given to Q.C. finished good is tested for following test at Production
section:
i. Viscosity
ii. Grinding
iii. Shade
iv. Drying Time
A) Sampling of finished goods :-

Sample should be drawn at filling stage ,kept in container already cleaned properly .
The lid should be tightly closed and there should be an empty space of around 5% after
the container is closed .The sample containers should be labeled properly .The
information supplied on the label is :
i. Name if the paint

ii. Batch No.
iii. Batch Size
iv. Date /month / year of manufacturing

The material is packed for dispatch only after the approval of Q.C.
Drums for finished goods packing should be screen – printed receiving and then stored
properly. Screen printed containers are further printed by using stencils as per the
requirements from time to time .
B) Stock :-
After the end of month the raw material and finished good stocks are taken and calculated
how much raw material are used in that month for preparing paint.

MECHINERIES:-
The machineries are available in factory are as follows-
Sr. Machine type Type RPM Total

No
1. Attriator Batch type 130-150 3
2. Sand Mill Batch type 1400-1500 2
3. Sand Mill continuous 2800 1
4. Stirrer/Mixer High speed 1400-2800 2
■ Attriator:-
Attriators are the modifications to the ball mills and sand mills . These are the batch type
operating machines.
Attriators consist of a cylindrical vessel called as shell. The attriator shell has water jacket
for cooling purpose .the temperature of machine is maintained using water flow through
the jacket . The temperature of the attriator should not be allowed to exceed 40ºc as it
affects the shelf life of the material.
Attriator used porcelain of ceramic balls, having diameter 8-20 mm, as grinding and
dispersion media. The quantity of ceramic balls used as grinding media depends on the
capacity of the attriator, e.g. 100 liter capacity attriator uses about 100 kg, in which the
size of ceramic balls is 8 mm & the size of ceramic balls in 150 liter capacity attriator
is 12 mm. at the center , attriator has a vertical shaft to which metal rods , of specified
length and thickness . are fixed at specified distance . at the end of the shaft it has paddles
this complete arrangement is rotated using an electric motor of capacity 5-7 H.P. The
speed of the rotation is about 130-150 RPM The attriator is charged from the top and at
the base it has outlet for discharging .
The current, voltage as well as temperature can be seen directly on the ammeter .
voltmeter and electric thermometer provided on machine .

■SAND MILL:-
Sand Mill are of two types; continuous and batch type –
Continuous type Sand Mill:-
It consists of a cylindrical container with a vertical axis and a multi-disc impeller
blade. The premixed mill base is pumped in through the bottom of the mill at a fixed rate,
such that the material emerging at the top of the container has sufficient grinding time
inside the grinding zone of the machine .
The grinding media are hardened glass beads or zirconium beads ,whose diameter is
1-3mm .The RPM of continuous sand mill is 2800. The mill base after grinding passes
through a cylindrical sieve near the top of the mill before being discharged. The job of the
sieve is to retain the beads inside the cylinder. Also there is arrangement of water-cooling
to control and reduce the mill base temperature during the grinding.
Following controls efficiency of the operation,
A) Resin or vehicle solids-ideally these should be low to medium.
B) Pigment to binder ratio-best grinding is achieved in the range of 8:1 to 20;1.
C) Grinding medium to mill base ratio 80:100.
D) Charge of the beads-Half of the cylinder volume.
Batch type Sand Mill:-

The structure and working of batch type sand mill is same as that of continuous
type except suction pump. This type of sand mill is charged from top and discharged from
bottom .Except loading and discharging there is no difference In batch type and
continuous type sand mills.

■ HIGH SPEED STIRRER:-
High speed stirrer is used for premixing of mill base before charging it to the attriator . Also
it is useful for manufacturing thinners and varnishes. There are two high speed stirrer. The
rotation of these stirrer is quiet high i.e. one has 1440 rpm & other has 2800 rpm. It has
vertical shaft, having serrated disc at base, which is rotated by using 5 H.P. motor .The chain
is provided for upward and downward movement. The efficiency of the operation depends on
proportionate dimensions of various parts of the disperser or dissolver. For example ,if
impeller or disc diameter is D ,then dimensions of other parts would be :container diameter –
2D to 3D height of impeller from the bottom of the container –D/2,MAX .Mill base depth –
2D ,speed of rotation of impeller –1500 rpm (peripheral speed).

■ PRODUCTION PROCESS:-
Weighing of raw materials (From store as per production sheet)
Mill base premixing (Using high speed stirrer)
Charging of attriator or sand mill (Batch type)
Discharging of attriator or sand mill (Batch type)
Intermediate testing (Shade)
Final addition
Sending sample to the Q.C. department
Approval of batch Rejection
Rectification
Sending sample to the Q.C. department
Packing

■SPRAYGUN:-
Spray gun is the instrument, which helps the get uniform layer on the metal panel. Spray
gun is attached to the compressor and with help of compressor get the to the spray gun.
Spray gun is conventional.
Metal gun is attach to the compressor gun is same like pot.
■Before use the gun firstly checks the gun is non-sticky & dry.
■Before applied the paint maintain the proper viscosity.
■spray the paint after filtering the paint.
■SHADEMATCHINGPROCESS :-
Shade matching is the important process for the paint production. The shade is match
with the help of the IS shade card or RAL shade card or by customers standard. It is
carried out after complete formation of paint.
SPECRO COLOUR METER

TESTINGS OF RAW MATERIALS
Basic raw material of paint are as follows:-
1. RESINS
2. SOLVENTS
3. PIGMENTS & EXTENDERS
4. ADDITIVES
TESTING OF RESINS:-
A. COLOUR:-
Color of resin is an important test as it affects color of the final product i.e. paint or
varnish. The color of resin is tested by taking clean & dry test tube & takes half test tube
of the given sample & the color is observed by holding this tube against light source.
Color of resin is as follows :-
Pale yellow →Epoxy Resin
Brownish yellow →Alkyd Resin
Dark Brown →Natural Resin / Varnishes
Water White →Acyalic Resin/M.F.Resin
Resin/M.F.Resin
B. CLARITY:-
Clarity is tested by two methods as follows:-
1. Clarity in bulk :-
Take the resin sample in a 100 ml glass beaker and keep it on a printed paper. The resin
should be so clear that the printed letters should be visible.
2. Clarity of resin film :-
This is observed by taking sample on a plate in the form of drawdown. Observe the film
for any spects, dust particle or other impurities. Solid resins are reduced to 50% by
solvents & then are tested.
\C. COMPATIBILITY :-
Resin are considered to compatible if when added together in a solution form &
intensively mixed. They yield a clear mixture, which remains clear after the evaporation
of the solvents.
Procedure:-
1.The sample of the resin to be tested is dissolved in solvent.
2.The resin & solvents are in ratio like 1:1,1:2, 1:3 up to infinite. If the solution is clear
Then given resin is compatible with given solvent. If there is cloudiness or turbidity then
incompatible with solvent
3.Also after evaporation of solvents, if no cloudiness, turbidity or flocculation is
perceived, the sample are considered compatible.
4. The film clarity of resin on glass plate should be clear.

D. % NON-VOLATILE MATTER(% SOLID CONTENT) :-
A solid content of resin solution is determined by weighing a small amount of solution
into a shallow Petri dish and heating it an oven to drive of the volatile components
subsequent weighing will give the weight of the residual non volatile matter, the
percentage of solid in the original sample can be calculated. Some precaution is necessary
to obtain uniform results. The layer will not be too thick, proper drying time and the
temperature are also important e.g.
Procedure :-
1. Take a empty weight of Petri dish (w1).
2. Take about 1-2 gms of sample resin (w2).
3. The Taken sample is put in Oven at 1200 C for 2 hours .
4. Taken out the sample and cool it at room Temperature and weight sample (w3).
5. Calculate the % NVM by following
% NVM=
NVM= W2-W1
W3-W1*100
Type of Resins Temperature Time
Alkyd &Epoxy esters 1200 C 1 hrs
Amino Resin 1000 C 2 hrs
Phenolic Resin 1350 C 1hrs
Polyamide Resin 1400 C 3 hrs
Acrylic Resin 1500 C 2 hrs
CNSL Resin 1200 C 2 hrs
Epoxy Resin 1500 C 2 hrs
E.VISCOSITY:-
Viscosity can be regarded as the resistance to flow. Viscosity of the resin & oil is the
most important property. The viscosity of the resin depends on the molecular weight
(degree of polymerization) & the strength of the solvents used for dissolution that is
solvent power of solvents. It must be noted that viscosity is critically temperature
dependent. Viscosity is measured by making 40% or 50% solution of resin sample. In
paint industries the most common method for its measurement is by Viscosity Ford cup
no.B-4. The viscosity is measured by usual procedure of viscosity measurement & it is
expressed in seconds.
Viscosity rise in AD(Air Drying) Resin should not be >50% after addition of driers.
The following apparatus shall be used in carrying out a test.
i. 0.5ºC.
A thermometer accurate to within 0.5º
ii. A stop- watch or stop-clock.
iii. A suitable stand ,provided with leveling screws.
iv. A spirit level
v. A straight-edged scraper for the top of the cup.

Procedure:-
1.Clean the ford cup, dry it & put it on the stand.
2. Hold the forefinger on the aperture of the ford cup & add the resin sample in the cavity
of the ford cup. Remove the air bubble from the sample. Ensure that the level of sample is
coincides with that of the top of the cup. Remove the excess sample by glass
rod drawing it horizontally.
3. Start the stop-watch immediately after removing the forefinger from the aperture &note
down the time required till the flow gets break into droplet viscosity measured by
seconds.
4.temperature at which viscosity is note down small changes in temperature may cause
large difference in viscosity of sample.
F.ACID VALUE :-
Acid value is the milligrams of alc. KOH required to neutralize free fatty acid in one gram of
resin sample.
REAGENTS:-
a) 0.1N. alc. KOH
b) Solvent mixture-
1.Benzene+Isopropanol (1:1) or
2.Toluene+Denatured spirit (1:1) or
3.Xylene
c) Phenolphthalein indicator
Procedure:-
1.Weigh about 2-3 gm of resin sample in conical flask .
2.Dissolved it in 25 ml any of the above mentioned solvent. (mix xylene).
3.Add 2-3 drop of phenolphthalein indicator.
4.Titrate it against 0.1N. alc. KOH solution.
5.End point is colorless to pink.
Calculation:-
Acid value of the resin is calculated as per the following formula.
Acid value = 56.1 x N. of KOH x B R

Weight of sample.
G. DRYING TIME:-
Drying time is the time required for the complete evaporation of the solvent & the
conversion of resin solution into the hard film. Film gets completely dried& the coat
become more smooth, plastic & completely protective to the surface.
In preparation of resin sample there is addition of 5-6 % driers & then mixture is applied
on panel to test drying time. The drying to be tested for:-
1. S.D.- Surface drying time
2. T.F.- Tack Free time
3. H.D.- Hard drying time

Combination Drier:-Lead base :- Lead Octoate(18%) : 1 LTR
Cobalt octet (6%): 300 ml
Manganese octet (6%):200ml
Calcium octoate (3%):500ml
Zirconium base: -Zirconium

-Zirconium octoate (6%) : 1.2LTR
Lead octoate (18%) : 500ml
Cobalt octoate (6%) : 250 ml
Manganese octoate (6%): 200 ml
Calcium octoate (3%): 500 ml
H.TOLERANCE WITH SOLVENT :-

Tolerance of the varies resins is tested with respective solvents according to their end use.
It is tested as follows :-
1.In a 100 ml measuring cylinder take 10 ml volume of resin.
2.Now add 10 ml solvent each time & mix thoroughly till cloudiness is observed in the
mixture.
3. If the solution remain clear up to the ratio 1:9 keep one part of the solution & add
remaining 9 parts solvent. If the solution still remains clear tolerance of resin with the
solvent is said to be infinite.
I. AMINE VALUE :-
Amine value is the number of milligrams of KOH equivalent to the amine alkalinity in 1
gm of resin.
Procedure:-
1. Weight about 2-3 gm of sample (W) of the polyamide in to 250 ml conical flask
accurately. Do not heat polyamide prior to adding the neutralized alcohol to the
sample.
2. To a separate beaker add 100ml of Isopropyl Alcohol & 2ml bromocresol green
indicator +(0.1 % in methanol)
3. Add the neutralized isopropanol to the weighted sample of the polyamide. Agitate
until dissolved. Titrate with std. HCL or H2SO4 solution (approximate 0.5N)
4. Color changes from blue to yellow. This is the end point. Note the burette
reading (v) & calculate the amine value by following formula-
formula-
AMINE VALUE=
VALUE= 56.1xN. of acid x B.R.
Weight of sample.

EXAMPLE OF RESIN TESTING : -
A.]
1. Party Name :-Arkema Chemicals
2. Product Name:-Alkyd Resin
3. Color: - Brownish Yellow
4. % NVM :- 70.50%
 W1- 8.02
 W2- 1.39
 W3- 9.00
5. Xylene Tollerance:- Infinite
6. MTO Tollerance:-Not compactible
7. Viscosity in 40% Xylene:-100 Seconds
8. Drying Time (+ 7 ml
Lead Base Drier) :-
 Surface Dry : 5 min
 Tack Free : 20 min
 Hard Dry : Over Night
B.]
1.
Party Name :-Arkema Chemicals
2.
Product Name :- Acrylic Resin
3.
Color:-Water White
4.
% NVM :- 61.06 %
 W1 : 8.18
 W2 : 1.31
 W3 : 8.98
5. Xylene Tollerance:- Infinite
6. MTO Tollerance:- Not compactible
7. Viscosity in 50% Xylene:-270 Seconds
8. Drying Time (+ 7 ml
Lead Base Drier)
 Surface Dry : 30 min
 Tack Free : 1.30 Hrs
 Hard Dry : Over Night
9. Gloss :- 90-95
10.Impact Test :- Passes
11. Flexibility Test :- Pass By Conical Mandrel

C.]
1. Party Name :- Ideal chem. Plast
2. Product Name :- Epoxy Resin
3. Color: - Water White
4. % NVM :- 76.42 %
 W1 : 8.13
 W2: 1.40
 W3: 9.20
5. Tail Test:- Absent
6. Viscosity in 50% Xylene: - 80 Sec
7. Drying Time (+ 7 ml :-
Lead Base Drier)
 Surface Dry :1 Hrs
 Tack Free : 2Hrs
D.]
1. Party Name :-
2. Product Name :- CNSL(Natural Resin)
3. Color: - Brownish Black
4. % NVM:- 70.86 %
 W1 :7.92
 W2: 1.21
 W3: 8.82
5. Viscosity in 40% MTO: - 80 Sec
6. Drying Time (+ 7 ml :-
Lead Base Drier)
 Surface Dry : 1 Hrs
 Tack Free : 3Hrs

TESTING OF SOLVENTS
Introduction:-
Solvents important constituent of paint& lacquers. Solvents are used to adjust the
viscosity of paint for the application purpose.(spraying or brushing)
Solvent get evaporated after the application and only the paint film remains on the
substrate. Solvents used in paints and lacquers are volatile liquids.
They are classified according to their chemical composition as follows:-
 Aliphatic solvents → M.T.O

 Aromatic solvents → Xylene, Toluene.
 Alcohol → Butanol, IPA.
 Ketones → MIBK(Methyl Isobutyl Ketone)
 Ester → Butyl Acetate, Ethyl Acetate.
Following are important properties of solvent : –

1) COLOUR
2) CLARITY
3) BARREL CONTAMINATION
4) SMELL
5) SP. GRAVITY BY HYDROMETER
6) SOLVENT EVAPORATION RATE
7) BOILING POINT (DISTILLATION RANGE)
8) REFRACTIVE INDEX

A] COLOUR : –
Color of almost all solvent is water white with the exception of petroleum solvents,
which have quite a distinctive color.
color.
Procedure:-
1] Take a solvent sample in to a test tube and observe in a light and report the color of
the solvent.
2]Compare the solvent sample to the standard one and report the result .
B] CLARITY :–
The clarity of the solvent depends upon the color of the solvent and testing procedure and
usually depends largely upon visual observation and comparison. The observation is
taken whether any haziness or cloudiness is present in solvent.
C] BARREL CONTAMINATION :–
It is the test by which presence of impurities in the solvent such as dust, rust, particles etc.
can be detected. Test is carried out by taking solvent in 250ml clean glass beaker and
observes the sample visually.
D] SMELL: -
It is very easy and quick test for purity of solvent. Most of solvent possess characteristic
odors. So by taking smell in comparison with std. sample already approved, test is taken.
E] SP.GRAVITY BY HYDROMETER :–
Sp. Gravity is heaviness. specific gravity is the ratio of density of solvent to density of
water or lightness in comparison with water. Density of water is one.
Procedure:-
1. Pour sufficient quantity of solvent in a 500 ml glass cylinder .
2. Let the level of solvent become steady and then insert hydrometer, gently into a
cylinder.
3. Note down the reading of hydrometer, which coincides with level of the solvent.
4. The reading is taken only when the hydrometer is steady and is not touching the walls of
the containers.
E.g. M.T.O ► 0.78
Xylene ► 0.86
F] SOLVENT EVAPORATION RATE :–
After sometimes solvent gets evaporated from film, when paint is applied on surface.
Drying of film depends on the rate of evaporation of solvent.
Rate of evaporation of solvent is closely associate with the boiling point of the solvent.
But presence of different kinds of impurities may interfere in a rate of evaporation.
The test is carried out by taking the one drop of solvent on filter paper. Time required for
complete evaporation is noted in seconds.

Toluene► 60 sec
E.g. Toluene►
Acetate►55 sec
Butyl Acetate►
G] BOILING POINT:-
It is the temperature range in which the solvent boils & gets evaporated. Depending upon
the presence of different components (impurities) the range may varies. But in general
solvents used in industries shows fixed distillation range which indicates the purity of
solvent.
Procedure:-
1. Arrange a 250 ml round bottom conical flask with a side arm on either an oil bath or
water bath, using a retort stand to support the flask.
2. Place the thermometer which covers the boiling range of the chosen solvent in the
distillation head fixed in the neck of the flask with thermometer bulb level with the
side arm.
3. Fix a water condenser to the side arm at an inclined angle and leading into a receiving
flask.
4. Place 100 ml of the industrial solvent to be tested, and the number of anti bumping
granules.
5. To the top, fix the distillation head. (Put a small amount of mercury or glycerin for a
thermal in the distillation head which covers the boiling range of the selected solvent.
The thermometer bulb should be in the level with side arm.
6. Heat the oil bath at the rate of 2˚C until distillation begins.
7. When the first drop of the distillates comes out, note down the temperature.
8. Then, for every 10 ml of distillate, go on recording the temperature.
9. Constitute distillation till all the contents have been distilled.
10. Plot a graph of volume of the distillate collected.
E.g.M.T.O = 144 - 1770 c

Mix Xylene = 110 - 1280 c
Toluene = 108 - 1150 c

I] DISTILATION RANGE:-
It is temperature range in which the solvent boils and gets evaporated .Depending upon
the range may varies .But in general solvents used in industries shows fixed distillation
range which indicates the purity of solvent .
Procedure:-
1. Arrange a 250 ml round conical flask with 100 ml solvent on heating mantel by giving
sufficient support.
2. Place the thermometer which covers the boiling point range of the selected solvent in
the neck of the flask in such a way that the bull of thermometer should coincide with
the level of side arm.
3. Fix a water condenser to the side arm at an inclined angle and keep a receiving flask
for collecting distillate.
4. Start the heating and water supply of water condenser after fixing the all joints by wax.
5. Raise the temperature of the heating mantle by 2-3 0 c/ min.
6. Note down the temperature which the 1st drop of solvent comes out as distillate.
7. Then record the temperature after collecting every 10 ml solvent till all the solvent
gets evaporated
8. .e.g. MTO – 144-1770c
Mix Xylene – 110-1280c
Toluene -- 108-1150c
J] ANILINEPOINT :-
This is determine only in case of aliphatic solvent depending upon the presence of
aromatic content impurities in solvents, solvent power of that solvent depends higher the
aromatic content , greater the solvent power and lower the aniline point.
Aniline point is defined as the minimum mutual solution temperature of equal volume of
aniline and aliphatic hydrocarbons.
Procedure:-
1. Take equal volume of aniline and suitable solvent in a clean and dry test tube .
2. Suspend the thermometer in a aniline solvent mix. And keep the test tube in a water
bath.
3. Raise the temperature of water bath slowly with constant stirring .
4. Note down the temperature when the mixture becomes clear .This Aniline point of
M.T.O. is 450 c.

EXAMPLE OF SOLVENT TESTING : -
A]
1. Name :- ACETONE
3. Clarity: - Clear
4. Smell:- Ok
5. Evaporation Rate :- 70 sec
6. Specific Gravity By Hydrometer :-0.8100c
7. Distillation Range:- 380c - 580c
8. Refractive Index:- 1.35
9. Barrel Contamination: - Nil
B]
1. Name :- BUTANOL
3. Clarity: - Clear
4. Smell:- Ok
5. Evaporation Rate :-330 sec
7. Distillation Range:-650c - 1200c

C]
1. Name :- BUTYI ACETATE (B.A)
3. Clarity: - Clear
4. Smell:- Ok
D]
1. Name :- TOLUENE
3. Clarity: - Clear
4. Smell:- Ok

E]
1. Name :- METHANOL
3. Clarity: - Clear
4. Smell:- Ok
F]
1. Party Name :-Guairá Industries
2. Name:- MTO
4. Clarity: - Clear
5. Smell:- Ok
G]
1. Name :- R- XYLENE
3. Clarity: - Clear
4. Smell:- Ok

TESTING OF PIGMENT &
EXTENDER
DEFINATION OF PIGMENT :- Pigment are those coloring matter which are insoluble or
substantially soluble in the liquid in which they are incorporated and remain more or less
unaffected by it.
Following are the test carried out for pigments &extenders :-
1. COLOR / APPEARANCE
2. SPECIFIC GRAVITY
3. MOISTURE CONTENT
4. OIL ABSORPTION
5. RESISTANCE TO ACID & ALKALI
6. RESISTANCE TO HEAT
7. MASS TONE & TINT TONE

A] COLOUR / APPEARANCE :-
This test is carried out only physical observation comparing this sample with standard
sample. This is a preliminary test which helps in deduction of pigment sample.
B] SPECIFIC GRAVITY:-
Specific gravity is the ratio of mass of pigment to the mass of given volume of pigment,
to mass of same volume of water.
Specific gravity of inorganic pigments is relatively higher as compared to organic
pigment.
Specific gravity is determined by pyknometer or by specific gravity bottle.
Procedure:-
1. Weigh the sp. gravity bottle with solvent , take weight of empty sp. Gravity bottle
as w1.
2. Nowfiil sp.gr bottle with water and note the weight as w2.
3. Empty the sp. Gr bottle fill it with solvent after drying bottle with acetone weight
the bottle and bottle and note weight asw3.
4. Add solvent is the sp. Gr bottle containing 2-5 gms .pigment note down the weight
as w5.
5. Add 2-5 Gms pigment in sp. Gr bottle and note down the weight as w4.
6. Calculate sp. Gr of solvent by using formula –
W3-w1
Specific gravity of solvent =
W2- w1
7.To calculate sp. Gr of pigment by using formula and above calculated sp. Gr
W 4−W 1
Specificgravityofsolvent= ∗sp . Grofsolven t
(W 4−w 1) – (w 5−w 3) !
Examples: - Specific Gravity of pigment.

pigment
Sr.no Name of Pigment Sp.gr.of pigment
1 Middle Chrome 4.86
.
2 Tio2 (Rutile) 4.01
.

C] Moisture Content:-
Moisture Content refers to the water left in the pigment after it has dried .
Procedure:-
1. Take a known weight i.e. 1 gms of pigment in a petridishalongb with a small glass rod
.
2. Then keep it in oven at 1050 c for hours .
3. Spread immediately the pigment by the glass rod.
4. The cool it in desiccator and weight it again.
5. From the loss in weight the% moisture content is determined.
Loss of weight
6. % Moisture content= ∗100
Weight of pigment
D] Oil absorption:-
Oil absorption is defined as the minimum amount of acid refined linseed oil required by
100 gms of a pigment to form a coherent mass.
The oil absorption figure represents the minimum weight of oil required to coat each
Pigment particle and to fill the voids between them .the factors which affect the oil
absorption value are :
a. Pigment type
b. Particle size
c. particle size distribution
d. shape of the particles
e. Pigment surface characteristics
f. Wettability by the oil and pigment itself
g. Time required for evaluation
h. Method
Procedure:-
1. Weight approximately w1 mgs of desired pigment on glass slab .
2. Make a lump of pigment by adding linseed oil from burette and continuously
rubbing with the help of a spatula.
3. From the volume of linseed oil knowing the specific gravity determine the amount
of oil required to form a coherent mass of w1 mgs of pigment (w2)
4. From the following formula determine the oil absorption
W 2∗100
Oil absorption=
W1

E] Tinting Strength:-
The term is related to colored pigments only. It is ability of colored pigment to impart it’s
color to white pigments.
The procedure is same as reducing strength, only the difference is that, here white
pigment remains fixed and colored pigments are std. one and sample one.
F) Reducing Strength:-
The term is related to white pigment only. It is the ability to white pigments to the color
of colored pigments. The ratio of colored pigments to white pigment is taken as 1:20.
Procedure:-
1. Take the same quantity of both std. and sample white pigments accurately.
2. Add the same quantity of colored pigments as per ratio in both std. and sample white
pigments.
3. Now disperse separately pigment mixtures by adding equal amount of resin and
solvent.
4. Rub either the pigment mix with spatula for same strokes or mixing is done in batch
type sand mill for 20 minutes.
5. Take comparative draw down on the clean and dry glass plate with the help of film
applicator in such way that std. should be on right side.
6. Observe the reducing strength of sample pigments comparing with STD.
G) Solubility (“ Bleeding”) of pigment:-
A pigment is ideally insoluble. Inorganic pigments are insoluble in organic solvents. The
solubility of organic pigments various with the pigments type, the Particle size, the nature
and Degree of substitution, the nature of resin, the solvents, and the temperature
encountered. Generally, toners and lakes are less soluble than the pigment dyestuff, but
strong solvents like ketones and esters give greater bleeding than the more widely used
hydrocarbon solvents. A few pigments have tendency to bleed with hydrocarbon solvents.
“Bleeding “ is the term used to describe the discoloration or staining which sometimes
occurs when a white or light colored paint is applied over a deeper color .It is generally
(but not invariably) due to the solubilizing effect of the solvents in the second coat on the
pigment in the first coat. The organic pigment, e.g. paranitroaniline red, is well known for
this tendency. A pigment which is very slightly soluble in the paint medium can function
quite satisfactory, provided the paint is not over coated as mentioned above.
Procedure:-
1. Weigh 10 gm of the pigment accurately and place it in 250 ml beaker.
2. To this ad 200 ml of the solvent combination, which can be used for further paint
preparation.

3. Stir the slurry for sometimes and keep it for 24 hrs at room temperature. Then filter
it.
4. If the filtrate is colored, the pigment is said to have a bleeding tendency.
5. Compare the filtrate with that of the original solvent for color.
6. For the hot paraffin wax bleed test, stir the pigment into melted wax and then filter
and note for any color change.
7. For oils which are too viscous for proper filtering, apply the pigment – oil paste as a
spot to a pile of filter papers , and compare the color of the oil which penetrates into
the underlying sheets with that of the clear oil on the same paper. ( In this case care
should be taken to distinguish between a finely dispersed pigment which may
migrate with the oil as it is absorbed by the paper and a true bleed due to solubility
of the pigment in the oil.)
8. For bleed into such materials as animal and vegetable fats , bacon ,ghee , etc., place
these materials in contact with a coated panel or paper , remove them at stated time
interval, and rate them for the degree of staining. (The temperature of this test is
important because it may very over a wide range under conditions of actual use.)
H) Acidity and alkalinity of pigment:-

Acidity is calculated by grams of sodium hydroxide required to neutralize 100 gm of the
pigment sample. Similarly, basicity is calculated as grams of acid required to neutralize
100 grams of the pigment sample.
Procedure:-
1. Weigh about 10 gm of the pigment accurately and keep it in a beaker.
2. Moisten it with a few drops of 95% ethyl alcohol and add about 200 ml of
freshly boiled water to it . Then transfer it to a 250 ml standard flask and make
a solution up to 250 ml mark .
3. Then filter this solution.
4. Reject the first 50 ml of the filtrate.
5. From the remaining portion of the filtrate, collect 50 ml of the filtrate it in a
conical flask and titrated for acidic or alkaline nature .( Acidic and alkaline
nature can be checked by a PH Paper )
6. If acidic, titrate it with 0.01 N sodium hydroxide . If alkaline, titrate it against
0.01 N hydrochloric acid .
I) Acidity and alkalinity of pigment:-

Organic pigments will decompose or sublime if subjected to sufficiently high
temperatures for extended periods. Many paint films encounter heat , either during a
stoving process , which may be in the region of 120 ºc to 200º c for periods of a few
minutes to an hour , or when applied to surfaces which remain at high temperature for
long periods.
It is essential that the pigments used in such paints should be resistant to the temperature
encountered and they have , therefore , to be chosen with care .

Temperature resistance vary from pigment to pigment and largely depends on the
chemical composition. Heat stability tests are carried out by subjecting the coating for
specific periods to standard temperatures.
EXAMPLE OF PIGMENTTESTING : -
Name of product-Titanium dioxide
1.Colour : – white powder
2.Appearance : - fine & smooth powder
3.Percentageof moisture contain-
 Wt. Of empty plate=9.21

 Wt.ofplate+pigment=10.29
 Wt. of after heating=10.28
=10.28-9.21/10.29-9.21
=1.07/1.08
=0.9907X100
=0.93%
4.Oil absorption value:-

 Density of oil-0.7
 Wt of pigment- 3.12
=0.9x0.7/3.12
=20.19 oil absorption value
TESTING OF ADDITIVE :-
Additives are the various chemical used in paints in small quantities to achieves
properties such as drying ,leveling etc .Additives play important role in the performance
of the paint .
Some Additives are given below :-
A.) AntisettlingAgent:-
Aluminium stearate is used as antisettling agents .Which prevents the settling (i.e.
Sedimentation) of pigment in the paints.

A jelly of Aluminiun Stearate is prepared in 15% of solvent turpentine at
temperature between 50-60c .The prepared jelly is then tested for colour ,clarity and
consistency.
B.) Matting Agents :-
These are used for matting effects /. The test is carried out in comparison with std .
Take equal quantities of sample and disperse them separately in some quantity of resins
& solvents . Then draw a comparative drawdown and then compare the matting effect
e.g.Ok 412, Aerosil R 972.
C.) Dispersing Agents :-
These Are used for proper dispersion of pigment in resin medium .Dispersing agent soya
lecithin has high acid value .Hence ,it is tested for acid value .e.g.Lofa .
D.) Driers :-
These are used for improving drying of the paint film .They are tested for colour,
clarity ,andviscocity .Determine of metal content is an important test for driers .
For example –
Zinc Octoate
Cobalt Octoate
Calcium Octoate
Zirconium Octoate
Lead Octoate
Testing of additive are as follows :-
A.VISCOSITY :-
Viscosity is rate of flow of fluid. Viscosity is expressed in second. Viscosity is measured
by Ford cup follows:
Procedure:-
1. Keep the clean & dry ford cup no. B4 in a vertical position on the stand, & level the
top of the cup & base of the stand.
2. Close the bottom orifice with the finger; fill the cup with freshly stirred bubble free
sample, until it just begin to overflow into the gallery. Pour slowly to avoid air
bubbles.

3. If bubbles are their allow them to rise and then remove them from surface with
spatula.
4. Check the level of sample coincide with that of top of cup, then set the stop watch.
5. Place suitable receiver under the flow cup, start the flow by removing the finger &
start the stop watch simultaneously. As soon as continuous flow line breaks into
drop, let stop the stop watch.
6. Note the time in seconds.
7. Clean the flow cup and repeat the procedure at last once.
8. The viscosity of liquid additive is then recorded in seconds .
B.DENSITY :-
It is measured by using density cup of 25ml capacity (gm/cc cup)
Procedure:-
1. Fill the clean density cup with sample by slowly pouring it in the cup to avoid air
bubbles.
2. Fit the lid of the cup tightly to the cup so that excess additive flows out from the
aperture of the lid.
3. Wipe out the overflowed additive so that exactly 25ml of additives remain in the
cup.
4. Weigh the cup filled with sample by using counter weight of the cup. Note the wt
of additives and calculate the density as follows:
Density = Mass = Weight of the Additive in gms
Volume of Additives in ml(25ml)
Density is expressed as Kg/Lit or gm/c
C. % OF NVM / ACTIVE CONTENT :-
A solid content of additive is determined by weighing a small amount of solution into a
shallow Petri dish and heating it an oven to drive of the volatile components subsequent
weighing will give the weight of the residual non volatile matter, the percentage of solid
in the original sample can be calculated.
Procedure:-
1. Take about 1-2 gm of additive sample in a clean & dry Petri dish previously
weighted.
2. Put the dish in oven for the specified time and temperature. Allow the dish to cool
room temperature and weight it again.
3. Calculate the %NVM by following formula.

W 2−W 1
% NVM¿ ∗100
W 3−W 1
D. AMINE VALUE :-
Procedure:-
1. Weight about 2-3 gm of sample (W) of the polyamide in to 250 ml conical flask
accurately. Do not heat polyamide prior to adding the neutralized alcohol to the
sample.
2. To a separate beaker add 100ml of Isopropyl Alcohol & 2ml bromocresol green
indicator +(0.1 % in methanol)
3. Add the neutralized isopropanol to the weighted sample of the polyamide. Agitate
until dissolved. Titrate with std. HCL or H2SO4 solution (approximate 0.5N) .
4. Colour changes from blue to yellow. This is the end point. Note the burette reading
(v) & calculate the amine value by following formula-
56.1 xN . of acid x B . R .
AMINE VALUE¿
Weight of sample .
TESTING OF PAINTS:-
Paints may be defined as ashomologenous ground mixture of pigment , resin, solvents
and additives.
Paints is used for mainly two purpose .
I. Decorative purpose .
II. Protective purpose .

After opening the sample container of the paint ,it is first examined as follow :
1. Separation :-
Any Separation or loss of homogeneity of sample is recorded .
2. Consistency :-
The sample is observed for any thixitropicbehavior.
thixitropicbehavior.
3. Surface Skinning :-
If there is a formation of skin on the surface of sample ,it is recorded & condition is
described i.e. thin film , thick etc.
The skinisliftedcarefully ,rested on the lid to allow any paint to drain into the container &
then discarded
Depending upon skinning, anti-skinning agent is used.
4. Settling of paint :-
For this , stirrer or pallet knife is inserted in the container to ascertain if the pigment has
settled & if so , weather settling is light or heavy, soft or hard.
TESTING OFFINISH GOODS :-

Finished goods properties & quality is checked by quality control &when fault are observed
quality control is improve them.
Following test are carried out on the basis of paint state :-
A).VISCOSITY :-
Viscosity is rate of flow of fluid. Viscosity is always expressed in second.
The unit of viscosity is poise. Viscosity is checked by with help of B-ford cup
Procedure:-
1. In the first stage take a B-ford cup & hang on the stand in vertical position & level
top of the cup & the base of the stand
2. After checking bubbles in the sample pour the bubble free sample of liquid paint in
the viscosity cup

3. If bubbles are observed remove the bubbles from the sample with the help of
spatula
4. Close the bottom aperture of the viscosity cup keep with your middle finger
5. Ensure that the level of sample is top of the cup if this is excess remove it with help
spatula
6. And set the stop watch & remove the finger from the bottom of the viscosity cup.
7. When stop the flow of liquid paint take down the reading in second & note down.
B).DENSITY :-
Density is the most important property of the liquid paint & it also known as weight per
liter or specific gravity.
Density is checked with help of density cup density cup capacity is 50 or 100 gm
Procedure:-
1. Take an accurate tare weight of the density cup.
2. Fill it with distilled water at room temperature & place the lid tightly on the cup.
3. Dry the density cup.
4. Fill the density cup with paint & place the lid on the bottom of the cup.
5. Press the lid & excess of the paint removed.
6. Weight the density cup with the help of weighing balance.
7. Weight of density cup – M
8. Weight of the density cup + paint -M2.
DENSITY= ( M2 – M1)
Volume of cup

= weight of paint
Volume of paint .
C).FINENESS OF GRINDING :-
Fineness of grinding means degree of dispersion of pigment or extender in resin or any
vehicle system.
Fineness of grinding usually measures in with the help of Hegman gauge. Hageman
gauge is flat slab having tapered grooves. Fineness of grinding is usually measured in
microns.
Procedure:-
1. Place the clean slab on the flat surface.
2. Take small quantity of paint about 1 to 2gm of paint on the Hageman gauge slab.
3. With the help of applicator draw down on the grooves with
uniform & sufficient pressure.
4. Hold the gauge at the eye level in inclined angle between 20 to 30 degree &
examine the surface of film immediately fitness of grinding are considered where
particles are observed.
D).DRYING TIME :-
Drying time of the paint is the converting liquid paint system into solid system after
application of the paint on the panel in the form of thin coat.
This system having three different stages as follows :-

1. ]SURFACE DRY : -
Surface dry is the stage of paint at which surface of paint film does not stick on finger
& no finger mark observed on panel
2. ]TACK FREE :-

Tack free is the stage at which paint surface is not stick on finger after pressing or it does
not show tacky structure & does not finger mark on the panel.
3. ]HARD DRY :-
Hard dry is stage at which paint film does not remove from the panel with the help of
finger nail & hard dry means paint film completely dry on the panel.
E).EVOLUTION OF DRY PAINT FILM PROPERTIES ( DRY FILM

TESTING ) :-
After complete drying of the paint film following test are carried out-
1. GLOSS :-Gloss means light reflection falling on paint

Gloss is very important property of paint film. Gloss of paint film is usually measure with
the help of Gloss-o-meter.
Procedure:-
1. Firstly calibrate the instrument .calibrate the instrument against standard gloss
indicator.
2. Place the gloss-o-meter on the prepared panel of paint sample.
3. Measure at least four portion of the surface of the specimen to obtain an indication
of gloss readings and average gloss is recorded .
4. Gloss is measured by using 45º or 60º incident head (angle).

2.FINISH :-
Finish of paint film measure whether film is matt or smooth. It is depending upon the
gloss.
There are five type of finish –
1. High glossy finish
2. Glossy finish
3. Semi glossy finish
4. Egg-shell finish
5. Matt finish
3.SHADE :-
Shade of the panel sprayed by sample is observed visually and the observation is noted as
different in hue as compared with the standard shade panel for the specific shade .
We have checking the shade by Spectro Meter ( Shade Matching Machine) .
Spectro Photo Meter
4.SCRATCH HARDNESS :-
In this method resistance to scratching under specific load , of a dried film of the paint is
tested in this case automatic scratch hardness is used this instrument consist of a hard
steel needle having a hemispherical shape & 1 mm diameter.
Procedure:-
1. Apply a coat of coat of paint on panel on metallic panel either brushing or
spraying .
2. Allow the panel to air dry in a horizontal position for 48 hours under specified
conditions or stove as specified in the material specification.
3. Test the panel under a load of 1000gm unless otherwise specified in the material
specification.

4. Fix the needle at the end of counterpoise , which is kept horizontal by adjusting
the length of the needle , and draw the panel under the needle at the rate of 30 to
40 mm per second .
5. A scratch , showing the bare metal shall not be produced when tested as above . if
scratch is produced then scratch hardness test is failed .
6. Similarly the material can be tested for various loads .
7. Any automatic device fulfilling the essential requirements of the prescribed
apparatus and giving comparable results may also be used .
5. CROSS HATCH TEST :-

This test measure the adhesion of paint on the panel .this test is carried out complete
drying of the paint film . in this test , a die with a number of close set parallel blades is
pressed into the paint film successively in two direction at right angle to each other the
second pressing is superimposed on the first , giving a pattern of squares . a strip of self
adhesive step stuck over the pattern is removed sharply , and adhesion of the film is
assessed from the amount of coating removed .

Procedure:-
1. Take a series of eleven parallel cuts on the painted panel with the help of cross
cut tester . the parallel cuts are taken 1 mm apart on the film of DFT , the
distance between two parallel cut should be 2 mm.
2. Take another series of similar cuts at right angle to the above cuts so that 100
squared of equal area are formed .
3. Apply the cello tape on the square , press and remove . no air should be
entrapped between tape and paint film .
4. Note the no. of squares removed during testing and records the percentage of
square showing loss adhesion .
6. FLEXIBLITY OR BENDING TEST:-

Flexibility of paint film means the ability to undergo bending without any damage or any
cracking of paint film this property important on metal substrate which are subjected to
temperature flotation .
Flexibility depends upon type of resin used , film thickness temperature of test ,duration
of drying . flexibility is checked by mandrel apparatus . mandrels normally used for
testing are ¼ or 1/8 inch.

Procedure:-
1. The paint is applied on thin strip ( 4 by 2 inch) and allowed for specified time .
2. The panel is then placed in mandrel apparatus.
3. Fold the apparatus in 180 degree and check the paint film stretched .
4. After bending , bend is examined for crack and damage of film . if film shows
no damage and continuous film form , then flexibility test is passes.
7. DRY FILM THICKNESS:-

Dry film thickness is important property of paint film .this test shows how thin coat
applied on panel.

Procedure:-
1. Initially adjust the coat meter by using known thickness plastic foil .on
standard panel .
2. After it , measure the D.F.T. of paint film by usual procedure and reading from
coat meter is taken as D.F.T. of paint .
3. Precaution should be taken that the panel should on flat surface.
4. Before taken D.F.T .it ensure that the film is complete dried .
8.IMPACT TEST:-
This test is devised to determine the degree to which the paint on metal surface can
accommodate rapid deformation by allowing a weighted indenter to fall on it from a fixed
height at 50cm. The impact may be on the coated surface or on the back of panel
( reverse impact ) according to specification requirements for the material . The apparatus
consist of steel block which slides vertically between two guides . Mounted under the
block is a tool holder in which is fixed an indenter. The block and tool fall under gravity
on to the die blocks is impacted by the tool .the depth of the indentation is varied by
inserting washers of known thickness between the indenter and tool holder . it is
necessary to use films of standard thickness and thickness of the panel must also be
constant .The weight of impact tester is 2.2Kg.
The failure of the paint film is shown by cracking and by the loss of adhesion at the
deformed portion of the panel .
Procedure:-
1. Apply the coating on the panel with a specified thickness and dry or stove the film
in the specified manner.
2. Ensure that the apparatus is vertical and that the tool holders falls freely.
3. Raise the tool holder to its upper position and fix the indenting tool firmly in
position .
4. Insert between the indenting tool and tool holder , steel spacing . washers equal in
thickness to the amount of indentation specified.

5. Place the coated panel , with the paint film facing down words (indirect impact) or
up words (direct impact) as specified , between the die blocks and it firmly in
position.
6. Remove the panel by separating the die blocks .
7. Inspect the film visually by normal corrected vision for cracking and loss of
adhesion.
8. Gently rub the painted surface of the deformed portion of the panel and again
examine for removal of the paint film .
9. Stoving Schedule :-
Stoving paints are cured by heating in oven at the specified temperature and for the
specified time :-
For example `: s.s1020 c /30 min .
After heating the film is completely cured to form a cross-linked structure to achieve
proper hardness.
10. Acetone Test :-

After this stoving schedule panel checks the resistance of the ketonic solvent .
(i.e.Acetone ) for 60 strokes and 5 minutes .
Procedure:-
1. Take some quantity of paint in 100 ml beaker with a clean and dry brush and
weight them together accurately .
2. Apply the paint on the clean surface of mohreschequer board so that complete
hiding is achieved .
11.Wet Opacity(Hiding Power) :-

Hiding power of paint is most important property .It is measured as the area in square
meters ,which can be painted by achieving complete hiding in one liter of paint.
Procedure:-
1. Take some quantity of paint in 100 ml beaker with a clean and dry brush and
weight them together accurately .
2. Apply the paint on the clean surface of mohreschequer board so that complete
hiding is achieved .
3. Again reweigh the beaker with remaining quantity of paint and brush .
4. From the difference in weight calculate the quantity of paint used for painting the
given area .
5. Find out the area which can be painted by achieving complete hiding using one
liter of paint as follows :-
Weight of paint used(in gm)
Volume of paint used (in ml) =
Density of paint

12.Two - Pack system :-
In case of two pack system (I.e.Epoxy paint and PU paint ) curing agent is added to base
for the proper drying time. The mixing ratio of base to hardner (curing agent) is as per
speci0fication .
In case of epoxy paint the mixing ratios is 3:1 (i.e. 3 parts Base and 1 part Hardner).
In case of PU paint the mixing ratio is 4:1 ( i.e.4 parts Base and 1 Part Hardner ).
13.Pot Life :-
Pot Life is defined as the complete curing of base by the reaction between base and
curing agent .
Procedure:-
1. Mix the base and the Hardner in the ratio mentioned as per specification on
porcelain dish .
2. Note the time required to the mixing to get converted in a solid phase from liquid
phase ,is called as pot life of that system.
14. Overcoat On Primer :-

In case of fast primer ,adhesion of second coat of the paint on primer coat is tested .
First apply a thin coat of primer on the panel and allow drying it for a specified time
(about 24 hrs.) After that rubs the surface slightly with polish paper and applies the other
coat of epoxy or PU paint on that primer coat and dry it for specified time .After this
allow the panel into oven at 1200 c for 30 minutes for giving hardness to the paint .Cool
the panel and check the cross cut adhesion test .
15. Resistance To Water As Per IS 101 :-

This test is taken after 48 hrs .Curing for air drying paint and after the specified stoving
schedule for stoving paint. Immerse the panel in distilled water at room temperature for
48 hrs. Remove it from the water and examine after 4 hrs .The film shall no sign of
deterioration and shall retain at least 60% of the original gloss as determined by gloss -0-
meter .The paint film should not show any blistering.
16. Oil Resistance :-

This test is carried out after 48 hrs. Curing for air drying paint and after the specified
stoving schedule for stoving paint .Immerse the panel for 2 hrs. At the temperature of 50 0
c in mineral lubricating oil having a viscosity of 18centistroke or having a time of flow of
approximately 80 seconds for 50 ml at 60 0 c No .1 red wood viscometer .Remove the
panel from oil after 2 hrs and wipe the excess oil with a pad of cotton wool. Then keep at
room temperature for 30 minutes and then examine the panel for any sign of permanent
injury.

17. Resistance To Heat :-
This test is carried out after 48 hrs .Curing for air drying paint or after specified stoving
schedule for stoving paint. The panel is heated to the specified temperature and maintains
there for 2 hrs. Then keep the panel at room temperature for 1 hrs .
Examine the panel for adhesion , cracking , blistering and change of colour.

INSTRUMENTS USED FOR TESTING
Sr.No. Name of Test Instruments

1. Fineness of Grinding Hageman Gauge
2. Viscosity Ford cup B4
3. Density of Paint Density Cup of 25 ml
4. Specific Gravity Hydrometer
5. Gloss Gloss -0- meter with 600c incident
6. Impact Test Impact tester
7. Cross- Cut Test Cross cut Tester
8. Flexibility Mandrel flexibility tester of
Conical Mandrel ,¼”,1/8”
9. Scratch Hardness Scratch Hardness Tester
10. Dry film Thickness Coat Meter
11. Melting Point Melting Point apparatus
12. Corrosion Resistance Salts spray chamber
13. Balance Physical balance, Chemical
balance
14. Stirrers Magnetic Stirrer, lab scale Stirrer

15. Heaters Water bath, Hot plate, Heating
Mantle ,ovens ,Muffle furnace

MATERIAL INWARD, DESPATCHES,
PACKING
MATERIAL INWARD:-
Inward material should be received in good condition. Barrel of solvent & resins should
be properly scaled. Pigment bags should be scaled & are weighed properly before
accepting. For sampling containers are selected at random from bulk. Raw material
received should be used only after approval of quality control.
PACKING:-
The material is packed for dispatch only after the approval of Q.C.Drums for finished
goods packing should be screen- printed receiving and then store properly. Screen printed
containers are further printed by using stencils as per the requirements from time to time.
Packing for paint:- 500 ml.

1 liter
10.0 liter
15.0 liter
20.0 liter
Packing for thinner:-

5.0 liter can/drum
10.0 liter can/ drum
20.0 liter can/drum
30.0 liter can/drum
200.0 liter drum
Packing for Hardener:-

1 Letter bottle/can
5 Letter can

Dispatch Invoice

Goods Receive Receipt :-

Inward Material Receipt :-

THINNER MANUFACTURING
We are manufacturing the very type of thinners .It is a purely mixing .Solvents are
added in a container according to their properties .The final combination is always a clear
and water liquid .While selecting the solvent following precautions should be taken.
1. Such solvents should be avoided which give bleeding of pigments incorporated in

the paint.
2. Solvent should be free from moisture.
3. Solvent should not have strong smell or irritating sell while spraying.
The types of thinner are followed:-

1. Thinner PU
2. Thinner NC
3. Thinner Epoxy
4. Thinner QS
5. Thinner GP
6. Thinner Fast
7. Thinner HR
8. Thinner EST
9. Thinner Acro

SPRAY GUN
Spray painting is a painting technique where a device sprays a coating (paint, ink, varnish,
etc.) through the air onto a surface. The most common types employ compressed gas usually
air to atomize and direct the paint particles. Spray guns evolved from airbrushes, and the two
are usually distinguished by their size and the size of the spray pattern they produce.
Airbrushes are hand-held and used instead of a brush for detailed work such as photo
retouching, painting nails or fine art. Air gun spraying uses equipment that is generally larger.
It is typically used for covering large surfaces with an even coating of liquid. Spray guns can
be either automated or hand-held and have interchangeable heads to allow for different spray
patterns. Single colour aerosol paint cans are portable and easy to store.
Air spray gives the finest finish quality referred toas an automotive finisher Class a Finish.
SPRAYING CAP DESIGN

1. Cap a. external mixing
b. Internal mixing type,
2. Feed a. Gravity
b. Suction
c. Pressure type of paint storage cup
External mixing type of spray guns - This type of spraying gun mixes and atomizes the
Air and paint mixture out side the nozzle of the gun beyond the air cap. This gun is used
For all types of liquid spraying and is most suitable for fast drying liquids.
Internal mixing guns - These types of guns mix air and paint within the gun and air cap
Before they are released to atomization. This gun is used for low air pressure and
materialsof slow air drying nature.
Gravity Feed Cup spray gun- gun- The material cup is mounted over head on spray gun and
Material is fed under gravity. This gun is specially useful for small works and suitable for
Fastcolor change and for working with relatively lower air pressure.

A SPRAY GUN
Suction Feed Cup Gun- Paint cup is attached below the head of spraying gun and paint
isbrought in air stream with the help of vacuum created by high pressure of air stream.
Thecontainer is of limited volume capacity and suitable for small jobs only and that
requiresfrequentcolor changes.
Pressure Feed Spraying Guns-A

Guns-A big size container is attached to spraying gun through
Pipe hose to maintain paint supply from a container which is maintained under positive
Air pressure. The paint material under air pressure is made to flow to the gun
continuously. This type of gun is used for continuous operation also for materials too
heavy to be drawn up by suction.
PRINCIPAL COMPONENTS of SPRAYING GUN-

GUN- The spraying gun consists of
Following parts;
A) Main body- Main body of consists of metal cast and contains all control knobs, air
And fluid passages, a passage connecting gun body and fluid cup. The gun is shaped in
Such a way so as to handle easily without any discomfort. A trigger is provided near the
Handle that is used for controlling the flow of air and the fluid.
b) Air cap- It is a special nozzle in front of gun which directs compressed air into paint
Stream and so atomizes it and forms a spray. A cross section of this spray is known as
Spray pattern. Air caps are designed to give a wide variety of shapes and sizes of spray
Patters in addition to ensuring perfect atomization of material over a wide range of
Viscosity. Modern air caps have multiple jets and final choice of cap depends on
Following,
- Volume and pressure of the compressed air available,
- Type of paint feed system available,
- Type and volume of the paint to be sprayed,
- Nozzle size of fluid tip. Air caps are usually designed for a particular fluid tip.
c) Fluid tip- This is an orifice situated directly behind the air cap. It controls flow of
Paint and directs it in to air stream. It also forms seat for nozzle needle which cuts off
Flow of air and paint.

d) Thin needle adjustment- This adjustment controls travel of fluid needle which adjusts
The amount of paint passing through fluid tip and stop the flow when needed. The
Movement of needle is controlled by the trigger.
e) Trigger- A trigger is provided below the main body that controls movement of the
Needle, which further controls flow of paint and the air stream.
f) Air Valve- An air valve is provided at the back of gun body that controls air volume in
The air stream. Another valve is provided for paint stream.
g) Spreader adjustment Valve- This is a valve for controlling air flow to the horn holes
Which regulate the size of spray pattern?
Spray Booths - Spray booths are necessary for removal of spray mist from air, so that
Paint particles do not settle on painted articles, operators do not breathe contaminated air
And that air being exhausted is clean, thus avoiding pollution of atmosphere.
SPRAY BOTH
Following types of spray booths are commonly used:
a) Dry back spray booths- Dry back spray booth consists of a three-sided roofed canopy
Constructed of sheet steel fitted with a fan of suitable size and capacity to ensure efficient
Extraction over whole area of booth. Distributing plates are fitted over the fan to ensure
Uniform air distribution. These plates can be removed if required for cleaning. The fan
exit
Is usually placed near the out side wall so that only a short ducting is required for
Exhausting the polluted air to outside atmosphere.
b) Wet screen spray booths-

booths- These booths are fitted with wet screens. The over sprayed
Paint particles are trapped in water wet screen. These booths are further designed as two
Types:-
1) Down drought water washed spray booths- These booths exhaust the contaminated
Air through a floor grating. This is of distinct advantages where large or heavy articles are
Painted. In this case, roof of booth is not necessary, even the sides can be eliminated.
Heavy articles to be painted can travel on over head conveyor or trucks or even under
Their own power. The extracted paint laden air flows through a water tank below the
Grating and through a series of spray nozzles and baffles, which scrub the air free from
Paint particles before going to the exhaust.
2) Wet screen type -With

-With this type, the rear screen, usually enameled, is situated over
The tank in such a manner that water forms a complete water fall down the screen and
Over the space between bottom of screen and water in the tank. The contaminated water
Passes through a series of filters, filled with either coke or wood wool, before being
Pumped up to the top of screen where it passes through a series of jets arranged along the

Top of screen. Arrangements are made to maintain a constant level in water tank and
Facilities are provided for rapid draining and easy cleaning of system. Water is treated
With an alkaline additive (sodium met silicate or phosphate type) to precipitate and
Coagulate paint particles which then float on surface and can readily be removed, thus
Avoiding choking of pump filter.
Paint Formation for conventional spraying -Most -Most types of paints can be applied by
Spray guns, provided solvents are chosen carefully. These solvents should not be too fast
Evaporative, otherwise it will lead to a dry spray. In case, the solvents are too slow
Evaporating, it will lead to sagging. Solvents and thinners must have good cutting power
For paints so that large volume of thinner is not required to reduce viscosity for spraying.
In case of too much dilution, solids content in thinned paint is too low and produces
Inadequate thickness and opacity after drying or curing on finished product.
Spraying Technique - Spraying is a skilled job; it needs a number of controls such as:
a) Viscosity of Paints - Lower viscosity is easier for atomization and imparts good flow
In the field. High viscosity leads to inadequate atomization thus leading to structured
Appearance.
b) Fan Spread Pattern- The spray pattern is controlled by means of spreader adjustment
Valve.
c) Air pressure- Air to fluid ratio is generally adjusted by controlling air pressure. In
Case of pressure-fed paint supply, two independent adjustments is possible. At air
Pressure in pressure-pot can be varied to supply more or less paint and the atomizing air
Pressure can be increased or decreased while keeping the fluid pressure constant.
d) Fluid Adjusted - Fluid adjustment is done by means of fluid adjustment screw on the
Gun. This, however, restricts movement of trigger and also slows down spraying
Operation.
HOT SPRAY APPLICATION

Hot spray application is mainly applicable for spraying of nitro-cellulose lacquers. It is
Based on principle - for achieving atomization of paint, low viscosity is necessary. In
Conventional spraying this is obtained by adding thinner. However, addition of thinner
Reduces solid content of paint, which in case of Nitro-cellulose lacquers, is already low.
In hot spraying, viscosity reduction is obtained by heating paint or lacquer up to a
Temperature of 60-80°C. Viscosity reduces to about 1/3rd of that at normal temperature.
Because no thinner has been used, the %age of solids remains unchanged and thicker
Films are deposited. For heating of paint, various types of heaters are used, e.g.:
- Electrically heated water jacket
- Heating directly with electricity via a metal block
- Heating by superheated air (electrically heated)

Advantages of Hot Spraying Technique:-
* Because of high temperature, less energy is required for atomization of paint.
Therefore, less compressed air is required, about 1/2 that normally used in cold spraying
* Applied film contains higher solid content than in normal spraying because paint
Contains less thinner and also because higher proportion of solvents evaporates during
hot
Spraying. In normal spraying, 1/3rd of total solvent evaporates before reaching the article,
At temperature 5-7°C below room temperature. In this hot spraying, 3/4th of the total
Solvent in paint evaporates. Drop in temperature is also higher but actual temperatures of
Paint film deposited is also higher. Therefore, defect like blocking is avoided in hot
Spraying.
* Better wetting of surface is achieved due to increased temperature. Better adhesion is

Obtained. Pin holes are reduced. Flow is better. Therefore, better gloss is obtained.
Orange peel is reduced.
* If stoving paints are applied by hot spray technique, short flash off is required.
Therefore, dirt pick up is reduced.
Formulation of Coatings for Hot Spray Process- Two types of paints can be
formulated for hot spray process,
1. Non convertible coatings- Lacquers are classified as non convertible coatings.

Polymers are dissolved in strong solvents like in the case of Nitro-cellulose lacquers.
Higher % of true solvents is needed in hot spray lacquers to avoid turbidity in the coating.
Solvents should be kept to a minimum; otherwise a dry dusty film is obtained. Medium
Boiling solvents such as butyl acetate, MIBK, methyl cellulose, xylene and butane should
Be used. It is possible to use high viscosity grades of nitro-cellulose for hot spraying.
These grades give better hardness and durability but are not suitable for cold spraying.
2. Convertible Paints (both air drying & stoving)-These

stoving)-These should be formulated for
drying in air either by oxidation or by chemical reaction between two co-reactants.
Surface drying catalysts such as cobalt drier should be kept at a minimum. Higher % of
butane should be used to ensure stability of paint at high temperature. Two pack paints
should not be used for conventional hot spraying.
AIRLESS SPRAY APPLICATION

Airless spraying is rapidly increasing in popularity as a method of paint application has
Been developed to eliminate the use of high pressure air as atomizing medium.
Atomization takes place only when the liquid attains a high velocity beyond a particular
Value. (Flow becomes turbulent).This is ‘Raleigh’s Principle’. In conventional spraying,
a large volume of air is required to atomize a very small quantity of paint (1%)because
specific gravity of air is very low as compared to that of paint. So for giving high velocity
to the jet of paint, large quantity of air is necessary. The spray, therefore,
Contains a very small amount of actual paint. This shows relative inefficiently of
Conventional spraying process. Principle used in airless spraying can best be illustrated
by comparison with a garden hosepipe. With a full aperture, jet of water is obtained but
on reducing this aperture (i.e. effectively increasing the speed of water through a small
orifice), the critical speed is reached and the jet breaks up to form a spray of water
droplets (Laminar flow becomes turbulent). Two other factors which help to atomize
paint in airless spraying are:
1) Effect of resistance of stationary atmospheric air surrounding spray tip to high speed
Jet of paint,
2) Rapid evaporation of solvents at nozzle tip. There is tremendous volume increase on
Evaporation.
Airless, Theory of Operation

 Airless spray atomization hydraulic force through a cat’s eye shaped orifice.
 2000+ psi fluid pressure
 Fastest and heaviest spray finish and is measured in liters per minutes.
 Transfer efficiency = 50-60%
 Protective coatings
2000+ psi fluid pressure
Transfer efficiency = 50-60%
Equipment for Airless Spraying- Airless spray equipment consists of a means of

Producing high pressure on the paint and a special gun connected via a pressure -
resisting

Hose. The unit works on principle, as explained above, of applying a high hydraulic
Pressure to paint to force it through a tiny orifice. This high pressure is obtained from a
Normal paint spraying compressor unit via an air powered pump which develops a final
Paint pressure from 20 to 30 times that of the incoming compressed air. If, for example,
Incoming air pressure is 6-7 Kg / sq.cm. Then pressure on paint will be 120 to 180
Kg/cm2. In some units, stainless steel pumps are used so that acid catalyzed paints can be
Handled. Pump operates only when trigger on gun is depressed. A series of fine sieves is
Incorporated in the unit to avoid clogging tiny gun nozzle with extraneous paint particles.
Here is normally a fine mesh sieve at base of pump unit and also a further sieve in tip
Assembly. The pressurized paint is transferred to spray gun via a spirally wound stainless
Steel reinforced Teflon or nylon hose, specially designed to withstand pressures in excess
Of possible maximum developed.
Spray gun consists only of a tungsten carbide ball value and seat, a sieve assembly and
Tungsten carbide type or orifice. Tungsten carbide is used to reduce the abrasive wear
Caused by coarse pigment particles in paint. These tips are most important part of
Equipment and are specially shaped to give various spray patterns and are available in
A wide range of orifices to suit the type of paint being sprayed (3/1000” to 20/1000”).
A blow gun device is provided for cleaning the tip, if it gets blocked. Only two variables
Are available for adjustment in airless spraying -
a. Size of the tip and

b. Input air pressure (on paint).
High pressure is not exerted on the paint container. Paint gets sucked up into the high
Pressure zone in the pump compartment. Hot airless spray units are also used.
Advantages of Airless Spraying:
* Airless spraying is much faster than conventional spraying. Thicker films are
Obtained, especially useful with primers and primer surfaces.
* As air is not used for atomization of paint, there is no overspray. Paint droplets fall on
The ground within a few feet, instead of being carried past the article. Hence powerful
Water wash, exhaust fan for removing solvent vapors. (Large volume of air is not
Removed from paint shop). Therefore, this process is useful for spraying large objects
Which cannot fit into a spray booth, e.g. air crafts, ships, buildings, etc?
* There is no bounce back in airless spraying, hence inside surfaces can be sprayed more
Easily (barrels, refrigerators, washing machines, beer cans and other containers).
* This leads to cleaner finish owing to the fact that less dirt and foreign matter are
Deposited in the wet film. Oil and water droplets usually present in air are also avoided.
Disadvantage - Tips of the sprayer are expensive and require frequent replacements.
Paint Formulation for Airless Spraying- Generally, paints suitable for conventional
Sprayingis also suitable for airless spraying. More rapidly evaporating solvents should
Be used for efficient atomization and to avoid runs and sags in the paint film. Highly
Pigmented undercoats and primers do not normally require much solvent adjustment.
Atomization is easier with low viscosity fluids and primers are thixotropic, their wider fan
Using the same tip than the corresponding finish coats. Glossy paints require a fast
Evaporating solvent combination and a degree of thixotropic structure. All paints should
Be free of bits, skins and other extraneous matter.

ELECTROSTATIC SPRAY APPLICATION
We manufacturing the High Build Epoxy Paints those are apply by the Electrostatic
spray application.
Conventional spraying is a very wasteful operation. For example, on open work (e.g.
grill) as much as 75 percent of paint is wasted. Electrostatic spray technique was initially
Developed by Ransburg of United States to reduce paint wastage to a minimum and to
Enable processes to be made automatic operations. Electrostatic spraying can be divided
Into following methods:
A). Automatic Electrostatic Spraying:

(I) Air assisted electrostatic spraying
(ii) Disc or bell painting
B) Electrostatic Hand Gun
A) (I) Air assisted electrostatic spraying- This is known as Ransburg paint mist into a
Powerful electrostatic field produced with the help of negatively charged grids. (Voltage -
Higher than 100,000 volts). The article to be painted is earthed. Paint droplets acquire
Negative electric charge while passing through the electrostatic field. Paint particles,
Therefore, get attracted towards the oppositely charged article. This method made
Automatic spraying possible and paint wastage was reduced. But it suffers from
drawbacks
Such as:-
 Compressed air is still essential
 Overspray is not completely eliminated
 Powerful exhaust arrangements are necessary
 Spraying is carried out at lower pressures than in conventional spraying.
Thisresult in blocking of the passages in the gun
ii) Disc sprayer-

sprayer- This is known as Ransburg No. 2 process. Use of compressed air is
Completely eliminated in this process. Rotating discs or rotating bells are used as
Applicator heads. The disc or the bell is rotated by an electric motor at a speed of 1000
Rpm. The thinned paint is fed through the hollow shaft on which the disc or bell is
Rotating. The paint is spread to the periphery due to the centrifugal force exerted by the
Rotating head. The periphery of the disc or bell is charged to volts. The paint acquires this
Charge and paint particles being all negatively charged, get repelled from one another and
A fine spray or mist is formed. The article to be painted is earthed and, therefore, acquires
Positive charge by induction. Negatively charged paint particles get attracted towards the
Article which then gets painted. The choice of the disc or bell is dependent upon the size
And shape of the article. Discs are usually placed at the centre of a circular path of the
Conveyor, bells are used as applicators. Discs and bells both can have reciprocating
Motion along with rotation, so that total vertical surface of the article can be uniformly
Painted.

ELECTROSTATIC SPRAYING

Phosphating Method:-
PHOSPHATING
Iron, Zinc, Manganese phosphating
Iron and Zinc Phosphate are Paint base coating
Manganese phosphate – oil retention
Selection of Phosphate coating will depend on end use of article and economies
Quality checking of phosphate Coating (Zinc phosphate)
Visual Observation – Uniform grey color

Film weight – 2 ~ 4.5 gms/m2
Crystal size - < 10 μ Dip System
< 15 μ Spray System
Crystal structure – Columnar Dip system
Needle shape Spray system
'p' ratio - > 90 Dip system
> 70 Spray system
CRYSTAL STRUCTURE

Reaction Mechanism
Phosphating in automotive
Phosphating is an electro chemical process.
The steel surface is converted in to a surface with inorganic coat over it in this stage.
Tri caution phosphate are used for automotive &auto ancillary .
Tri caution phosphate is based on three captions namely.
Zinc
Manganese and
Nickel
Advantages of tri caution phosphate

-Complete coverage.
-High alkaline solubility resistance gives maximum corrosion protection.
-Optimum crystal morphology.
-High bath stability.
-Low heat losses.
-Reduced maintenance.
-Tri caution phosphate is the current ‘state of art’ in pretreatment. It is used in all major
automotive companies worldwide.
Theory of phosphate
Orthophosphoric acid (H3PO4) is a tri basic acid. It contains three replaceable hydrogen
Atoms, giving rise to three series of salts. The divalent metals (Zn, Ni, Mg) form three salts
viz,primary, secondary, tertiary with phosphoric acid. Primary salts are main phosphate
coating forming chemical in the phosphating bath
Mechanism of phosphating
Phosphate bath consists of the following
FREE ACID (Basically free phosphoric acid)
TOTAL ACID (Primary phosphate of Zn, Ni, and Mg)
ACCELARATOR (Based on inorganic or organic oxidizing agent)
Phosphating chemistry
Etching/ pickling of the surface.
Formation of phosphate crystals.
Formation of sludge.

STEP 1- PICKLING OF SURFACE
Fe + 2H3PO4 Fe (H2PO4)2 + H2 (g)

Primary iron phosphate
Fe + 2H+ Fe2+ + H2 (g)
STEP 2 – FORMATION OF PHOSPHATE CRYSTALS
3Zn2+ + 2H2PO4- + 4H20
Zn3(PO4)2*4H20 + 4H+
(HOPEITE)
STEP 3 – FORMATION OF SLUDGE
Fe2+ + H+ (O ) Fe3+ + HOx
Fe3+ + H2PO4- FePO4 + 2H+

Sludge
Phosphating chemical: Primary Zinc phosphate, Free Acid.
Metal + Free Acid Metal Primary Phosphate + H2

(O)
Metal Phosphate (FePO4) sludge
Metal + Primary Zinc Metal Zinc phosphate + Free acid

Phosphate Zn2Fe (PO4)24 H2O (Phosphophyllite)
Primary Zinc phosphate Zinc Tertiary phosphate + Free Acid

Zn3 (PO4)24 H2O (Hoplite)
The reaction proceeds at proper temperature, treatment time.
PASSIVATION :-
 Seals the gap between phosphate crystals

 Improves corrosion resistance
 Hexavalent chrome is an environmental concern
 Chrome free passivation chemicals are available
 Eliminates contaminants from surface.
.

INDUSTRIAL WATER SPECIFICATION
PHYSICAL
Sr. No. ITEM STANDARD
1 Appearance Clear
2 Color colorless
3 Turbidity 2.0 max
4 Odor odorless
5 pH value 5.8 - 8.0
6 total dissolved solids 300 mg/lit max.
7 Conductivity 100 us / cm.
CHEMICAL
Sr. No. ITEM STANDARD
1 total hardness 150 mg/lit max.
2 Sulphates 5.0 mg/lit. max.
3 Chlorides 25.0 mg/lit max
4 Nitrates 10.0 mg/lit max
5 dissolved iron as Fe 0.3 mg/lit. max.
6 Chromium 0.05 mg/ lit.
7 chemical oxygen demand max. 5.0 mg/lit.
mg/lit.
PROBLEMS DURING PRETREATMENT
1. Improper Degreasing
Causes: Water break phenomenon is observed on all over the component or locally.
Degreasing bath concentration, temp. ,lower than specification.
About Equipment: Nozzles are clogged, higher oil content in bath.

Chromated or plated steel.
Inadequate quality of oil.
2. Yellow/Rusty phosphate coating

Yellow phosphate coating is observed after drying.
Rusted surface, inadequate derusting
Causes: Ineffective surface conditioner – Acidic/Alkaline.

Phosphate bath – High F. Acid, Lower T. Acid
- Low accelerator content, Low temp.
- Low Zinc content.
About Equipment: Nozzle clogging, Low circulation, inadequate exhaust.

3. Powdery phosphate coating
White, powdery phosphate coating is observed where powder can be taken away by
hand.
Causes: Improper quality of substrate, Water rinsing not effective,

Inadequate phosphate bath, Higher Total Acid / Free Acid Ratio
High temperature, drying in the interstate zone.
About Equipment: Check conveyor Speed
4. Incomplete phosphate coating

Phosphate coating is not formed completely on the surface. Base metal, blue colour is
Visible
Causes: Poor quality of substrate steel, improper degradability, improper surface

Conditioning, drying in the interstate zone
SALTS SPRAY METHOD:-

The
The salt spray (or salt fog) test
test is a standardized and popular
popular corrosion
corrosion test method, used
to check corrosion resistance of materials and surface
surface coatings.
coatings. Usually, the materials to
be tested are
are metallic
metallic (although stone, ceramics, and polymers may also be tested) and
finished with a surface coating which is intended to provide a degree
of
of corrosion
corrosion protection to the underlying metal. Salt spray testing is an accelerated
corrosion test that produces a corrosive attack to coated samples in order to evaluate
(mostly comparatively) the suitability of the coating for use as a protective finish. The
appearance of corrosion products (rust
(rust or other oxides) is evaluated after a pre-determined
period of time. Test duration depends on the corrosion resistance of the coating;
generally, the more corrosion resistant the coating is, the longer the period of testing
before the appearance of corrosion/ rust. The salt spray test is one of the most widespread
and long established corrosion tests.
tests. ASTM
ASTM B117 was the first internationally recognized
salt spray standard, originally published in 1939. Other important relevant standards
are
are ISO9227,
ISO9227, JIS
JIS Z 2371 and
and ASTM
ASTM G85.

APPLICATIONS:-
Salt spray testing is popular because it is relatively inexpensive, quick, well standardized,
and reasonably repeatable. Although there may be a weak correlation between the
duration in salt spray test and the expected life of a a coating
coating in certain coatings such as hot
dip
dip galvanized steel,
steel, this test has gained worldwide popularity due to low cost and quick
results. Most Salt Spray Chambers today are being used NOT to predict the corrosion
resistance of a coating, but to maintain coating processes such as pre-treatment and
painting, electroplating, galvanizing, and the like, on a comparative basis. For example,
pre-treated + painted components must pass 96 hours Neutral Salt Spray, to be accepted
for production. Failure to meet this requirement implies instability in the chemical
process of the pre-treatment, or the paint quality, which must be addressed immediately,
so that the upcoming batches are of the desired quality. The longer the accelerated
corrosion test, the longer the process remains out of control, and larger is the loss in the
form of non-conforming batches. The principle application of the salt spray test is
therefore enabling quick comparisons to be made between actual and expected corrosion
resistance.
resistance. Most commonly, the time taken for for oxides
oxides to appear on the samples under test
is compared to expectations, to determine whether the test is passed or failed. For this
reason the salt spray test is most often deployed in a quality audit role, where, for
example, it can be used to check the effectiveness of a production process, such as the
surface coating of a metallic part. The salt spray test has little application in predicting
how materials or surface coatings will resist
resist corrosion
corrosion in the real-world, because it does
not create, replicate or accelerate real-world corrosive conditions.
conditions. Cyclic corrosion
testing
testing is better suited to this. The apparatus for testing consists of a closed testing
cabinet/chamber, where a salt water (5% NaCl) solution is atomized by means of spray
nozzle(s) using pressurized air. This produces a a corrosive
corrosive environment of dense salt water
fog (also referred to as a mist or spray) in the chamber, so that test samples exposed to
this environment are subjected to severely corrosive conditions. Chamber volumes vary
from supplier to supplier. If there is a minimum volume required by a particular salt spray
test standard, this will be clearly stated and should be complied with. There is a general
historical consensus that larger chambers can provide a more homogeneous testing
environment.
Variations to the salt spray test solutions depend upon the materials to be tested. The most
common test for steel based materials is the Neutral Salt Spray test (often abbreviated to
NSS) which reflects the fact that this type of test solution is prepared to a neutral pH of
6.5 to 7.2. Results are represented generally as testing hours in NSS without appearance
of corrosion products (e.g. 720 h in NSS according to ISO 9227). Synthetic seawater
solutions are also commonly specified by some companies and standards. Other test
solutions have other
other chemicals
chemicals added including
including acetic acid
acid (often abbreviated to ASS)
and acetic acid with
with copper chloride
chloride (often abbreviated to CASS) each one chosen for the
evaluation of decorative coatings, such as electroplated copper-nickel-chromium,
electroplated copper-nickel or anodized
anodized aluminum.
aluminum. These acidified test solutions
generally have a pH of 3.1 to 3.3

Some sources do not recommend using ASS or CASS test cabinets interchangeably for
NSS tests, due to the risk of cross-contamination
cross-contamination,, it is claimed that a thorough cleaning of
the cabinet after CASS test is very difficult.
difficult. ASTM
ASTM does not address this issue,
but
but ISO
ISO 9227 does not recommend it and if it is to be done, advocates a thorough
cleaning.
Although the majority of salt spray tests are continuous, i.e.; the samples under test are
exposed to the continuous generation of salt fog for the entire duration of the test, a few do
not require such exposure. Such tests are commonly referred to as modified salt spray tests.
ASTM G85 is an example of a test standard which contains several modified salt spray tests
which are variations to the basic salt spray test.
Standardization:-
Electroplated and yellow chromate bolt with white corrosion

Zinc flake coated bolt with red rust after testing
Chamber construction, testing procedure and testing parameters are standardized under
national and international standards, such as ASTM B B 117 and ISO 9227. These standards
describe the necessary information to carry out this test; testing parameters such as
temperature, air pressure of the sprayed solution, preparation of the spraying solution,
concentration,
concentration, pH,
pH, etc. Daily checking of testing parameters is necessary to show
compliance with the standards, so records shall be maintained accordingly. ASTM B117
and ISO 9227 are widely used as reference standards. Testing cabinets are manufactured
according to the specified requirements here.
However, these testing standards neither provide information of testing periods for the
coatings to be evaluated, nor the appearance of corrosion products in form of salts.
Requirements are agreed between customer and manufacturer. In the automotive industry
requirements are specified under material specifications. Different coatings have different
behavior in salt spray test and consequently, test duration will differ from one type of
coating to another. For example, a typical electroplated zinc and and yellow passivated
steel
steel part lasts 96 hours in salt spray test without
without white rust.
rust. Electroplated zinc-nickel
steel parts can last more than 720 hours in NSS test without red rust (or 48 hours in CASS
test without red rust) Requirements are established in test duration (hours) and coatings
shall comply with minimum testing periods.
Artificial seawater
seawater which is sometimes used for Salt Spray Testing can be found at
at ASTM
International.
International. The standard for Artificial Seawater is ASTM D1141-98 which is the
standard practice for the preparation of substitute ocean water.
Uses:-
Typical coatings that can be evaluated with this method are:

 Phosphated (pre-treated) surfaces (with subsequent paint/primer/lacquer/rust
preventive)
 Zinc
Zinc and zinc-alloy plating (see also
also electroplating).
electroplating). See ISO 4042 for guidance
 Electroplated
Electroplated chromium,
chromium, nickel,
nickel, copper,
copper, tin
 Coatings not applied electrolytically, such as zinc flake coatings according to ISO
10683
 Organic coatings, such as rust preventives
 Paint Coating
Hot-dip galvanized surfaces are not generally tested in a salt spray test (see ISO 1461 or
ISO 10684).
10684). Hot-dip galvanizing
galvanizing produces zinc
zinc carbonates
carbonates when exposed to a natural
environment, thus protecting the coating metal and reducing the corrosion rate. The zinc
carbonates are not produced when a hot-dip galvanized specimen is exposed to a salt
spray fog, therefore this testing method does not give an accurate measurement of
corrosion protection. ISO 9223 gives the guidelines for proper measurement of corrosion
resistance for hot-dip galvanized specimens.
Painted surfaces with an underlying hot-dip galvanized coating can be tested according to
this method. See ISO 12944-6.
Testing periods range from a few hours (e.g. 8 or 24 hours of phosphated steel) to more
than a month (e.g. 720 hours of zinc-nickel coatings, 1000 hours of certain zinc flake
coatings).
CUSTOMER COMPLAINT REPORT
Sr. No Customer name & Immediate Analysis Action planned, Review of

&date of details of Actions responsibility & action for

receipt of Complaint taken target date for effectiveness
complain action & status of
t action
1. XYZ LTD Sales Container We gives the After
DATE : - person Mr checked at party instruction to instruction the
04/09/2017 sanjay patil side by sanjay production production
visited to patil. We take department the department
party. new batch of empty barrels people closing
thinner & which we kept at the container
replace it. outside in open or barrels.
condition should
Complaint :- close with lid.
THINNER CL Min 2 days
[KBL]
INCOMPACTIBIL
ITY PROBLEM .
[ water content in
thinner]
NAME OF
PERSON:-
Complained :-
XYZ
Costing required in handling the Customer

Complaint:-

Particulars Amount in Rs
Visiting to customer for attaining the complaint 200
Transport Cost 1000
Raw Material required in Reprocessing Nil
Timing required to reprocessed /Labour Charges 300
Wastage Charges
Total Cost 1500
PROJECT:-
To Develop a High Performance Epoxy
Paint and Primer
Introduction:-

The high performance epoxy primer & paint used on parts of a railways & the
parts of ships .where we required higher level corrosion resistance as well as
acid& alkali resistance.
This standard of prescribes the technical requirements and methods of testing

for two pack epoxy paint system intended to be used at areas where improved
corrosion resistance is needed under server corrosion .The material shall be
suitable for application on interior of coaches like lavatory area, turn under etc.
The material may be used on surfaces having surface finish equivalent of ISO
specification done by mechanical cleaning.
The specific advantage of resin which we used in the high performance primer
&paint having a low viscosity at lower temperature and better chemical
resistance.
It can be used for various applications like adhesive, laminates, low solvent or
solvent less coatings & civil application. It is also being used in combination
with resin in order to prevent crystallization of latter.
For drying of such resin the hardner which we used the based on polyamide
.The hardner is specially formulated for solvent free &high solids curing
coatings with excellent resistance to organic solvents , particularly alcohols and
motor fuels .It finds application with appropriate grades of epoxy resin for tank
lining of chemical processing equipments and maintenance coatings.
REQUIREMENTS FORHIGH
PERFORMANCE EPOXY PAINT &
PRIMER
Sr.No. Characteristics Requirements
1. Finish Smooth –matt / Semi glossy

2. Color As per requirement
3. Drying Time (at room temp) a. Surface dry – 2 hrs
b. Tack free – 4 hrs
c. Hard dry – 16 hrs
4. DFT 80-150 μ
5. Scratch Hardness No such scratch as to bare metal
6. % NVM 70±5%
7. Flexibility Test No visible damage of film
8. Resistance salts spray No sign of corrosion up to 2000
hrs
9. Resistance to Chemicals:-
1. 25% caustic soda soln (w/v) Shall not show any sign of
2. 30% sulphuric acid (v/v) blistering & wrinkling of paint
3. 20% hydrochloric acid (v/v) film up to 1800 hrs
10. Pot Life ( at room temp) 3 hrs

11. Impact Resistance Shall be free from cracking in the
deformed coating.
12. Resistance to distilled water Shall not show any sign of
blistering & wrinkling.
FORMULATION OF PAINTS:-
Epoxy Resin is used is manufacturing in based bisphenol–f and Diluents. In
combination With Degba. And Cycloaliphatic amine adducts.

As a Party requirement Pot life should be more than 3 hrs. Then we take trial
Batches of Resin and Hardner. As followed
We take first trial batch of Resin and Hardner, the mixing ratio is 1:1 then pot
life is 30 minutes.
Then we take second trial batch, the mixing ratio is 4:1 then pot life is 1.30 hrs.
After the second trial batch then we take third trial batch there mixing ratio is
9:1 at this ratio we got the pot life is more than 3 hrs.
Sr. Name of particles Quantity

No.
1. Resins 45-50%
2. Pigments 25-32%
3. Solvents 10-15%
4. Additives 2-3%

TESTINGS OF EPOXY PRIMER &
PAINTS:-
1. EPOXY PRIMER
Sr.No Tests & Specification Results
1. Viscosity 100 sec

2. Density 1.47 gm/cc
3. Fineness of Grinding 5 Hg
4. Mixing Viscosity 70 sec
5. Mixing Density 1.35 gm/cc
6. % NVM 75.64 %
7. Drying Time
 Surface Dry 30 min
 Tack free 2.30 hrs
 Hard Dry Over Night
8. Finish Smooth & matt
9. DFT 90-100 μ
10. Pot Life More than 3 hrs
11. Cross hatch Test Passes

12. Scratch Hardness Test 1500 gm Passes
13. Impact Resistance Passes
14. Mixing Ratio 9:1

2. EPOXY PAINT
Sr.No Tests & Specification Results
1. Viscosity 90 sec
2. Density 1.32 gm/cc
3. Fineness of Grinding 7 Hg
4. Mixing Viscosity 60 sec

5. Mixing Density 1.28 gm/cc
6. % NVM 75.00 %
7. Drying Time
 Surface Dry 60 min
 Tack free 3 hrs
 Hard Dry Over Night
8. Finish Smooth & S/G
9. DFT 80-100 μ
10. Pot Life More than 3 hrs
11. Cross hatch Test Passes

12. Scratch Hardness Test 1500 gm Passes
13. Impact Resistance Passes
14. Mixing Ratio 9:1

Characteristics of Paint:-
 Resistance to Acid & Alkali is good.
 Resistance to Adhesion &Flexibility test is Excellent.
 Resistance to Distilled Water is good.
 Resistance to Salts Spray is good.
 Resistance to Abrasion Test is good.
 Resistance to Impact Test is good.
Uses of paint &Primer:-

 It is used as in Parts ofRailways.
 It is also used in Parts of Ships orMarine.
 It is also used in Industrial coatings.
 The paint is used on Interior of Coaches like Lavatory area, turn under
etc.
 It is used at areas where improved Corrosion Resistance is needed
under severe Corrosive Conditions.


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Deccan Education Society’s

Technical Institute, Pune- 04

Diploma in Surface Coating

WE SHALL ENHANCE CUSTOMER SATISFACTION ,

Mr. SHIRISH PONKSHE Mr. PRASAD PURANDARE

Deccan Education Society’s Pune- 04 Page 2

Quality paint systems No of Customer QC Max.1/month

2. On time delivery Order not Dispatch Max.5/month

3. Continual Improvement No of Design Max.1/year

TUFF COAT POLYMERS PVTLTD

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I have great pleasure in submitting this in plant training project report

I acknowledge with great regard to our coordinator Mr.R. H. DONGRE SIR.

I would like to express my sincere thanks to,

Mr. S .D. Ponkshesir&Mr P.D. PurandaresirDirectorsof Tuff CoatPolymer

I gave best regards to Mr.AnilAmbre(Production Department) who taught me

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The various products range of the company is as follows-

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FINISHED GOODS AND PACKING SECTION :-

A) Sampling of finished goods :-

i. Name if the paint

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Sr. Machine type Type RPM Total

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Batch type Sand Mill:-

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Mill base premixing (Using high speed stirrer)

Charging of attriator or sand mill (Batch type)

Discharging of attriator or sand mill (Batch type)

Intermediate testing (Shade)

Sending sample to the Q.C. department

Approval of batch Rejection

Sending sample to the Q.C. department

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SPECRO COLOUR METER

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Acid value = 56.1 x N. of KOH x B R

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Zirconium base: -Zirconium

H.TOLERANCE WITH SOLVENT :-

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 Aliphatic solvents → M.T.O

Following are important properties of solvent : –

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E.g.M.T.O = 144 - 1770 c

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Examples: - Specific Gravity of pigment.

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