Paints Market - Industry Profile

Industrial Modernization Center
Industrial Modernization Program
Export Support Study for Paints and Coating

Industry
Reference No.
PS_442.RE
Prepared by
Talal Abu-Ghazaleh Associates Ltd
Member of
Talal Abu-Ghazaleh Organization
This report prepared by: Dr. Mohamed A. Sherif Omran (Team Leader/ International Consultant-
Economist); Eng. Mohey Abdel-Razic (PMP, Paints and Coating Expert); Eng. Ahmed Maher Mohamed
(Paints and Coating Expert); Shaymaa Mohamed Omran (Consultant-Economist); Silvana Saad Salama
(Junior Consultant-Economist); Ahmed Samy (Junior Consultant); Islam Mohamed (Trainee).
Cairo, December 2008

Export Support Study for Paints and Coating Industry – Ref: PS_442.RE
Submitted to: Industrial Modernization Center – Industrial Modernization Program
Prepared by: Talal Abu-Ghazaleh Associates Ltd. Page ii of 56
Submission Letter (to be scanned and inserted here)

Prepared by: Talal Abu-Ghazaleh Associates Ltd. Page iii of 56
Contents
RESULT BASED LOGICAL FRAMEWORK................................................................................................. V
I. SECTOR ASSESSMENT ................................................................................................................................. 6
I.1 INDUSTRY STRUCTURE .................................................................................................................................. 8
I.2 RECENT LAWS, LEGISLATIONS AND REGULATIONS OF PAINTS AND COATINGS INDUSTRY ........................... 12
I.3 INSTITUTIONAL STRUCTURE THAT SERVES PAINTS, COATINGS AND RESINS SECTOR .................................... 14
I.4 MARKET STRUCTURE ................................................................................................................................... 17
I.4.1 Egyptian economy and importance of the paints and coating sector.................................................. 17
I.4.2 Paints Market in Egypt ....................................................................................................................... 21
I.4.3 Industrial Coatings Market in Egypt .................................................................................................. 23
I.4.4 Global Coatings Market ..................................................................................................................... 24
I.4.5 Egyptian market share of the industry in the international market .................................................... 26
I.4.6 Local market supply and the competition structure ............................................................................ 26
I.4.7 Sales and Marketing strategies ........................................................................................................... 28
I.4.8 Existing Support to paints, coatings and resins industry .................................................................... 28
I.5 MANUFACTURING PROCESS OF PAINTS, COATINGS AND RESINS .................................................................. 29
II. DATA COLLECTION/ SOURCES ............................................................................................................. 30
II.1 SECONDARY DATA ..................................................................................................................................... 30
II.1.1 Main producers of Paints and Coating by country............................................................................ 30
II.1.2 Egyptian Imports of Paints and Resins and their Raw Materials ...................................................... 31
II.1.3 Egyptian Exports of Paints and Coatings.......................................................................................... 34
II.2 SWOT DATA (STAKEHOLDERS)................................................................................................................. 36
II.2.1 Who are the Stakeholders? ................................................................................................................ 36
II.2.2 Paint and Coating Exporters’ Population and Sample Size:............................................................. 37
III. ANALYSIS ................................................................................................................................................... 39
III.1 PAINTS AND RESINS EXPORTS................................................................................................................... 39
III.2 EU DEMAND ON PAINTS AND COATING PRODUCTS .................................................................................. 40
III.3 EXPECTED EU AND NON-EU EXPORTS OF PAINTS AND COATINGS........................................................... 41
III.4 EXPECTED DEMAND ON EGYPTIAN PAINTS AND COATING TO INTERNATIONAL MARKETS ........................ 42
III.5 SWOT ANALYSIS ..................................................................................................................................... 43
III.5.1 Private Sector Stakeholders: .................................................................................................... 43
III.5.2 Public Sector and Government Stakeholders ................................................................................... 48
IV. RESULTS AND FINDINGS........................................................................................................................ 48
IV.1 A PLAN TO OVERCOME THE WEAKNESS AND THREATS THAT FACE THE PRODUCT..................................... 48
IV.2 EXPECTED EXPORTS AFTER EXPORT SUPPORT ........................................................................................... 52
IV.3 EMPLOYMENT ........................................................................................................................................... 53
IV.4 INVESTMENT IN THE INDUSTRY AND EXPECTED GROWTH AFTER THE SUPPORT ......................................... 54
IV.5 EFFECT OF ENERGY PRICING SYSTEM ON PAINTS AND COATING INDUSTRY ............................................... 54
V. CONCLUSION AND RECOMMENDATIONS ......................................................................................... 54
V.1 RECOMMENDATIONS: ......................................................................................................................... 54
V.2 SUGGESTED STUDIES .......................................................................................................................... 56
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Annexes No. of Pages

Annex A: A simple industrial profile model with expected economic indicators for a
medium scale project for producing 2 types of paints and a type of resins. 12
Annex B: Manufacturing Process 10
Annex C: Recent Laws, legislations, and regulation of paints industry 10
Annex D: Top Paints Manufacturing Companies 1
Annex E: Paint’s Exports by HS Codes and countries 2
Annex F: Custom Duties 5
Annex G: HS Codes for Raw materials and Intermediate and final Products 2
Annex H: Environmental Screening 12
Annex I: Self Monitoring 128
Annex J: List of interviewed organizations 2
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Industrial Modernization Center (IMC)

Export Support Study for paints and Coating Industry
Result Based Logical Framework
Hierarchy of Expected Baseline and Indicative Targets Timeframe
Reach Performance Indicators Assumptions/ Risks
Objectives Results Baseline Targets
1. Goal (long 1. Impact 1. Beneficiaries 1. Impact Indicators Baseline Value (base Target Values (target years) Assumption statement:
term objective) Increased Exports and 1.1 Total Egyptian Exports year=2007) 1.1 EGP 208.0 bn (2008), EGP 1.1 Private sector takes the lead
Promote Egyptian Egyptian exports industrial sectors 1.2 Industry GDP 1.1 EGP 177.9 bn 233.9 bn (2009), EGP 259.5 bn in improving the Egyptian
Industrial Exports Source& Method: (2007) (2010), EGP 287.7 bn (2011), export sector in the fluctuated
Egypt: 5-year forecast table, 1.2 EGP 158.7 bn EGP 319.8 bn (2012). International markets.
Country View, Economist (2007) 1.2 EGP 170.9 bn (2008), EGP Mitigation strategies:
Intelligence Unit; Zawya 184.4 bn (2009), EGP 196.4 bn 1.1 Government strategy is to
website, last updated: 24 June (2010), EGP 206.4 bn (2011), support the export sector.
2008. EGP 216.5 bn (2012).
Note: Indicators at this level are The baseline and targets are at constant 2001/02 prices.
generally monitored and or (bn: billion)
evaluated via sector or country
strategy reports.
2. Purpose 2. Outcome: 2. Beneficiaries 2. Outcome Indicators Assumption statement:
(medium term Increased paint Exporters and 2.1 Paint & resin’s exports 2.1 $83 m (2007) 2.1 $119 m (2009), $139 m 2.1 Reduction of international
objectives) and resin’s paint and resin’s Source& Method: (2010), $163 m (2011), $191 m prices.
Improve paint and exports producers (raw * Data warehouse, MTI/ (2012), $224 m (2013). Mitigation measures:
resin sector in materials and GOEIC. 2.1 The study suggests 12% of
Egypt end products) * ComTrade Website proposed support to mitigate
unexpected price decrease.
3. Project Inputs 3. Output 3. Beneficiaries 3. Output Indicators 3.1 No financial 3.1 Proposed financial support: Assumption statement:
& Activities 3.1 proposed Paint and 3.1 paint & coating export support is in the base 12% i.e. $14 m (2009), 12% 3.1 Expected subsidy level is
3.1 Paint & resins subsidy level(s) coating support year (2007) but there is i.e. $17 m (2010), 10% i.e. $16 higher than what was expected
assessments producers (raw technical support m (2011), 10% i.e. $19 m Mitigation measures:
3.2 Collecting 3.2 Simple materials and 3.2 Adoption of proposed through existing (2012), 5% i.e. $11 m (2013). 3.1 The proposed subsidy will
required data industrial profile end products) industrial model & study agencies, such as IMC. 3.2 Proposed three industrial be phased out in 5 years.
3.3 Analysis model & study recommendations 3.2 Proposed industrial models& study
3.4 Reporting recommendations models& study recommendations
recommendations
1 2 3 4 5a 5b 6
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Export Support Study for paints and Coating Industry
I. Sector Assessment
First of all, it is important to know what are paints and coatings. The following paragraph is
a good start to know what are paints and coatings: “…. what are coatings? Coatings are
everywhere; they are all around us. If you are reading this report in an office, then your desk,
PC, telephone, the shelving on the walls and even your cabinets will all have been given some
form of coating. At home your television, fridge, furniture and most of your other household
items will also rely on coatings for protection and outward appearance. Then there’s the
paint used to decorate the walls both at home and work. Of course, the car (or the train, or
the bus) that you used to travel between the two will also have coatings on their exterior and
interiors, as well as on all their moving and non-moving parts. How about the airplane you
take to your international meetings, the boat you cruise on during vacations, the bridges you
cross, the buildings you pass, the list goes on and on. Coatings are a central part of the
world we see around us every day…”1 (The Global Coatings Report 2006)
Paints and coatings are well known long time ago. The Ancient Egyptian used it to write and
draw pictures on the walls of their Temples and Pyramids. It is a very well known and old
industry in Egypt.
Paints can be divided into two main types: decorative (architectural) and the industrial.
Alkyd Resins group is one of the intermediate products needed for manufacturing synthetic
architectural and industrial paints. Also, Paints entails contents of resins, pigments, solvents,
and additives.
The study focused on the following HS 1992 Codes:
Paints: HS 1992 Codes: 3208 – 3209 – 3210 – 3214
3208 - Paints and varnishes (including enamels and lacquers) based on synthetic polymers or
chemically modified natural polymers, dispersed or dissolved in a non-aqueous
medium; solutions as defined in Note 4 to this Chapter.
3209 - Paints and varnishes (including enamels and lacquers) based on synthetic polymers or
chemically modified natural polymers, dispersed or dissolved in an aqueous medium.
3210 - Other paints and varnishes (including enamels, lacquers and distempers); prepared
water pigments of a kind used for finishing leather.
1
Akzo Nobel’s Inaugural Global Coatings Report “The Global Coatings Report 2006: Painting a picture of the
industry”, 2006.
3214 - Glaziers' putty, grafting putty, resin cements, caulking compounds and other mastics;
painters' fillings; non-refractory surfacing preparations for façades, indoor walls,
floors, ceilings or the like.
Resins (intermediate products): HS 1992 Codes: 3903 – 3905 – 3906 – 3907 - 3908
3903 - Polymers of styrene, in primary forms.
3905 - Polymers of vinyl acetate or of other vinyl esters, in primary forms; other vinyl
polymers in primary forms.
3906 - Acrylic polymers in primary forms.
3907 - Polyacetals, other polyethers and epoxide resins, in primary forms; polycarbonates,
alkyd resin, polyallyl esters and other polyesters, in primary forms
3908 - Polyamides in primary forms.
Raw Materials: HS 1992 Codes: 3204 - 3206 - 3207 - 3211 - 3212 - 3803 - 3805 - 3806 -
3814 - 3815 - 3823 - 3909 - 3912
3204 - Synthetic organic colouring matter, whether or not chemically defined; preparations as
specified in Note 3 to this Chapter based on synthetic organic colouring matter;
synthetic organic products of a kind used as fluorescent brightening agents or as
lumin
3206 - Other colouring matter; preparations as specified in Note 3 to this Chapter, other than
those of heading 32.03, 32.04 or 32.05; inorganic products of a kind used as
luminophores, whether or not chemically defined.
3207 - Prepared pigments, prepared opacifiers and prepared colours, vitrifiable enamels and
glazes, engobes (slips), liquid lustres and similar preparations, of a kind used in the
ceramic, enamelling or glass industry; glass frit and other glass
3211 - Prepared driers.
3212 - Pigments (including metallic powders and flakes) dispersed in non-aqueous media, in
liquid or paste form, of a kind used in the manufacture of paints (including enamels);
stamping foils; dyes and other coloring matter put up in forms or packing's for reta
3803 - Tall oil, whether or not refined.
3805 - Gum, wood or sulphate turpentine and other terpenic oils produced by the distillation
or other treatment of coniferous woods; crude dipentene; sulphite turpentine and other
crude para-cymene; pine oil containing alpha-terpineol as the main constituent.
3806 - Rosin and resin acids, and derivatives thereof; rosin spirit and rosin oils; run gums.
3814 - Organic composite solvents & thinners, n.e.s.; prepared paint/varnish removers
3815 - Reaction initiators, reaction accelerators and catalytic preparations, not elsewhere
specified or included.
3823 - Industrial mono-carboxylic fatty acids; acid oils from refining; industrial fatty
alcohols.
3909 - Amino-resins, phenolic resins and polyurethanes, in primary forms.
391220 - Cellulose nitrates (incl. collodions), in primary forms
391231 – Carboxymethyl cellulose & its salts, in primary forms
For more details about these HS 1992 Codes see Annex G.
I.1 Industry structure
I. ACRYLIC POLYMER EMULSIONS

Locally
Produced RM Locally Consumed
Products
Quality Control
Raw Materials:
Monomers Formulation Processing
Sales &
Catalysts Acrylic Polymerization Process Marketing
Polymers are (homopolymerization,
Acrylic Acid
custom made to Copolymerization, etc)
Preservatives fit industry
needs
Surfactants
Exported
By-Products & Products
Imported RM Wastes
Local Demand (only paint industry): 50,000 – 60,000 Tons

Local Production: 50,000 Tons (for all industries …. including paints, leather, carpets, …etc)
Local Producers: Only three main Producers (Vinavyl Egypt – Eagle & Clariant JV Company) - Projected
production in EAP and expansion projects in existing producers.
• There is increasing demand for different types of water base emulsion polymers for
the production of paints for indoor uses, ready made putty and sealers.
• The use of water base emulsion is compliant with EC directives and the
environmental Legislation.
• The estimated consumption of the Egyptian paint industry is around 50,000 – 60,000
MT/year.
• While the estimated local Production (for all industries …. including paints, leather,
carpets,…etc) is 50,000 Tons , so there is a big gap in Supply/Demand equation,
which creates a feasible investment opportunity in this domain.
• Local Producers: Currently there are only three main Producers for such products
(Vinavyl Egypt – Eagle & Clariant JV Company) – But in the meantime there are
projected productions in EAP and expansion projects in existing producers.
• The main competition comes from:-
* Turkey (Organik Kymia)
* Dow, Jebel Ali, Dubai
* Synthomer Middle East, Saudi Arabia
II. Resins
Exported
Imported Quality Control
products
Raw Materials:
Exporters
Oils/ Monomers Processing:
Fatty Acids Formulation: 1. Addition
Poly Acids Resin is 2. Reaction
generally
Polyols 3. Thinning Marketing Sales
custom-made to
Solvents fit the needs of 4. Filtering
industry
Catalyst customers 5. Adjusting
6. Filling
Domestic
Locally produced producers of
By-products/ waste Paints
III. Paints
Exported
products
Quality Control
Imported
Exporters
Formulation: Processing:
Raw Materials:
Paints are 1. Mixing
Pigments generally
2. Grinding Marketing
Solvents custom-made to
Binders fit the needs of 3. Finishing
Additives customers 4. Filling
Wholesalers
Contactors
Retailers
Locally produced
Painters
Emissions/ waste
Local consumption
PAINTS
• Volume: 417,000 tons (2000-2005)
• Value: LE 2.1 billion (2000-2005)
Architectural (Decorative) Paints (65%by Industrial Paints (35% by volume and 49%
volume & 51% by value of the market) by value of the market) Comprises:-
Comprises:-
OEM automotive coating
Synthetic paints
Automotive refinishing paints
Emulsion paints
Stoving electrostatic enamels
Synthetic varnish
Metal work stoving enamels
Tinted paints
Wood coatings
Heavy duty paints
Informal sector contributes 15%
Marine paints
General purpose industrial paints
Paint and Coatings Inputs:

Paint and coatings industry is utilizing about 57% of its inputs from domestic resources.
These resources are raw materials, energy, packaging, human resources & equipments. The
following table shows an average distribution of the cost elements.
Table 1.1: Source of cost elements in manufacturing of paints and coatings, 2007-2008
% of input cost of Imported Domestic
Inputs
total cost component Component
Raw material* 80% 55% 45%
Energy 2% 100
Packaging 3% 5% 95%
Human Resources 10% 100%
Depreciation of Assets (buildings,
5% 100%
machines, equipments, etc)
Total 100% 43% 57%
* The raw materials percent (domestic & imported) are weighted average for Architecture and Industrial paints.
Source: Interviews and experience of paints and coatings professionals.
Paints and Resins Production:

According to available data for the period from 2005-2008, the national average production
of paints is about 613,000 ton. It is value is LE 2.9 billion (at fixed price of the period 2000-
2005). The utilized capacity is estimated at 84% of the available capacity of paint and
coatings production, for one shift. The support of the paints industry will improve the
utilization of the available capacity without new investments. The current unutilized capacity
of production (which is estimated at 16% for one shift) can be totally absorbed. Moreover,
the increase in capacity utilization can reach 116% of total available capacity in case of
working two shifts (16% + 100%). These production capacities do not include resins as an
intermediate product for paint and coatings industry.
Egypt exports about 10% of its resins production as an exported final product; the other 90%
is being utilized as an input (intermediate product) for domestic paint industry. Resin
production is estimated at 136,000 ton as an average of the period 2003-2007. The unutilized
capacity of resin production is estimated at 29% of the available capacity of resin production.
It is expected that the resin capacity will be expanded to meet the increase in the international
and domestic demand.
Table I.2 represents the average quantities and values of production of decorative and
industrial paints during three periods: 2000/2005, 2005/2008 and 2008/2013. The table
shows the efforts in producing resins locally to reduce the imported resins.
The percent of domestic components, as an average of the period 2000/2005 was about 52%
and it was increased to 56% as an average of the period 2005/2008, and it is expected to be
increased to reach 63% in the period 2008/2013. This will be achieved by the efforts of the
companies in the sector and the expected support of the government.
Table I.2: Production of Decorative and Industrial Paints through the periods 2000/2005,
2005/2008, and 2008/2013
Average Production Average Inputs
Period Paints
000'ton % Billion LE* % Local Imported
Decorative 271 65% 1.1 51% 52% 48%

2000-2005 Industrial 146 35% 1.0 49% 52% 48%
Total 417 100% 2.1 100% 52% 48%
Decorative 462 75% 1.8 63% 60% 40%

2005-2008 Industrial 151 25% 1.1 37% 52% 48%
Total 613 100% 2.9 100% 57% 43%
Decorative 620 75% 2.5 63% 68% 32%

2008-2013 Industrial 202 25% 1.5 37% 56% 44%
Total 822 100% 3.9 100% 63% 37%
Note: Value of production was estimated using fixed prices (average prices of the period 2000-2005).
Source: quantities of production from 2003-2008 from the Industrial Development Authority (IDA) and from 2000-2002
from the interviews and experience of paints and coatings professionals.
I.2 Recent Laws, Legislations and regulations of paints and coatings industry
The Egyptian paints market has always demonstrated competition over the past years, mainly
in the architectural sector. The market is characterized by a large number of low quality paint
producers (mainly emulsion paints). Currently the government is taking serious and strict
steps towards improving quality across the paints industry through the enforcement of
Egyptian quality standards.
Environment Aspects:
There are number of laws and regulations that address the different environmental violations.
The following are the laws applicable to the paints industry.
• Law 4/1994 & its executive regulations (gaseous emissions from combustion of fuel -
incineration of solid waste - Gas emissions generated in the production lines - gas
emissions in boiler house - temperature and humidity in Work Environment – noise -
Ventilation - Smoking - control of hazardous materials and wastes - keeping
Environmental Register - …).
• Law 38/1967 amended by Law 31/1976 (the collection and disposal of solid wastes)
• Decree No. 134 of 1968 Ministry of Housing, Utilities and Urban Communities
(MHUUC) (guidelines concerning Solid Wastes)
• Law 43/1979, the Law of Local administration, (Concerning Solid Wastes)
• Law 137/1981 for Labor & Minister of Housing Decree 380/1983, Minister of Industry
Decree 380/1982 (Work environment conditions )
The industry follows number of pollution abatement (prevention) measures in the three media
(air, water and soil). These include: In-plant modifications - In-Process modifications - End-
of-pipe (EoP) measures
Although Egyptian Environmental Laws do not require water and energy conservation
measures, these measures are being considered in the industry (using natural gas – using solar
cells – recycling waste products - …)
Also the industry applies (to a certain extent) the Cleaner Production concept (CP) for
pollution reduction through in-process, in-plant and resource conservation, in
contradistinction to end-of-pipe treatment. In many cases, the adoption of CP could eliminate
the need for (EoP) treatment.
For more details regarding the above section, refer to Annex C. In addition, Annex H
includes the Environmental Screening Form B and Annex I includes Self-Monitoring Manual
for Paints Industry; which are very important for environmental aspects.
Quality Standards:
Manufacturing paints involves handling & using many of hazardous materials. Mishandling
of such materials could lead to severe safety or environmental consequences.
• The Products must meet Egyptian standards No. 1539/2008 (Emulsion Paints), No
1757/2008 (Matt Paints) & No. 793/2008 (Gloss & Semi gloss Paints)
• International Standardization Organization certificates: ISO 9001 of Quality
Management - ISO 14001 of Environment related issues Management - ISO 17025 of
Lab. Results Credibility - & others)
• The European Directive 2004/42/CE, this sets out limitations on emissions of VOC due
to the use of organic solvents in most decorative paint.
• The EU agreed to carry out a second round of impact assessments on its controversial
Registration, Evaluation and Authorization of Chemicals (REACH) proposal, the mood
both inside and outside the chemicals industry has gradually started to shift, with
disparate factions beginning to coordinate efforts to improve the proposals. REACH
was first presented in May 2003 as a solution to EU concerns about the safety and
administration of chemicals. The aims of the proposed new regulations, which would
replace 40 separate pieces of current legislation, are meant to decrease human and
environmental exposure to chemicals whilst simultaneously enhancing the
competitiveness and innovative capabilities of the EU chemicals industry. Under the
proposed legislation, the European chemicals industry would have to register the
properties of substances with a central EU database. The process is expected to take
until 2016 to complete. Meanwhile, the availability of chemicals to consumers,
particularly low-volume niche products, will decline.
Currently the government is taking serious and strict steps towards improving quality across
the paints industry through the enforcement of Egyptian quality standards. All Egyptian
Quality Standards in Paint Industry had a backup reference to other International Standards
(e.g. ASTM – DIN - …). Also these Standards are now based on paints performance rather
than paints formulation, thus giving enough room to innovative R&D activities in cost
savings-product development-performance improvement and other related criteria.
I.3 Institutional structure that serves paints, coatings and resins sector
The generic structure of involved institutions in an economy is the organizations that are
managed by government, public sector, PARASTATAL, and non-government agencies. Each
of these organizations has its role in each sector of the economy. The importance of the role
may differ according to the nature of the sector. Chart 1.1 presents this generic structure and
the role of government in each category. It is important to say that the government has a
specific role in all of the institutions in the economy.
The following is a brief description of the institutions that serve the paints and coating export
sector in Egypt:
1) The government organizations, such as, but not limited to:
Ministry of Finance: Egyptian Customs Authority and Tax Authority
Ministry of Trade and Industry: Commercial Representation Sector (CRS), Egyptian
Organization for Standardization and Quality (EOS) and General Organization for Export
and Import Control (GOEIC)
Ministry of State for Environmental Affairs: Egyptian Environmental Affairs Agency.
2) Public Sector such as the Egyptian Petrochemicals Holding Company.
3) The PARASTATAL organizations such as the Chemical & Fertilizers Export Council and
the Chamber of Chemical Industries. These organizations are considered to be under a
kind of supervision of the government. In addition, these organizations are attached to
the whole government system. The government issues a decree to appoint the export
councils members. Although, the Chairman of the Chamber of Chemical is elected by the
members of the chamber, the government appoints the Chairman of the Federation of
Egyptian Industries, which is on the top of all Chambers.
4) The last category is the Non-Government Organizations (NGOs) which is not well
presented in the paints and coating export sector. The generic structure of an NGO is the
domination of the private sector on establishing, preparing objectives and managing it. In
addition, these NGOs have to be endorsed by the Government (by Law) and be under the
monitoring system of the government.
The absence of the NGOs in the paints and coating export sector causes the scattered
behavior of the paints and resin exports. In addition, the absence of NGOs delays the
development and improvement of the whole paints and coatings sector.
Chart 1.1: Major Relationships between Private Sector and Government Institutions
Organization Role of Examples for the paints & coating export sector
Government
Government Direct Customs, Taxation, environment, EOS, GOEIC

Management
Public Sector Indirect Egyptian General Authority for Petroleum

Management
PARASTATAL Supervision Chemical Chamber and Export Council
Non-Government Direct Monitoring Private sector associations (do not exist in the
(Associations) paints and coating export sector)
Private Sector Indirect Private sector companies (Producer and

companies Monitoring Exporters)
Source: Sector interviews
The major institutions that provide direct support to paints and coating sector are the
Chemical and Fertilizer Export Council and the Chamber of Chemical Industries. The two
institutions are PARASTATAL institutions, i.e., they are under direct supervision of the
government; however the private sector is playing a major role in them. This does not
undermine the role of these PARASTATALS, which are very important in the transitory
periods to facilitate the communication between private sector and government. Even, in
case of having a private sector association, the government has to monitor its performance.
In addition, the Industrial Modernization Center (IMC) is another institution that provides
valuable kinds of support to develop the paints and coatings industry.
Paints and Coatings Sector is in a great need to have a pure private sector institution to reflect
its needs and provide its own solutions.
Chemical & Fertilizers Export Council (CFEC) is an organized framework for exporters and
producers in the chemical and fertilizers domain. It provides consultancy work in the
preparation of strategies and plans to increase Egyptian exports of chemicals and fertilizers
sector and improve its efficiency. The vision of CFEC is to integrate all companies in the
chemical and fertilizers field to increase its exports. The mission of CFEC is to develop and
promote Egyptian exports of the Chemical and Fertilizers Industries to increase their
competitiveness in the international markets, especially the small and medium enterprises
(SMEs). The Council is composed of eleven divisions: fertilizers; plastic and rubber;
cleaners; papers; paints, coatings and inks; pesticides, glass products; organic chemicals;
inorganic chemicals; photo products and materials; and diversified chemicals.
Chamber of Chemical Industries (CCI) was founded in 1942 by ambitious small group of
businessmen in the field of chemical industries. The main roles of the Chamber are to
represent and defend the interests of its members on both national and international levels in
different business and technical issues. The Chamber is composed of six divisions:
Diversified Chemicals (411 members), Paints and Inks (310 members), Plastics (1,276
members), Detergents (152 members), Paper and Carton (100), and Rubber (145)1.
What is an association?
An association is a civil society organization/ non-government organization (NGO). It is
formed by a group of people (producers or traders) to achieve certain objectives. These
objectives cannot be achieved by individual producer or trader. The effectiveness of an
association is a result of how deep the members are convinced about the importance of its
objectives and work together as a team in order to achieving these objectives. The
association is a body to serve its members and the sector, as well. In addition, the associations
play a major role in the economic development through improving the competitiveness
1
The Egyptian General Organization for Industrialization, 2005.
position of its members within domestic markets and the competitiveness position of its
sector in the foreign markets.
Law 84 of 2002 is the most current law that regulates the civil society organizations in Egypt.
Under this law the association can perform a lot of activities for the benefit its members and
the sector as well, such as training and technical assistance.
The financial sources of an association are: membership fees, grants and light loans,
government exemptions, discount on large amount of purchases, other sources. The
sustainability of the association is a result of the success of the association. If the association
provides good services to its members it will be sustained for a longer period.
The paints and coatings sector is in a real need for association(s) to help resolving major
problems beyond the capabilities of each individual firm.
I.4 Market structure

I.4.1 Egyptian economy and importance of the paints and coating sector
Macroeconomic Overview1
According to in depth analysis by the Economist Intelligent Unit; the following is a brief
overview for the Egyptian economy concerning the Egyptian Government policy trends,
Economic growth and the inflation in Egypt.
Egyptian Government Policy Trends
The government's five-year National Development Plan, which covers the period from
2007/08 to 2011/12, has been partly superseded by more pressing concerns. To counter the
impact of rising inflation, a package of public-sector wage increases was implemented and
the food ration card scheme was extended to more low-income families. Measures introduced
so far have included sharp cuts in income tax rates and customs duties. The government has
also started to reduce fuel subsidies. Natural gas prices for energy-intensive industries will
increase, so that domestic prices will gradually converge on world market prices. Future
reform is expected to continue along similar lines, although at a measured pace, as the
government is aware of the risk of social dislocation if its liberalization programme moves
too quickly. Strikes and protests against privatization and rising prices may lead the
government to proceed more slowly with larger divestments, especially in the labor-intensive
manufacturing sector.
1
Economist Intelligence Unit
Egyptian Economic Growth

EIU outlook for Egypt's growth prospects remains broadly positive. Real fixed capital
formation continues to be the main driver of economic growth, owing to broad success with
the government's economic reform policies and strong demand in the manufacturing and
construction sectors. Over the next two years, investment will continue to be supported by
buoyant business confidence, as the government moves ahead with its improvements to the
business environment, and as private investment continues to expand. A number of large-
scale infrastructure projects will also sustain investment, helped by oil-driven liquidity from
the Gulf. However, economic expansion will be constrained by robust import growth, spurred
on by the manufacturing industries, even if the increase in capital goods imports promises
well for the future strength of the economy. There is a concern about the impact of rising
inflation, which, in the near term, is likely to put a strong constraint on private
consumption—another driver of growth—as it undercuts households' purchasing power.
Overall, it is expected that the GDP growth in 2007/08 will remain at 7.1%. Slower
investment growth in 2008/09, as many projects are completed, will result in a modest
economic slowdown, to 6.7%. If inflation does not fall by as much as it is expected in 2009,
private consumption is unlikely to recover and business confidence could be eroded by rising
interest rates.
Inflation in Egypt
Inflation averaged 9.5% in 2007, pushed up by rising food and energy prices. The year-on-
year rate of inflation rose sharply in the first quarter of 2008, to 14.4% in March and 16.4%
in April. The government has imposed a series of fuel price increases in recent months and
raised the sales tax on cigarettes on May 5th. Consequently, headline inflation soared to
19.7% in May and there could be more spikes in inflation, which could climb as high as 22%
before the end of 2008. Inflation is expected to average 17.1% in 2008 as price growth is
expected to remain high in the second half of 2008. However, in 2009 inflation should be
constrained by tighter monetary policy and the strength of the Egyptian pound against the
dollar, as well as by a strong base-effect from the second half of the year. Therefore it is
forecasted that inflation will average 9.7% in 2009. However, if the government continues to
cut energy subsidies, fuel prices will rise, and this in turn will affect inflation expectations,
leading to further, second-round price increases and demands for higher wages. With strong
domestic demand and high international commodity prices, the risks are strongly on the
upside.
Important Economic Indicators

Table I.3 represents selective economic indicators were defined for the period 2007/2008 and
predictions from 2009-2012, where it showed that the population is expected to increase
steadily to reach about 84 Million. Also the Country Growth Domestic Product is expected to
increase in a good pace to reach 278 Billion US Dollars, which is a sign of economic
improvement in the economy due to the merge in the international economy and the growth
all over the Egyptian sectors which is currently evolving and is expected to improve even
more in the next period.
Also this growth is reflected in the household consumption which is expected to grow by
108% from 2007 till 2012 to reach about 190 Billion US Dollars.
Regarding the percentage change in exports and imports from goods and services, it’s clear
that the predictions show a decrease in both indicators however the decrease in Imports is
greater than the decrease in exports which show a higher dependence on the external world in
the next period however the gap between exports and imports in 2012 is less than the gap in
2007, which show a better expected position in international trade.
Table 1.3: Selective economic indicators projections from 2007- 2012:
Exports of
GDP (US$ bn at Household Imports of goods
Population goods &
Years market consumption & services
(m) services (%
exchange rates) (US$ bn) (% change)
change)
2007 76 129.8 91.4 23.3 28.8
2008 77.5 172.7 120 17 20.8
2009 79.1 201.2 138.3 13.2 15.9
2010 80.6 223.3 153.1 10.6 14
2011 82.1 248.1 170.2 11.1 14.2
2012 83.7 277.7 190.3 11.9 15.1
Source: Economist Intelligence Unit – Zawya Premium
Petrochemicals
Below is the value chain of petrochemicals which show the petrochemical industry starting
from the Raw materials till reach the major end use markets. This chain is used to give an
overview about the whole chain of this sector and thus define its importance.
Source: Industry Insight Petrochemicals – Zawya
Investment and Employment:

The available data on investment and employment in the Egyptian paints and coating sector
includes ink. According to the Chamber of Chemical Industries, as of April 2008 the number
of paints and Coatings factories is 227 (including ink factories), with investments of LE 11.2
billion. According to the General authority of Export and Import Control (GOEIC), as of
July 2008 the number of paints and coating exporters is 388 of which 152 represent more
than 99.5% of the value of exports.
The following chart describes the relationships between the 227 producers and the 388
exporters. The number of companies who are producers and exporters is unknown. As a
general note; most of the important and detailed information about paints and coatings sector
was not available.
Producer Producer & Exporter

Companies Exporter Companies
Companies
The chemical industries contribution to the GDP is 26%1 and the paints sector contribution to
the chemical industries is about 14%, i.e. the paints and coating sector represents about 3.6%
of the GDP.
According to Egypt State Information Service, labor force at the national level is 22.4 million
(2006/2007). According to the Chamber of Chemical Industries, the paints labor force is
about 12,000 (2008).
I.4.2 Paints Market in Egypt

a. The estimated annual volume (formal and informal) of 271,000 tons and 462,000 tons of
architectural paints being consumed in Egypt as averages for the two periods (2000-2005
and 2005-2008) using the fixed prices of the period 2000-2005, which corresponds to a
per-capita consumption of 3.8 kg, including synthetic paints, emulsion paints, synthetic
varnishes and tinted paint. According to the current booming in construction in Egypt and
the small amount of imports of architectural paints, the sector should increase its domestic
production to satisfy the growing demand in Egypt.
b. The informal sector is estimated to form 15% of the whole volume.
c. Thus the formal sector is estimated to represents 350, 000 Tons of paints, with value of
LE 1.8 billion (average 2005-2008).
d. As an average for the period 2005-2008 (using fixed prices of 2000-2005), it is estimated
for the industrial paints to form 25% of the whole market (by Volume) & 37% (by
Value), i.e., 151,000 tons, with LE 1.1 billion. The contribution of the informal sector in
the industrial paints market is minor or negligible.
The Formal Egyptian Architectural paints market composition by volume & value are
estimated to be as follows:
Table I.4: Egyptian Architectural paints market composition by volume & value
Items by Vol.(ton) By Value (LE)
Synthetic Paints 30% 47%

Emulsion Paints 60% 36%
Synthetic varnishes 2.5% 4.5%
Tinted paints 7.5% 12.5%
100.0% 100%
Source: Companies' analysis.
1
Egypt State Information Service (SIS); www.sis.gov
The Egyptian paint industry is a highly fragmented one, with several players (including
"home-made" paints produced by the informal sector). Mainly around 50-60 local major
producers are satisfying most of Egypt's demand. There are more than 380 exporters of
paints and coatings products. However, only three companies export more than 65% of the
value of exported paints and coatings (2005-2007).
Consumers and market segments are divided as follows:
a. Regular paint traders who are divided according to the size of their business into
distributors, wholesalers, and retailers.
b. Tinting paint traders who are divided into outlets owned/managed by the manufacturing
companies, outlets owned by the trader and deals only in specific companies products
(Franchise scheme), and outlets owned by individuals & deal in products from
different/all companies.
c. Contracting segment that includes consulting firms, contractors, and decorators
d. Painters
e. Owners of buildings & houses.
The demands of these categories are diversified, from which are the following examples:
a. Regular paint traders evaluate level of demand on products, profit margins, and payment
facilities.
b. Tinting outlets evaluate the amount of marketing support given to them by the company,
price of the products, and the product diversification.
c. Contractors evaluate company’s reputation, availability of a complete system of paints,
technical specification of the products, and payment facilities.
d. The painter evaluates availability of products in different price categories to suit the
different demands of his customers, technical characteristics of the products, and the
different promotions available on the products.
e. Owner of the household evaluates color variety, different paint effects, and prices.
The customers identified 4 critical service requirements:
1. Product quality: to provide high performance upon application. (e.g. brushability - hiding
power - whiteness - color retention ..)
2. Product consistency: (minimum variation between batches, cans, orders) , (specially for
colored paints)
3. Availability: equivalent to on-time delivery. Therefore logistics & supply chain
management are key business elements.
4. Price: Fair pricing in such a competitive market is a key concern. The industry is highly
price competitive (the premium category forms only 10% of the market)
Some customers change suppliers for a marginal price advantage (big volumes sum up at
good revenue).
Customers consistently rank these as the most important product & services attributes.
Their relative importance may vary at times (e.g. at high demand season) and with different
customer categories.
I.4.3 Industrial Coatings Market in Egypt

Industrial coating is used to coat everything from exterior roofing to roads and bridges. It
must be able to protect the substrate from corrosion, abrasion and UV damage. But
increasingly, aesthetics and appearance retention are becoming important attributes as well.
Protecting the substrate–whether metal, plastic or wood–is the primary purpose of an
industrial coating. However, gloss, gloss retention and chalking resistance are critical factors
to consider, especially when the coated structure is visible to the public and may be viewed as
an eyesore. Also considerations of the functionality are there in terms of durability,
weatherability, excellent scratch-resistance and performance for initial and aged solar
reflectance and thermal emittance,
There are extensive industrial coatings portfolios, covering a vast array of markets and
technologies. Some of the primary application areas include automotive decorative parts,
consumer electronics, appliances, coils and extrusions, wood coatings& general metals.
Another area for growth is in maintaining aging infrastructure. Industrial maintenance is the
fastest growing segment for industrial coatings. As many of bridges, overpasses and storage
tanks age, the need for maintenance and recoating becomes more important.
The Egyptian industrial paint market consists of four categories in production descending
order:-
1- Car refinish
2- Wood varnishes
3- Protective and marine paints
4- Others, including auto OEM and powder coating
There are several challenges that are affecting the paints market including the rise in raw
materials costs, energy prices and the economic slowdown. The unprecedented escalation in
the price of oil, natural gas and raw materials is having a significant impact on everything
from manufacturing to shipping costs. The manufacturing companies should deal with these
challenges by focusing on the development of sustainable and renewable products. The

companies should also pay close attention to results of voice-of-the-customer interviews to
ensure all R&D efforts are being focused on marketable technologies & products.
In order to stay afloat in this challenging environment, industrial coatings manufacturers must
develop innovative solutions for their customers. Environmentally responsible and
sustainable products offer the industrial coatings market opportunities for growth.
The growth and increased awareness of green technology initiatives will continue to require
sustainable coatings solutions. In the aluminum extrusion industry, products which are low
Volatile Organic Compounds (VOC) coatings have less impact on the environment.
The production of resins and polymers is increasing in Egypt due to the increase in paint
production and exports, attention to be made for the production of styrene acrylic.
I.4.4 Global Coatings Market1

From global perspective industrial coatings are enjoying growth in a number of emerging
areas. Economic growth in emerging markets, as well as emerging regions, is key drivers of
growth for industrial coatings. Product and process innovations are other aspects that are
crucial for continued growth. Consumer product coatings are the current fastest growing
segment for the industrial coatings segments. These include everything from cell phone
covers and laptops to hairdryers and goggles.
Annex D presents the Top Paints Manufacturing Companies (with minimum annual revenues
of US$ 100 million) in 2007, with the nationality and revenue of each company.
The companies are ranked from 1 to 67 according to their revenues. Continentally, these
companies can be grouped as follow: Europe (25 companies) – North America (21) – Asia
(17) – Australia (2) – South America (1) – Africa (1). The top 5 companies are Akzo Nobel,
Henkel, ICI, Sherwin-Willims & PPG. It is worth noting that Akzo Nobel (the 1st top
company) acquired ICI (the 3rd top Company) in an acquisition agreement valued EURO 11
billion.
According to the Akzo Nobel’s Inaugural Global Coatings Report entitled “The Global
Coatings Report 2006: Painting a picture of the industry Coatings market is a growing one.
The report analyzed the different countries according to their economies and construction
sectors.
1
Akzo Nobel’s Inaugural Global Coatings Report “The Global Coatings Report 2006: Painting a picture of the
industry”, 2006.
In 2005, the global coatings market was worth US$85.7 billion, or 26.5 billion liters. From
2001-2005, the annual growth was 2.7% in constant value terms and 4.2% in volume terms.
Between 2005 and 2010, the annual growth rate is forecast to accelerate, to 5.4% in constant
value terms, and 5.6% in volume terms because of the construction boom.
United States housing construction encouraged by low interest rates and changes in
demographics, as empty nests resize and relocate, and double income household purchase
new homes and remodel existing ones. The US current financial crisis will have negative
impact on the housing construction.
Turkey urbanization has resulted in housing and office building in major cities; economic
recovery driving investment in company premises and delayed building maintenance;
rebuilding of Marmara region following 1999 earthquake. In five and 10-year government
funded development program
China is the world’s largest construction boom, 2008 Beijing Olympics, plus 2010 World
Expo (Shanghai) and Asia Games (Guangzhou) leading to massive investment in urban
infrastructure. Home ownership has seen explosive growth since the closure of the
government backed welfare housing scheme in 1998, and the real estate market is officially
estimated to maintain its current rate of 10% over the next five years.
Brazil is new construction began to pick up post-2005, and was accelerated in 2004, the
government introduced the National Housing System to bring additional housing to a country
with a shortfall of more than seven million units.
Spain is a strong economy, high second home/tourism demand, and increased immigrant
demand has kept Spain one of the leading European countries in terms of new building starts.
In 2004, the UK Government announced a £3.5 billion program to build over 70,000
affordable homes in three years. This follows a period of slow housing construction, which
has led to under-supply.
Global demand to rise 3.9% annually through 2011
World demand for architectural paints is forecasted to rise by 3.9 percent per year through
2011 to reach 22 million metric tons, valued at $47 billion. Although respectable, growth will
decline in comparison to the performance of the 2001 to 2006 period, due to a significant
projected deceleration in global building construction expenditure growth through 2011.
Developing countries to be fastest growing markets
Gains will be paced by developing countries in the Asia/Pacific region, with the world’s two
most populous nations -- China and India -- both seeing large gains in their markets. In 2006,
architectural paint demand in China and India stood at 1.2 and 0.6 kilograms per person
respectively. In contrast, per capita demand in developed countries averages around nine to
twenty kilograms. North America will register weakest gains of all regions through 2011. The
current housing and mortgage crisis in the US portends unfavorably towards new residential
building construction spending growth through 2011, hindering paint sales to the new home
market. Moreover, sales to the much larger home repainting segment will also be hindered by
declining sales of existing homes -- which are often repainted when they are to be sold.
Western Europe will also register weak growth, with below average economic and building
construction growth prospects, mortgage sector weaknesses in some constituent nations and
stagnant regional population growth all to blame.
Water-based paints have expanded their dominance
Over the past decade, water-based paints have expanded their share of the global architectural
paint market from 62 percent to 70 percent. Solvent-based paints have seen a corresponding
decline in their share of the market, due to environmental concerns regarding their high
volatile organic compound emissions, and due to improving technology enabling water-based
paints to provide all the positive benefits of solvent-based paints without the associated
environmental negatives.
I.4.5 Egyptian market share of the industry in the international market

In 2005, the global coating’s market was worth US$85.7 billion, or 26.5 billion liters1; while
the Egyptian coating’s market was worth US$ 750 million, or 450 million liters.
Architectural Paints (also called Decorative Paints) in Egypt account for almost 75% by
volume and 63% by value, as average of 2005-2008. In contrast the share of Architectural
Paints stands globally at 45%, with the rest accounted for by industrial and special purpose
coatings.
I.4.6 Local market supply and the competition structure

* The Competitive position in Architectural Paints is as follows:
a. In Synthetic Paints (which forms 51% by value & 38% by Vol.) PACHIN is the market
leader, the next player is SIPES.
B. In Emulsion paints (which forms 34% by value & 54% by Vol.) SIPES is the market
leader, the next player is PACHIN
c. In Varnishes (6% by value & 4% vol.) MIDO, KAPCI and GLC are the key players.
1
(Ref.: Copyright Finni and Partners 2007/2008)
d. In Tinted Paints (9% by value & 5% by Vol.), the key player is JUTON, with PACHIN &
SCIB as the following players.
* The competitive position in industrial paints is as follows:-

• KAPCI, Mido and National are the main producers of car refinish,
• Al –Gammal is the main producer for auto OEM
• Juton is the key player in marine paints
• Pachin and MIDO are the leaders for protective paints
* The main players in resin and polymers are Vinavyl Egypt, Eagle, Clarent, EAB and
PACHIN
On the other hand, the Architectural Paints market is divided into three (3) price categories:
Premium, Middle, and Economic. Juton is the key player in the premium category, while
PACHIN is the key player in the middle category. There is no leader for the economy
category because of the large number of players.
The Egyptian paint industry is about to take off as a result of the forecast growth in the
construction sectors. This potential growth is emphasized by the favorable demographics
(50% under the age of 25 years), which will result in a significant demand for housing
within the next decade. This view is reinforced when one compares the per capita
consumption of paints in Egypt with that of other countries. The average per-capita
consumption in the nineties for Egypt is about 2.0 kg/per-capita1 which is very low compared
with the world average (15 kg per-capita) and the developed countries (22 kg per-capita).
Table 1: Average Consumption of Paints (Kg), 1990’s

Region Average kg/capita
Egypt 2.0
India 0.6-0.7
South East Asia 4.0
US 31.0
Developed Countries 22.0
World 15.0
Source: Business Standard, Indian Paints' Industry: Emerging Trends and Opportunities, HC Brokerage.
1
This average per-capita consumption increased to reach 3.8 kg as an average of the period from 2000-2008.
However, it still low compared to the per-capita average in the developed countries.
The annual market growth varies between the different paints types:
Estimated market growth (by volume) of Emulsion Paints is 14%, 5% for Synthetic Paints,
10% for Synthetic Varnishes , 15% Tinted Paints.
PACHIN is the paints market leader, whether we refer to production size, or sales volume
and value. KAPCI is the leader of export of paints and coatings; while Eagle is the leader for
exports of alkyd resins. The possible entry of additional international competitors forms a risk
to the industry. While we believe that the threat from imported paint is limited, several
international companies have set up operation in Egypt through subsidiaries and joint
ventures. As Egypt continues to raise its profile with international investors, additional
international paint companies could seek entry into the Egyptian paints market placing
pressure on margins, particularly if growth in the industry overall slows down.
I.4.7 Sales and Marketing strategies

The Marketing Strategies should cover the following aspects: What products to sell, who are
the target customers, the policies of Pricing, Advertising, Promotion, Sales and Distribution.
• The Decorative Paints market is divided into 3 segments: The Economic segment (10-
15%of the market), the Middle segment (70-80% of the market) & the Premium
segment (10-15% 0f the market). From marketing view, these products are
considered as “commodities” and the strategy of this category of products is
applicable to it.
• The Industrial Paints marketing is of Business-to-Business form, with a very wide
distribution network.
• Alkyd resins are either kept for own uses or sold to local& external customers.
The selected Strategy of each company depends on the following considerations:
1. Volume of customer segments.
2. Loyalty of the customers to the products
3. Degree of competition within the industry for the customer segment
Each Company develops its own estimates of what can be sold, to whom, when, in what
quantity & at what price.
Accordingly it takes its own decisions concerning Products Portfolio – Prices – Sales effort –
Distribution System – Geographic coverage – Expenditure level of advertising & promotions
I.4.8 Existing Support to paints, coatings and resins industry

The government support paints, coating and resins sector through several channels:
Institutional support:
Paints and Coating divisions in the Chemical and fertilizers Export Council and Chamber of
Chemical Industries are the two institutions that provide support to the paints and coating
sector in Egypt. This support includes provide support to members to participate in domestic
and international fairs with the cooperation of the Egyptian Exporters Association
(Expolink); prepare promotion missions and meetings outside Egypt; provide reports with up-
to-date data and statistics; support member companies to improve their competitiveness
positions and obtain ISO and similar certificates; vocational and management training; and
support establishing websites for the member companies and become members of the
international marketing and sales websites.
Capacity Building:
The Industrial Modernization Center (IMC) provides valuable support to building capacity of
the paints and coating sector through technical assistance and training programs.
I.5 Manufacturing Process of paints, Coatings and resins

Paints can be divided into two main types: The Decorative Paints (also called Architectural
Paints) & the Industrial Paints.
Architectural paints: are used for building and decorative purposes.
Industrial paints can be divided into eight categories, which includes automotive OEM
(Original Equipment Manufacturing) stoving paints, automotive refinishing (cellulosic and
polyurethane) paints, stoving (acrylic) electrostatic enamels, metalwork (alkyd-based) stoving
enamels, wood finishes, heavy duty paints, marine paints and general industrial paints.
Paints Raw Materials RM falls into four main categories: binders, pigments, solvents and
other materials (additives, fillers, driers …). Most of these raw materials are imported. Only
Carbonates, Talc and some solvents are locally manufactured, but most of the raw materials
are imported.
The manufacturing process is broadly similar for all types of paints. It comprises Mixing,
Milling (not for emulsion & some synthetic paints), Finishing & filling.
Alkyd Resins group is one of the raw materials needed for manufacturing synthetic
architectural paints & industrial paints. There are number of local manufacturers for the
Alkyd Resins. Other resins, such as acrylic latex for emulsion paints (local manufacturer for
acrylic emulsions exist) and most resins for industrial paints, are imported.
Manufacturing Alkyd Resins include an exothermic, reversible chemical reaction in which

fatty acid or vegetable oil; Phthalic Anhydride; and a polyol (e.g. Pentaerythritol/ glycerol)
are reacting to form a viscous materials (honey like) mass of alkyd resin.
• The produced paints should meet the National Standard Regulations for Paints
(1539/2008 – 1757/2008 – 793/2008)
• The rise in raw materials costs, rise in energy prices , the economic slowdown , Low
Volatile Organic Compounds VOCs requests , more strict environment regulations ,
new technologies (Nanotechnology,…) , energy saving needs , shift to Green chemistry
& the call for Green Products …. All these & other challenges face the industry & its
R&D activities.
More details about Paints Manufacturing are included in Annex B which is covering:
overview, raw materials, production process, quality assurance, product development, human
resources, legislative & environmental issues, international certificates, & international
developments
II. Data Collection/ Sources

II.1 Secondary Data
Sources of Data on exports are the Chemical and Fertilizers Export Council and the Data
Warehouse of GOEIC.
Source of data on production is Industrial Development Authority (IDA) and the study
interviews.
Source of data on investment is Chamber of Chemical Industries
Source of data on employment is Egypt State Information Service and Chamber of Chemical
industries.
Sources of data on foreign markets are EUROSTAT and ComTrade
II.1.1 Main producers of Paints and Coating by country

The following table shows the main Paints manufacturing companies in the main producing
countries:
Table II.1: Main paint producers by country.
COUNTRY Main Paints Producers
USA Sherwin-Williams , PPG , Du Pont , RPM , Valspar , 3M , H.B.Fuller , Masco ,
Rhom&Haas and Benjamin Moore.
Germany Henkel , BASF coatings , DAW & Brillux.
The Netherlands Akzo Nobel & Sigmakalon ,
Japan Kanasai , Nippon Paints , Dai Nippon Toryo , Chugoku Marine Paints & DIC
COUNTRY Main Paints Producers

Switzerland Sika & Forbo
Mexico Comex.
Norway Jotun
Denmark Hempel , Dyrup & Flugger
India Asian Paints & Berger
Finland Kemira
Australia Orica & Watty
South Africa Barloworld
South Korea KCC & DPI
Turkey Yasar
Brazil Renner
Jordan National
Portugal CIN
Austria Tigerwerk
Taiwan Yung Chi
Spain Titan
Italy Boero Group & Inver SpA
Thailand Toa Paints
Russia Empils , Russian Coatings
Source: Coatings World, 2008.
II.1.2 Egyptian Imports of Paints and Resins and their Raw Materials
During the last 6 years Egypt was importing significant amount of paints and resins to satisfy
the increasing demand of the construction and industrial sectors in Egypt. Meanwhile, Egypt
is practicing increased exports of paints and resins. Table II.2 presents the trend of imported
paints, resins and raw materials. From 2002-2006, the imports of paints and resins are
fluctuating but with an increasing rate. However, in 2006-2007 paints import does not follow
the same rate, it is constant, see chart II.1; this because of the increased production of paints
in Egypt in the last few years, which satisfied part of the local demand (import substitution)
and increased the paints exports (export promotion). Meanwhile, the imports of raw
materials are following the trends of paints and resins with rate of increase in the last 4 years
as a result of the current booming in the paints sector. The value of raw materials imports
was almost doubled from 2002 to 2007, i.e. it increased from US$109.2 million in 2002 to
reach US$206.2 million in 2007.
Table II.2: Imports of Paints, Resins and Raw Materials, 2002 - 2007
Total Imports of Paints Total Imports of Raw
Years Paints Resins and Resins Materials
$ Million $ Million $ Million $ Million
2002 30.4 71.7 102.1 109.2
2003 27.2 68.6 95.8 93.6
2004 23.0 69.9 92.9 78.7
2005 35.0 102.6 137.6 138.9
2006 43.6 108.0 151.6 183.7
2007 43.6 135.2 178.8 206.2
Source: Calculated from the data of Egyptian Customs, Ministry of finance
Chart II.1: Imports of Paints and Resins, 2002-2007
200.0
180.0
160.0
140.0
Million US $
120.0 Paints
100.0 Resins
80.0 Total imports
60.0
40.0
20.0
0.0
2002 2003 2004 2005 2006 2007
Years
Chart II.2: Imports of Raw Materials, 2002-2007
250.0
200.0
US$ Million
150.0
100.0
50.0
0.0
2002 2003 2004 2005 2006 2007
Year
The source of data on custom duties is the Presidential Decree No. 39/2007; “Customs Tariff
According to the Amendments of the Harmonized System 2007” and its amendment on 2
April 2008, Ministry of Finance, Arab Republic of Finance. These custom duties were
examined to find the effect of reduce or even eliminate some of them on the performance of
the sector and on the custom revenues. At this stage no change is required, however, after few
months when the status of the current international financial crisis becomes clearer, these
custom duties need another review to assess their impact on the sector.
A. Imported Products
Annex “F-1”presents the custom duties for imported paint and coating products. These
custom duties serve as a protection to domestic industry; its range is from 2% - 20%.
B. Imported Intermediate products

Annex “F-2”presents the custom duties for imported intermediate products. These custom
duties serve as a protection to domestic industry of intermediate products.
C. Imported Raw Materials

Annex “F-3”presents the custom duties for imported raw materials. These rates were
reviewed to assess their effectiveness.
II.1.3 Egyptian Exports of Paints and Coatings

According to the data from GOEIC and Chemical and Fertilizers Export Council, the major
exports markets for Egyptian paints and coatings are the Arab and African countries. Annex
“E” includes more detailed information about export values by HS 1992 Code and destination
regions.
A. Paints and Coating Exports by Region

The available data for three years (2005-2007) in table II.3 and Chart II.2 shows that the
value of Egyptian exports during this period were 65.8% to Arab Countries, 19.6% to Africa
(excluding Arab Countries), 4.7% to Europe, 1.7% to Asia (excluding Arab Countries), and
8.4% to other countries.
Table II.3: Paints and Coatings Exports (USD) by Region, 2005-2007.
Region 2005 2006 2007 Total 3 Years % Cumulative %
Arab Countries 13,022,354 23,556,824 40,209,502 76,788,680 65.79% 65.79%
Africa* 2,573,424 8,353,641 11,949,080 22,876,144 19.60% 85.39%
Europe 727,629 702,730 3,799,970 5,230,328 4.48% 89.87%
Asia* 315,223 969,413 738,625 2,023,262 1.73% 91.60%
Other Countries 1,621,562 3,804,523 4,374,842 9,800,927 8.40% 100.00%
Total Exports 18,260,192 37,387,131 61,072,019 116,719,342 100.00%
* Does not include Arab Countries.
Source: General Organization for Export and Import Control (GOEIC)
Chart II.2: Exports of paints by Region
100%
90%
80%
70%
60% Other Countries
US $ 50% Asia
40% Europe
30% Africa
20% Arab Countries
10%
0%
2007 2006 2005
Years
Source: Table II.3

B. Paints and Coating Exports by HS Code

Table II.4 presents the value of paints and coatings exports (USD) by HS Code, 2005-2007.
The table shows that the highest values of exports are from HSC 3210 and 3208.
The table shows that HS Code 3210 represents 37.6%, 49.4%, and 63.1% of the value of total
exports in 2005, 2006, 2007 respectively, i.e. the value and ratio of its exports are increasing
in the last three years. HS Code 3208 represents 52.6%, 47.9%, and 35.4% of the value of
total exports in 2005, 2006, 2007 respectively, i.e. while the value of its exports is increasing,
its ratio to total annual exports is decreasing. HS Code 3214 represents 1.4%, 1.4%, 1.0% of
the value of total exports in 2005, 2006, and 2007, i.e. while the value of its exports is
increasing; its ratio to total annual exports is decreasing. The exports of HS Code 3209 are
decreasing and its ratio to annual exports is decreasing; it decreased from 8.4%, 1.3%, to
reach 0.05% of the value of total exports in 2005, 2006, 2007 respectively.
Table II.4: Paints and Coatings Exports (USD) by HS 1992 Code (product), 2005-2007
3208 3209 3210 3214 Total Paints
Year $ million % $ million % $ million % $ million % $ million
2005 9.6 52.6% 1.5 8.4% 6.9 37.6% 0.3 1.4% 18.3
2006 17.9 47.9% 0.5 1.3% 18.5 49.4% 0.5 1.4% 37.4
2007 21.6 35.4% 0.3 0.5% 38.5 63.1% 0.6 1.0% 61.1
Source: General Organization for Export and Import Control (GOEIC)
B. Resins Exports
Table II.5 presents the value of alkyd resins (HS Code 390750) exports (USD) by region. It
shows that the majority of its exports allocated to African Countries (45.9% of total exports
of Alkyd resins) and Arab Countries (45.6% of total exports of Alkyd resins); i.e. 91.5% of
Alkyd Resin exports is allocated to African and Arab Countries as a total of 2005-2007.
Exports of Alkyd Resins to Asian and European Countries presented only 4.8% and 3.1%,
respectively.
Table II.5: Alkyd Resins (HSC 390750) Exports (USD) by Region, 2005-2007.
Total 3 Cumulative
Region 2005 2006 2007 Years % %
Arab Countries 946,630 4,588,051 8,459,240 13,993,921 45.60% 45.60%
Africa 582,355 4,314,792 9,177,702 14,074,850 45.87% 91.47%
Asia 64,525 623,381 770,233 1,458,139 4.75% 99.33%
Europe 204,990 300,629 447,432 953,050 3.11% 94.58%
Other Countries 0 0 206,537 206,537 0.67% 100.00%
Total Exports 1,798,500 9,826,853 19,061,144 30,686,497 100.00%
Source: Calculated from the data of General Organization for Export and Import Control (GOEIC)
The following table represents Egypt’s exports of all resins (including alkyd resins) by HS
Code. It showed that HS Code 3907 has the largest value of resins exports (because of alkyd
resins). HS Code 3907 represents 36.9%, 67.9% and 85.7% of total resins exports in 2005,
2006, and 2007, respectively. Exports of HS Code 3905 represent 20.7%, 21.5%, and 9.8%
respectively. The exports of the other HS Codes (3903, 3906 and 3908) are very minor
compared to the exports of HS Code 3907.
Table II.6: Resins Exports (USD) by HS 1992 Code

3903 3905 3906 3907 3908 Total Resins
$ $ $ $ $
Year million % million % million % million % million % $ million
2005 1.8 31.3% 1.2 20.7% 0.3 5.9% 2.1 36.9% 0.3 5.2% 5.8
2006 0.8 5.0% 3.2 21.5% 0.8 5.4% 10.2 67.9% 0.0 0.2% 15.0
2007 0.8 3.6% 2.2 9.8% 0.2 0.7% 19.2 85.7% 0.0 0.1% 22.4
Source: Calculated from the data of General Organization for Export and Import Control (GOEIC)
II.2 SWOT Data (Stakeholders)

II.2.1 Who are the Stakeholders?
The Approved list of Stakeholders includes:
1) Manufacturer (Paints, Coating & Resins)
2) Local Supplier of Raw Material (Carbonate, Talc, Resins & Acrylic Emulsion)
3) Solvent Suppliers (‫) ا ا ا
ول‬
4) Paints &Coating Wholesalers
5) Agents of International Supplier (of main raw material)
6) Industrial Modernization Center (IMC)
7) Federation of Egyptian Industries- Chemical Industries Chamber-Paints Section
8) Egyptian Organization for Standardization "EOS"
9) Egyptian Environmental Affairs Agency "EEAA"
10) Chemistry Authority
11) Professional Painters, Labors ,Consumers(Indirect Beneficiaries)
12) Service Providers (Shipping lines, clearing agents)
13) Custom Authority, Tax Authority
14) Foreign importers
15) Export Import Control Authority
16) Industrial Development Authority (IDA)
17) Local Exporters
18) Export Council
II.2.2 Paint and Coating Exporters’ Population and Sample Size:

The general objective of the study aims mainly at promoting exports at sector level and the
specific objectives are to carry out: 1) an export support study for painting and coating
industry and 2) a simple industrial profile model with expected economic indicators for a
medium scale project for producing two types of paints and a type of resins. This means that
the export sector is the targeted sector; however this does not mean that the study ignored the
domestic market. It is important to say that the domestic market is the backbone of the
foreign markets and it should be developed to complement the foreign trade and to be a
safeguard if any problems occurred in the foreign markets.
According to the general and specific objectives of the study, the paints and coating export
sector is the targeted population. According to the unpublished data of the General
Organization of Export and Import Control (GOEIC) – “presented in tables II.7, II.8 and
II.9;” during the last three years (2005-2007) the number of exporters were 388 (100%)
companies of which 152 companies (39% of total exporters) exported $5,000 or more per
year, i.e. $15,000 in the three years. The total value of exports of these companies in the three
years is $147.92 million (99.5% of value of total paint and coating exports). On the other
hand, 236 companies (61% of total exporters) exported less than $5,000 per year; the value of
exports of these companies, as a total of the three years, is only $669,845 (0.5% of value of
total paint and coating exports), which is very negligible amount. The companies in this
category are not regular exporters, but they are ad-hoc exporters (in and out).
The study depends on the direct interview with the key players of the sector and three sources
of secondary data: 1) statistics from reliable sources; 2) information from previous studies
and reports; and 3) information on international markets from reliable websites.
The paints and coating stakeholders are exporters, producers of final products and raw
materials, domestic market actors, public sector and government agencies. The data was
collected using SWOT checklists and questionnaires to obtain information from each of the
stakeholders’ category.
The secondary data was collected for Egyptian paint and coating exports and imports of final
products and intermediate products, production, and custom duties on imports of final and
intermediate products and raw materials. Also, it included data collected on major and
potential foreign markets such as Europe, Africa, Asia, Arab Countries and other regions.
[Note: the Arab countries are extracted from the Asian and African regions because of their
unique situation to Egyptian markets.]
Table II.7: The weight of the excluded exporters that export Less than US$5,000 per year
Total Exports
Annual Exports Annual exports # of Companies
(3 years, 2005-2007)
$5,000 or more 147,922,263 99.5% 49,307,421 99.5% 152 39%

Less than $5,000 669,845 0.5% 223,282 0.5% 236 61%
All Exporters 148,592,108 100.0% 49,530,703 100.0% 388 100%
Source: Calculated from data of General Organization for Export and Import Control (GOEIC), unpublished data.
Tables II.8 and II.9 present the structure of the sample and its relation to the export sector
population. In table II.8, the population of export sector is considered as 152 exporters that
exported 99.5% of total exports in the last three years (2005-2007). Three exporters exported
$95.94 million (65% of the total value of exports); seven exporters exported $22.95 million
(15% of the total value of exports); eleven exporters exported $14.5 million (10% of total
value of exports); and the remaining 128 exporters exported $14.6 million (10% of total value
of exports).
Table II.9 shows the percentage of the study sample of the above mentioned population. The
study interviewed 3 companies out of the 3 companies that exported 65% of the value of
exports; 2 companies out of the 7 companies that exported 28%; and 5 companies out of the
11 companies that exported 10%, and 6 companies out of 128 companies that exported the
last 10% in 2005-2007. As a total sample the study team interviewed 16 companies (11%)
out of the total 149 companies. The interviewed companies exported 74% of the total exports
in the last 3 years.
Table II.8: Paints and Coating Exports, in Million US$ (2005-2007)*

Category Population ($ million) Sample ($ million)
(% of Total Annual # of Average Total Annual # of Average
total Exports Exports Companies Annual Exports Exports Companies Annual
Exports) (3 years) ** Exports per (3 years) *** Exports per
Company Company
65% 95.94 31.98 3 10.66 95.94 31.98 3 10.66
15% 22.95 7.65 7 1.09 6.52 2.17 2 1.09
10% 14.46 4.82 11 0.44 6.64 2.21 5 0.44
10% 14.58 4.86 128 0.04 0.98 0.33 6 0.05
100% 147.92 49.31 149 0.33 110.08 36.69 16 2.29
* The data reflects the companies who export $5,000 or more per year through, 2005-2007.
** Total registered exporters are 388 companies, of which 149 are exporting $5,000 or more annually (They are 152 companies but 3
companies were repeated under different tax number and we had to merge them).
*** The sample size is 22; it includes the above mentioned 16 companies and other 4 paint and coating producers (non-exporters) and 2 raw
materials producers.
Source: General Organization for Export and Import Control (GOEIC), unpublished data.
Table II.9: The weight of the sample (%) to total population (Exports and Exporters)
Sample size of
Category (% of
Total Exports) Annual # of
Total Exports Exports Companies
65% 100% 100% 100%
15% 28% 28% 29%
10% 46% 46% 45%
10% 7% 7% 5%
100% 74% 74% 11%
Source: Table II.8.
III. Analysis
III.1 Paints and Resins Exports
World Paints and Resins Exports:
According to the ComTrade data for 2007, the world total export of paints and resins is
US$4.81 billion. In 2007, Malaysia is the highest export; its exports reached US$1.57 billion
and Mexico exports reached US$1.34 billion. Value of exports for Malaysia represents about
32.6% and Mexico represents about 27.9%, i.e. the value of exports for the two countries
forms about 60.5%% of total World exports and all other countries (about 52 countries)
represent only 39.5%.
Table III.1: Exports of paints and resins, 2007
Country $ %
Malaysia 1,566,697,212 32.6%
Mexico 1,341,855,492 27.9%
Other Countries 1,901,015,847 39.5%
World 4,809,568,551 100.0%
Source: ComTrade
Egypt Paints and Resins exports

The Data warehouse of the General Organization for Export and Import Control (GOEIC) is
the most reliable data source for Egyptian exports. It was used as a source of data to perform
the Egyptian export analysis.
Egypt Paints Exports:
The following table includes the actual (2005-2007) and expected (2008-2013) exports of
paints by HSC. The expected exports were estimated using the export data of GOEIC. The
strong competition of neighbor countries such as Tunisia, Greece, and Turkey and China is a
threat to the Egyptian paints exports and the whole industry as whole. The growth without
support is expected to be low because of these threats. The following table represents the
expected exports without support in the coming 5 years.
Table III.2: Actual (2005-2007) & Expected Exports of paints (2008-2013) without support ($ Million)
Paints Exports by HS 1992 Code
Year Total Without Support
HSC 3208 HSC 3209 HSC 3210 HSC 3214
2005 9.60 1.54 6.86 0.25 18.26
2006 17.92 0.48 18.47 0.51 37.39
2007 21.60 0.32 38.52 0.62 61.07
2008 21.03 0.08 54.11 0.44 75.66
2009 21.89 0.09 57.84 0.45 78.08
2010 22.78 0.09 61.83 0.47 80.58
2011 23.71 0.09 66.10 0.49 83.15
2012 24.68 0.09 70.66 0.50 85.81
2013 25.69 0.09 75.53 0.52 88.56
Source: Economic Analysis of the Study.
Egypt Resins Exports:

The following table includes the actual (2005-2007) and expected (2008-2013) exports of
resins by HSC. The expected exports were estimated using the export data of GOEIC. Also,
the situation of resins exports is similar to paints exports, except that resin exports are much
lower than paints exports. The strong competition of neighbor countries such as Tunisia,
Jordan, and turkey is a threat to the Egyptian resins exports. The growth without support is
expected to be low because of these threats. The following table represents the expected
exports without support in the coming 5 years.
Table III.3: Exports of resins by HS Code without support (US$ Million)

Resins Exports by HS 1992 Code
Year Total Without Support
HSC 3903 HSC 3905 HSC 3906 HSC 3907 HSC 3908
2005 1.80 1.20 0.34 2.13 0.30 5.76
2006 0.75 3.22 0.81 10.19 0.04 15.01
2007 0.81 2.20 0.16 19.19 0.03 22.39
2008 0.16 0.89 0.01 24.62 0.02 25.69
2009 0.16 0.92 0.01 25.70 0.02 26.80
2010 0.16 0.94 0.01 26.83 0.02 27.96
2011 0.17 0.97 0.01 28.01 0.02 29.17
2012 0.17 0.99 0.01 29.24 0.02 30.43
2013 0.18 1.02 0.01 30.53 0.02 31.75
III.2 EU Demand on Paints and Coating products

The EU market should be the potential market for Egyptian paints and coating products. The
analysis of the EU demand is being done using the HS codes for paints and coating products;
the original products are 3208: 10/20/90 (solvent based paints) and 3907: 50/99 (Alkyd
resins).
Table III.4: Expected reduction in EU paints and resins production in the next 5 years (Euro million)
Expected reduction in EU production due to VOC Expected reduction in EU production
Regulation (Euro million) (Euro million) Grand
Total Total Total
Year HS Code HS Code
reduction reduction (Euro
million)
320820 320810 320890 3208 390750 390799 3907
2008 0.39 0.00 0.00 0.39 0.00 0.00 0.00 0.39
2009 0.81 0.62 1.01 2.44 0.61 0.71 1.33 3.77
2010 1.25 1.26 2.12 4.63 1.86 1.42 3.28 7.91
2011 1.29 1.93 3.32 6.54 3.12 1.42 4.54 11.08
2012 1.33 1.96 3.47 6.77 3.14 1.42 4.56 11.33
2013 1.38 1.99 3.63 7.00 3.16 1.42 4.58 11.58
Source: Economic Analysis of the Study (estimated using EuroStat data)
The grand total figures form the expected total reduction in the value of mentioned HSC
products by EU in the next 5 years. These values expected to be available for all exporters
around the World. If Egypt exports about 10%- 30% annually of these values this will be
good achievement.
III.3 Expected EU and Non-EU Exports of Paints and Coatings

The EU market should be the targeted market to examine the sustainability the Egyptian
paints and coating standards. If Egypt sustains its exports to the EU markets, then its exports
to other regions can be sustained. Existing demand by other countries is being analyzed in
the light of their levels of production, exports and imports of paints and coating. Meanwhile,
Egypt’s exports to Arab countries and Africa are very promising, but the high competition
due to the export subsidies by competitor countries is a major threat to Egyptian exports.
Table III.5: Actual (2005-2007) and Expected (2008-2013) EU and Non-EU Exports of
Paints and Coatings (US$ million) by Region (without support)
Arab Other Total without
Year Africa* Europe Asia* Countries Countries support
2005 2.57 0.73 0.32 13.02 1.62 18.26
2006 8.35 0.70 0.97 23.56 3.80 37.39
2007 11.95 3.80 0.74 40.21 4.37 61.07
2008 17.58 5.61 0.91 45.94 5.61 75.66
2009 18.62 5.95 0.94 46.76 5.81 78.08
2010 19.71 6.30 0.97 47.59 6.01 80.58
2011 20.85 6.67 0.99 48.42 6.22 83.15
2012 22.05 7.06 1.02 49.26 6.43 85.81
2013 23.30 7.46 1.05 50.10 6.65 88.56
* Does not include Arab Countries
III.4 Expected Demand on Egyptian Paints and Coating to international

markets
The following table presents the situation with the government support. The support will
help the sector in covering its costs and attract new investments to be utilized. This will have
social impact by creating new jobs.
The exports to Arab countries will increase from $40.21 million in 2007 to $71.94 million in
2013. Also, the exports to Africa will increase from $11.95 million in 2007 to $67.95 million
in 2013. The total exports will increase from $61.07 million in 2007 to $176.91 million in
2013.
Table III.6: Expected increase in Egyptian paints Exports with Support (US$ million) by
Region
Arab Other Total with
Year Africa* Europe Asia* Countries Countries support
2005 2.57 0.73 0.32 13.02 1.62 18.26
2006 8.35 0.70 0.97 23.56 3.80 37.39
2007 11.95 3.80 0.74 40.21 4.37 61.07
2008 17.58 5.61 0.91 45.94 5.61 75.66
2009 23.52 7.53 1.07 50.63 6.74 89.48
2010 31.11 10.00 1.24 55.57 8.04 105.95
2011 40.74 13.13 1.43 60.76 9.52 125.57
2012 52.84 17.07 1.64 66.22 11.21 148.98
2013 67.95 22.02 1.87 71.94 13.13 176.91
* does not include Arab countries.
The following table presents the paints exports by HS 1992 codes. HSC 3210 comprise the
majority of Egyptian exports; it will increase from US$38.52 million in 2007 to US$138.61
million in 2013. HSC 3208 will increase from US$21.60 million in 2007 to US$37.46
million in 2013.
Table III.7: Exports of Paints by HS Code with support (US$ Million)

Year HSC 3208 HSC 3209 HSC 3210 HSC 3214 Total With Support
2005 9.60 1.54 6.86 0.25 18.26
2006 17.92 0.48 18.47 0.51 37.39
2007 21.60 0.32 38.52 0.62 61.07
2008 21.03 0.08 54.11 0.44 75.66
2009 23.60 0.09 65.31 0.48 89.48
2010 26.49 0.10 78.82 0.54 105.95
2011 29.74 0.10 95.14 0.59 125.57
2012 33.38 0.11 114.84 0.66 148.98
2013 37.46 0.11 138.61 0.73 176.91
The following table presents the resins exports by HS 1992 codes. HSC 3907 (Alkyd resins)
comprise the majority of Egyptian exports; it will increase from US$19.19 million in 2007 to
US$45.74 million in 2013. The exports of acrylic resins are still minor compared to the
acrylic resins.
Table III.8: Exports of Resins by HS Code with support (US$ Million)
Year HSC 3903 HSC 3905 HSC 3906 HSC 3907 HSC 3908 Total With Support
2005 1.80 1.20 0.34 2.13 0.30 5.76
2006 0.75 3.22 0.81 10.19 0.04 15.01
2007 0.81 2.20 0.16 19.19 0.03 22.39
2008 0.16 0.89 0.01 24.62 0.02 25.69
2009 0.17 0.96 0.01 27.87 0.02 29.02
2010 0.18 1.04 0.01 31.54 0.02 32.79
2011 0.19 1.12 0.01 35.70 0.02 37.05
2012 0.21 1.21 0.01 40.41 0.02 41.87
2013 0.22 1.31 0.01 45.74 0.02 47.32
III.5 SWOT Analysis

SWOT analysis approach was used in performing all of the meetings/ interviews with the
stakeholders of the paints and coatings sector. SWOT acronym stands for strength, weakness,
opportunities, and threats facing the sector. In this case, SWOTs are:
Strengths: attributes of the organizations that are helpful to achieving the objectives of the sector
Weaknesses: attributes of the organizations that are harmful to achieving the objectives of the
sector
Opportunities: external conditions those are helpful to achieving the objectives of the sector
Threats: external conditions those are harmful to achieving the objectives of the sector.
III.5.1 Private Sector Stakeholders:

Private sector stakeholders include paints and coatings producers and exporters and raw
materials producers. Also, general information was gathered from painters to assess the local
market.
Table III.9: Summary of the Producers and Exporters SWOT findings in the paints and coating sector in Egypt
Internal Factors External factors
Strengths Weaknesses Opportunities Threats
- Paints and Coating business is an old and - Limited number of skilled - High potentiality in increasing Egyptian - Loosing international markets if the sector does
promising industry in Egypt professionals and exports to penetrate new markets and not adjust itself to the new standards, such as
- Sales have grown steadily by 4% from 2003 to technicians; replace the reduction in European REACH. All companies should be ready for
2006 - Lack of written reports. production in some paints and coating any new certificate.
- New tax law improved the sector performance - Some bureaucratic issues products - Commercial attaches sometimes are not
- Adopting with the environmental standards is still in some of the tax - Demand on paints and coating is booming experienced enough to do promotion job.
doable organization. in the international markets - Price of nitrocellulose in the local market is
- Egyptian paints and coating products have an - Informal producers are - Commercial attaches are good resources for higher than the imported one and is lower
excellent reputation penetrating the industry due export promotion, if they have promotion quality.
- Paints and coatings do not need large to ease of production of low experience. - Most of domestic raw materials are not up to
investments; it needs know-how to improve quality products. - Price and quality of Toluene in domestic the standards (i.e., are not certified under a
products. - Low quality/ low price markets are good. quality standards system) this affects the
- Local inputs represent in average 59.5% of products dominate domestic - Car factories are penetrating African exports to developed countries.
cost of exported products. Local inputs are markets especially in poor countries such as Libya, Kenya, Senegal - The continuing increase in raw materials’
know-how, raw materials, packing, and labor areas. and Sudan. This will increase demand on prices, especially petrochemical products will
cost. - Painters who do not have OEM paints. affect negatively the sector.
- wide product range good experience distort - Improve paints and coatings’ product up to - How and when the African Countries will react
- Computerized system for logistics paints domestic markets in the standards is a must for sustainable to the quality standards certifications.
- Large companies have good marketing most cases by directing export markets. - Retroactive implementation of some
systems: 1) local market: business to business customers to inappropriate - Taxing exported materials and intermediate governmental decrees (raw materials and
in car and wood and distribution network in products. products and subsidizing exported final energy) is very discouraging because the
construction paints. 2) foreign markets: - Wide range of improper products will have positive effect on companies sign contracts before delivering their
distributors, agents, or branches in country. products within the sector is exports and the whole sector. Some products and cannot apply the price increase on
However, abroad branches are very expensive. not good for the whole countries implement this policy to protect the signed contracts. Laws should be applied
sector. their national industries. gradually.
- High cost of R&D reduces - Egypt can expand the production of paints - Obtain reports and certificates analysis is an
opportunities in improving/ and coatings due to low wages. This issue with the Chemical Authority. High cost
producing new products. reduces the cost of production and increase of analysis and delay of receiving certificates
- High health risk for the competitiveness. have negative impact on exports.
labors in the sector. - Water based Car Varnishes is a potential - Commercial law does not support credit sales.
- Storage of bulky products is product; however, water based prices are In the past the check used to be the instrument;
very expensive and can be a about 20% higher now, there is no good instrument.
weakness in some cases. - Increasing demand on Emulsions world - Individualism of Egyptian business reduces the
- High cost of customer wide opportunities of team building approach. Also,
services and technical - Powder coatings is better on an the one-man-show behavior is another problem
support. environmental basis that affects negatively the implementation of

- Lack of safety and fire - REACH1 is strong opportunity for the delegation of authority approach.
fighting standards. improving paints and coating production. - High regional competition from neighboring
However, REACH is very expensive “Euro countries (Jordon, Tunisia, Libya, etc who
30,000 for each product.” subsidize their exports of paints and coatings.
- Some countries such as China are - Reduction on Alkyds’ demand in the long run.
decreasing the subsidy on raw materials and - Increase in transportation costs and freight.
the sector as a whole. - Powder coating may affect industrial paints
- Factoring guarantees debt collection markets.
(Factoring Egypt Credit). It increases the - Lengthy procedures of Customs caused lots of
payback of loans and improves cash flow. losses to the Company.
- License procedures are very lengthy and
complicated
- Drawback scheme is an obstacle in some cases.
- Low quality of local packaging containers
(metal or plastic).
- Market instability
- The education system is not replying to the
demand of the business. The qualification of the
graduates is inferior to the needs.
1
REACH is the new Regulation on Registration, Evaluation, Authorization and Restriction of Chemicals. It entered into force on 1st June 2007. It streamlines and improves the former legislative
framework on chemicals of the European Union (EU).
The main aims of REACH are to improve the protection of human health and the environment from the risks that can be posed by chemicals, the promotion of alternative test methods, the free
circulation of substances on the internal market and enhancing competitiveness and innovation.
REACH makes industry responsible for assessing and managing the risks posed by chemicals and providing appropriate safety information to their users. In parallel, the European Union can take
additional measures on highly dangerous substances, where there is a need for complementing action at EU level.
Table III.10: Summary of the Packing Materials SWOT findings in the paints and coating sector in Egypt
- Some factories have - No availability of steel due to the - High export potentials to - Custom duties on template are high
imported machines shortage of iron neighbor countries - Custom employees do not know the nature of our industry and ask strange
and equipments in - Lack of qualified workers - Establish and institute questions
good quality - Unexpected and sudden changes in RM for packing and - Raw materials take three days to be cleared by custom, it can be reduced to less
- Awareness of ISO prices packaging to improve than a day as Dubai (for example)
and certification is in - High increase in power costs the labor skills - There is no standardization for paints and coating filling cans.
process - The manual method of cutting the steel - If there is a problem with packing materials it goes back to the paints and coatings
- Some companies sheets in some backing factories is a company not the packing company!
have computerized handicap for the development of the - - Raw materials Prices & its availability are big risks for the continuity of the
systems to control industry. business.
logistics of raw - Low salaries and long working hours for - It already caused erosions in profit margins
materials and labor - Decrease in Alkyd consumption (due to the shift into Emulsion & low VOC
recycling of - packaging sector needs restructuring products)
industrial waste - Lack of storage area - High increase of imported Raw material Prices (Price fluctuations)
- Small and medium companies cannot - Increase in raw materials prices especially solvents. Government is monopsonist
cope with ISO standards (sole producer and seller). The government does not communicate with
stakeholders before taking major decisions
- Low quality of local packaging containers (metal or plastic)
- Foreign investors in the paints & alkyd resin business
- The priority of the MENA region for the suppliers of raw materials was
deteriorated. The 1st.priority is given to China & India due to their huge
consumption. The suppliers now offer higher prices in MENA region.
Table III.11: Summary of the Painters SWOT findings in the paints and coating sector in Egypt
- Experienced people can identify the - The Contractor prefers to supply larger - It is suggested that no one should work as - Some painters use 2nd or 3rd grades of
different grades and quality of paints. number of painters. Most of the time he a painter unless he has a license as a paints instead of 1st grade. These grades are
- There is a Syndicate for Technicians; hire one or two qualified painters and painter. demanded for outside painting and shanty-
painters are part of this syndicate. It five or six young men who do not have - The exam of painters must be done by old town buildings. If these grades are used in
provides health and pension any knowledge about paining and experienced painters. Two licenses higher quality buildings it cases bad results.
insurances. - Any person can impose himself to this should be provided: a. Painter license and - Dishonesty is the cause of bad results
- Some large companies have unique job without any experience. b. Painter Assistant. - Illegal factories are very harmful for the
trade marks hard to be copied or - Most of painters don know any thing - Legal/ large factories have to improve sector
mimicked. about the Syndicate for Technicians. their trade marks and make them hard to - Painters do not like to work as permanent
- Cheap paints are demanded by low - Some painters mix fake paints and be mimicked. employee with a company because there is
income groups original ones to gain from the price - Painters can work part time with large no guarantee that he will continue.
- Some large companies trained difference but this cause bad impact on companies; but they should have the - Fake raw materials have bad effect on the
painters and painter’s assistants and the sector. opportunity to move between companies sector; fake zinc is a popular example.
let them work in the local market. and private contracts
The painter put the name of this
company on his workshop and the
company provides his shop with its
products. This had high positive
impact on the sector.
III.5.2 Public Sector and Government Stakeholders

The team of experts analyzed the gathered information from the Egyptian Organization for
Standardization and Quality (E.O.S.), Ministry of Trade and Industry (MTI); Egyptian
Petrochemicals Holding Co.; Egyptian Environmental Affairs Agency, Ministry of State for
Environmental Affairs; Egyptian Customs, Ministry of Finance; General Organization for
Export and Import Control (GOEIC); and Industrial Development Authority, Ministry of
Trade and Industry.
The following table includes major Strengths, Weaknesses, Opportunities, and Threats that
facing the paints and coatings sector while dealing with other stakeholders such as
PARASTATAL organizations, public sector and government. This analysis is an assessment
of the effect of these organizations on the paints and coatings industry.
Table III.12: SWOT Analysis of the effect of other stakeholders on the sector
Strengths Weaknesses
- Good understanding of environmental aspects - High demand on petrochemical products, the import
- Low cost of domestic inputs process and procedures of these products need to be
simplified.
- Efficient R&D in large companies
- Lack of reliable information
- Paints industry is very old in Egypt; there are very
efficient technicians (but limited number of them) - Fragmented sector
- The sector has good number of entrepreneurs; they need to - highly depends on specific imported raw materials
work together to resolve the sector problems. - Focus on domestic markets (3 companies export 65% of
total value of exports)
- Unskilled painters who have negative effect on the sector
Opportunities Threats
- Utilization of IMC, Export Council and similar - Retroactive implementation of some Government decrees
organizations to enhance the performance of the sector. - Absence of strong entities to improve the performance of
- The current reforms in standardization, custom, painters and labor
environment, and Tax Authorities have positive results on - Export subsidy by competitor countries
the sector. This should be utilized by the producers and
- REACH is very expensive “Euro 30,000 for each
exporters
product.”
- Provide reliable information to the data collection
- Subsidized petrochemical products in some Oil Arab
authorities, this will have positive impact on the sector
Countries
- Reduction in specific paints and coatings products in EU
- Although the current custom and tax duties are suitable for
Countries.
paints exports and imports, they may be reviewed in the
- Utilization of available bilateral agreements near future as a result of the current international financial
- REACH is strong opportunity for improving paints and crisis.
coating products to be environmental friendly.
IV. Results and Findings

IV.1 A Plan to overcome the weakness and threats that face the product
The study concluded that the paints and coatings sector is a scattered sector, i.e., most of the
key players are working independently and depend on the existing government, public sector,
and PARASTATAL institutions. The PARASTATAL institutions are supervised directly by

the government; however, it is important to state that the PARASTATAL institutions playing
an important role in the transition period to ease the communication between private sector
and government and to strengthen the government/ private sector partnership.
The need for an association for the sector is very important to give the sector the chance to
communicate as one entity with other organizations through the existing institutions and
directly; depends on the situation. The importance of creating this association is to have the
sector feel ownership on this association. In the beginning it can be used to share information
between the individual companies and provide support to the weak links in value chain of the
sector such as painters and packaging materials. After the interviews and meetings within the
sector, we can conclude that there are very ambitious individuals within the sector who can
lead this effort.
The following two tables provide the weaknesses within the sector and the threats facing the
sector, how to mitigate them, and who should do them.
Table IV. 1.1: Mitigating the Weaknesses within the Sector
Weaknesses Recommended mitigations Who will do it
- Limited number of skilled There is a need for more training The sector through an
professionals and technicians; programs to improve their skills. association that generates funds
to sustain this task. Currently,
Technical and Vocational
- Lack of written reports. It is important to implement training on
Educational Training program
technical report writing.
(TVET) is implementing a
vocational training. (EU funded
program)
- Some bureaucratic issues still in some More attention to the employees who Tax Department
of the tax organization. implement the tax law will resolve this
issue.
- Paints and coatings do not need large n/a
investment; this attract adventurers
who have no experience in
penetrating the business and produce
low quality products
- Low quality/ low price products n/a

dominate domestic markets especially
in poor areas.
- Painters who do not have good More training for painters is a must. The proposed association can
experience distort paints domestic Some companies did comprehensive play an important role in this
markets in most cases by directing trainings to painters and provided them issue because improving the
customers to inappropriate products. with financial support but in an individual local market is very important to
company bases (not as a sector solution). the export sector.
Weaknesses Recommended mitigations Who will do it

- High variation in quality of products This can be mitigated by a well The formulation of such
within the sector is not good for the established association to harmonize the association needs ambitious
whole sector. members of the sector. entrepreneurs who can make
changes in the sector.
- High cost of R&D reduces - The producers can arrange for bringing The proposed association and/or
opportunities in improving/ producing experts at lower costs. IMC can provide support in this
new products. regards.
- High health risk for the labors in the Emphasize the occupational of safety and All sector organizations
sector. Health concepts.
- Storage of bulky products is very Good planning using effective supply Producers
expensive and can be a weakness in chain system
some cases.
- High cost of customer services and Improve the competitiveness of the sector producers
technical support.
- Lack of safety and fire fighting Emphasize the occupational of safety All sector organizations
standards standards
Table IV.1. 2: Mitigating the threats facing the Sector

Threats Recommended mitigations Who will do it
- Loosing international markets if the sector All companies should be ready for any Government support is highly
does not adjust itself to the new standards, new certificate. This needs institutional recommended
such as REACH. and financial support.
- Illegal sector (fraud products) in refill More enforcement of existing laws Regulatory authorities
containers for famous companies with low should be done in the domestic market.
quality products.
- Commercial attaches sometimes are not More awareness of commercial Ministry of Trade and Industry
experienced enough to do promotion job. attaches to support export activities
- Price of nitrocellulose in the local market is Simplify the importing procedures Ministry of Trade and Industry
higher than the imported one and is lower
quality.
- Most of domestic raw materials are not up Establishing standards for domestic raw Quality Control Authority
to the standards (i.e., are not certified under materials
a quality standards system) this affects the
exports to developed countries.
- The continuing increase in raw materials’ Adjust the formulation of the paints and R&D
prices, especially petrochemical products coating to reduce petrochemical inputs.
will affect negatively the sector.
- How far the African Countries from Egyptian producers must be ready for The government and all other
REACH certification. the REACH standards. This needs organizations of the sector

institutional and financial support.
- Retroactive implementation of some Laws should be applied gradually. The government should
governmental decrees (raw materials and This can be reached through good consult with private sector
energy) is very discouraging because the communication by private/ government before issuing such an
companies sign contracts before delivering partnership. effective decision.
their products and cannot apply the price
increase on the signed contracts.
- Obtain reports and certificates analysis is an More attention to export related Chemical Authority
issue with the Chemical Authority. High procedures
cost of analysis and delay of receiving
certificates have negative impact on
exports.
- Commercial law does not support credit More awareness on the commercial Government
sales. In the past the check used to be the law.
instrument; now, there is no good
instrument.
- Individualism of Egyptian business reduces It is a cultural issue. This needs long It is an issue should be treated
the opportunities of team building term development at the national level; at the national level for all
approach. Also, the one-man-show not at the sectoral level. sectors.
behavior is another problem that affects
negatively the implementation of the
delegation of authority approach.
- High regional competition from other More support to the exporters to The Government institutional
countries (China, Turkey, etc) who compensate such market distortion. and financial support
subsidize their exports of paints and
coatings.
- Reduction on Alkyds’ demand Implement new technologies to Producers
produce competent products
- Increase in transportation costs and freight. Export support Government financial support
- Powder coating will affect paints markets. Implement new technologies to Producers
produce competent products
- Lengthy procedures of Customs caused lots Revisit the procedure for simplification Custom Authorities
of losses to the Company.
- License procedures are very lengthy and Revisit the procedure for simplification Industrial Development
complicated Authority
- Drawback scheme is an obstacle in some Revisit the procedure for simplification Custom Authorities
cases.
- Low quality of local filling containers This is very weak part of the sector. It Exporters and producers
(metal or plastic). needs government support and through a powerful association
producers cooperation to develop the with the government support.
whole packaging materials industry.

- The education system is not replying to the This is a common problem in all the The government at the
demand of the business. The qualification sectors in Egypt national level.
of the graduates is inferior to the needs.
IV.2 Expected exports after export support

The following chart and tables include the results of the analysis of the actual exports and the
expected levels of exports with and without support.
The proposed support is 12% to 5% of the value of exports for the specified HS Codes, as
follows: 12% for first and second years, 10% for the third and fourth years, and 5% for the
fifth year. The total cost of support is US$77.43 million and total returns of support will be
US$123 million for the five years, i.e. the increase in paints and resin exports is from $101
million in 2008 to $224 million in 2013.
Chart IV-1: Exports of Paints and resins from 2007-2013
$200.00
$180.00
$160.00
$140.00
US$$120.00
Million
$100.00
$80.00
$60.00
$40.00
$20.00
$0.00
2007 2008 2009 2010 2011 2012 2013
Year
Actual paints exports Paints exports without support Paints exports with support
Actual resin exports Resin exports without support Resins exports with support
Table IV.2: Actual (2005-2007) and Expected Exports (2008-2013) of paints and resins
Total Paints and Resins
Annual Proposed Support
Exports Impact of
Increase in
Year Without With Support
Exports
Support support % US$ million
US$ million US$ million US$ million US$ million
2005 24.02
2006 52.40 28.38
2007 83.46 31.06
2008 101.35 101.35 0.00 17.89
2009 104.80 118.51 13.71 17.16 12% 14.22
2010 108.36 138.74 30.38 20.23 12% 16.65
2011 112.05 162.62 50.57 23.88 10% 16.26
2012 115.87 190.85 74.98 28.22 10% 19.08
2013 119.82 224.23 104.41 33.38 5% 11.21
Total Returns of Support 122.88 Cost of Support 77.43
Source: 2005-2007 represent actual data from GOEIC. 2008 is an extrapolation using the available data of the three quarters
of the year. 2009-2013 estimated from the Economic Analysis of the Study.
The proposed support program expects significant decrease in paints and resin imports. The
following table includes the expected increase in exports and expected decrease in imports.
This will reduce the gap between exports and imports and change the trade balance for paints
and resins from negative to positive in 2010.
Table IV.3: Actual (2005-2007) and Expected (2008-2013) Exports of Paints and resins (With Support)
Paints Resin Total
Year Export Net Exports Export Import Net Exports Export Import Net Exports
Import $M
$M $M $M $M $M $M $M $M
2005 18.26 34.97 (16.71) 5.76 102.64 (96.88) 24.02 137.61 (113.59)
2006 37.39 43.55 (6.17) 15.01 108.03 (93.02) 52.40 151.58 (99.18)
2007 61.07 43.61 17.46 22.39 135.20 (112.82) 83.46 178.82 (95.36)
2008 75.66 31.12 44.54 25.69 110.81 (85.12) 101.35 141.93 (40.58)
2009 89.48 30.06 59.43 29.02 107.60 (78.58) 118.51 137.66 (19.15)
2010 105.95 29.03 76.92 32.79 104.49 (71.70) 138.74 133.52 5.22
2011 125.57 28.04 97.53 37.05 101.46 (64.41) 162.62 129.51 33.12
2012 148.98 27.09 121.89 41.87 98.52 (56.66) 190.85 125.61 65.23
2013 176.91 26.17 150.75 47.32 95.67 (48.36) 224.23 121.84 102.39
( ) Amounts between brackets are negative values
Source: Economic Analysis of the Study
IV.3 Employment
The financial return is not the only return of the export support; there is social impact as well.
The export support will improve the performance of the sector and attract new investments as
a result of increased production. These investments will increase the direct and indirect
employment. Production of paints will increase by about 209 thousand tons to cover the
expected increase in exports and local market (see Table I.2). The increasing production by
40-50 tons yearly will create one job in the paints sector. Accordingly, the job increase will
range from 4,180-5,225 new direct jobs due to the increased paints production. It is expected
that the increase in the resin production will range from 30-50 thousand tons. Also this is not
only the new jobs created but there is indirect jobs to be created in the paints and resins
exports sector, wholesale and retail sector, painters, and services sectors.
IV.4 Investment in the industry and expected growth after the support
The new technologies in shifting into Low & Zero-VOC products, Green Chemistry, Hybrid
Paints, Energy-Efficient Coatings, Nanotechnology & other trends will require extensive
investment in R&D activities and manufacturing equipment development.
It is not expected that number of paints and coatings companies (227 companies “according
to data from the Chemical Chamber”) to be increased, but improvements and expanding of
production capacity is the expected, which will need an increase of about 20-30% of existing
investments.
IV.5 Effect of energy pricing system on paints and coating industry

Energy is about 2% of the cost of goods (COG), which is a minor cost element. The increase
in energy pricing will have insignificant effect on the overall cost of the final product.
V. Conclusion and Recommendations

The study concluded that the paints and coatings sector is a scattered sector, i.e., most of the
key players are working independently and depend on the PARASTATAL institutions.
These PARASTATAL institutions are supervised directly by the government. It is important
to state that these institutions playing an important role in the transition period to ease the
communication between private sector and government.
The need for an association for the sector is very important to give the sector the chance to
communicate as one entity with other organizations through the existing institutions and
directly, depends on the situation. The importance of creating this association is to have the
sector feel ownership on this association. In the beginning it can be used to share information
between the individual companies and provide support to the weak links in value chain of the
sector such as painters and packaging materials.
V.1 Recommendations:
In general, the producers and exporters of the paints and coating sector should start thinking
of the formulation of an association to resolve their main issues. It is important to start with
fewer issues for a newly formed association. Some of the findings of this study (weaknesses
and threats) can be used in this matter.
The recommended support should be as follows:
1) Avoid any retroactive decrees that will affect the sector negatively and discuss
these kinds of decisions with the industry representatives before issuing these
decrees.
2) The current custom duties were assessed and there is no need for immediate
change of any of them. However, after few months when the status of the current
international financial crisis becomes clearer, these custom duties need another
review to assess their effectiveness.
3) There are domestic and foreign development programs. It is important to gather
information about these programs to be used (if appropriate in developing the
sector).
4) Direct Export Financial Support: The direct financial support should be present
to the active exporting companies, with agreed upon & transparent criteria. This
support is an important incentive to the serious companies, in order to enhance the
Concept & the Culture of Export-Oriented Industry. Such a direct support can be
in a form of export support at 12% for a period of 5 years on declining bases.
In addition to the traditional financial support to the Paints Exporters, the Paints & Coatings
industry needs indirect supports in order to enhance the qualifications & the competitive
advantages of the Egyptian companies in the international markets.
These indirect supports to exports should cover the Legalization, R&D and Packaging
industry.
a. Legalization Supports: Institutional, administrative & financial supports to
qualify the companies for acquiring the international certificates in order to
enhance their export qualifications (REACH, ISO 9000, ISO 14000, etc).
However the IMC is providing significant support in this regard.
b. R&D Supports: Clear evidences indicate a shift in paints into Low & Zero-VOC
products, Green Chemistry, Hybrid Paints, Energy-Efficient Coatings,
Nanotechnology & other trends. Institutional, Technical & Financial supports in
R&D activities (which -by nature- are of high costs). The Egyptian companies
should implement professional R&D programs in order to develop their products
& find innovative solutions to the threats of rising RM prices and more strict
environmental legislations. Also, Communication Tools should be adapted
between the companies & the national technical centers (universities, research
centers, advanced laboratories …) aiming to enhance the SYNERGY in this
domain. However the IMC is providing significant support in this regard.
c. Develop Packaging materials industry: The quality of the filling & packaging
material is a prime factor in export business. Interviewed main paints exporting
companies stated that filling materials are the primary cause for customer claims.
Institutional & Financial Supports are essential to develop the Packaging materials industry.
V.2 Suggested Studies

1) A comprehensive review of the HS Codes at the Chemical Industry level to identify
the specific HSC for each sector (including paints sector).
2) The suggested association should initiate and be the owner of a detailed database of
the sector in order to resolve the contradicting information/ data.
3) Expedite the preparation of the strategy for the paints and coatings sector to identify
the vision of the sector in light of the Egyptian Industrial Strategy.
Annex A: Models
A.1: C/R Auto. Coatings

*** *** ***
Index
1) Systems.
2) Technology.
3) Market.
4) Raw materials and suppliers
5) Investment.
6) Price / Revenue.
7) Potential.
C/R Auto. Coatings
*** *** ***

1- Systems:-
• Water – based base coat.
• Water – based 2 component topcoat system.
• Water – based 1 component and 2 component primers.
• High solid 2K topcoat.
• Water – based etch primer.
• Water – based 2K filler.
2- Technology:-
• The need to reduce environmental pollution is one of the most pressing needs
of the coatings industry nowadays and in the future.
• Newly legislation concerning Voc laws are lither.
o Forcing paints & Coatings companies to change the way in which they
treat environmental pollution thin, in short, means using new coatings.
o Forcing paints & coatings companies to gravitate to industrialized

economics where environmental pollution lows are not regulated.
o The preferred choices for the future, from a coatings perspective are
either to move to high solids, UV (Solvent free, Solvent containing or
water-born) , Powder (UV or low temperature cure option) or Solvent
free technologies.
o Changes in European VOC lows and legislation are good indicator as to

what will eventually happen in this context, it is good to look at Some
relatively new VOC Legislation that has filtered through the European
community – The first Legislation to briefly review is the "paints,
Varnishes and Vehicle Repair Directive (2004/42/EC)" commonly
known as the paint products Directive (PPD). This Legislation relates to
specific VOC Limits being placed upon paints, Varnishes and Vehicle
repair coatings and will equate to significant reductions in VOC
emissions being removed from the marketplace I.e. at the moment the
VOC emission of Coatings (relating to decorative Market in Europe)
equals to something like 800K tons of VOC emission Ca. 5% of all
VOC emissions from all sources in Europe.
VOC Legislation – Car refinish products March 2007:-
Product subcategory Coatings VOC (g/L)

Preparatory 850
Preparatory and cleaning
Pre-cleaner 200
Body filler / Stopper All types 250
Surfacer/filler and general 540
Primer
metal primer Wash primer 780
Topcoats All types 420
Special finished All types 840
To satisfy this legislation, paints & coatings industry in Egypt should conduct projects
to produce the Car Refinishes Automotive paint system.
This needs availability of Hinge know-how and great Co-operation with world wide
research centers.
The expected economic impacts: are to increase the export activities, production
facilities, Labors and the turn over of the company, the expected social and
environmental impacts are decrease the emission of harmful solvents will lead to
improve health and more clean environment.
3-Markets:-
There is now potentials to export C/R Automotive coatings systems to EC Countries,

So for these systems are in compliance with EC directive (2004/42/EC) This is
because of the world wide needs to change to water based paints to overcome the
VOC emission problem by producing a new generation of products with extremely
low VOC emission.
By applying this new environmentally friendly technology the profit manganese in the
paint market. So, this project is the only opportunity to export these products to these
countries which have set the environmental legislation.
4- Raw Materials & Suppliers:-

• Acrylic resin Hydroxyl type water base (Nuplex, Bayer & DSM).
• TiO2 (Kronos ,DuPont & Cristal)
• s
• Pigments (Clariant, Ciba, and Schulz).
5- Investment:-
A production line for producing 5,000 tons/year (one 8 hours shift basis) needs an
estimated investment of Euro 300,000.
6- Potential:-
The estimated market needs in EC countries, now, is about 400 MT / year.
A.2: Manufacturing of Styrene / Acrylic Emulsion
*** *** ***
Index
8) Introduction.
9) Technology.
10) Market / Potential.
11) Raw materials.
12) Investment.
13) Price / Revenue.

Manufacturing of Styrene / Acrylic Emulsion
*** *** ***

(I)- Introduction:-
• There is increasing demand for water base emulsion polymers especially

styrene / Acrylic (Sty/Ac) for the production of wall & welling paints for
indoor uses, ready made putty and sealers.
• The estimated consumption of Egypt is around 25,000 – 30,000 MT/year.
• The use of water base emulsion is compliant with EC directives and the
environmental Legislation.
(II)- Technology:-
Emulsion polymerization by Semi continuous process. This process involves the

introduction of initial charge of selected mixtures of styrene & Ethyl Acrylate
monomers with Colloidal stability agent such as Hydroxy ethyl cellulose having a
selected M.W.
The degree of Hydrolysis are included in the initial charge with

5-10% of the monomers mixture to make the pre-emulsion, the reminder of the
monomers is added over a period of several hours at the same time, we add the
initiator, buffer solution but in separate line.
(III)-Markets /Potential:-
- Local market needs is about 25,000 – 30,000 MT/Year.
- The Local production of Styrene / Acrylic is about 2,000 – 3,000 MT dedicated for
textile industry application.
- The main competition comes from:-
* Turkey (Organik Kymia of production capacity 12,000 MT/Year.
* Dow, Jebel Ali, Dubai (production) capacity of 60,000 MT/Year.
* Synthomer Middle East, Saudi Arabia (production capacity of

40,000 MT / Year.
* The imported prices is now about 1,400 – 1,500 $ / MT CIF Alex.

(This price is changing).
(IV)- Raw Materials
• Styrene monomer.
• Ethyl Acryl ate monomer.
• Ammonium persulphate.
• Acrylic acid.
• Preservative.
• Non Ionic Surfactant.
(V)-Investment.
A production line of 4,000 L , st.st Reactor System (vessel , jacketed , with agitator ,
st.st. vertical column , centrifugal feed pump & Control panel) ,needs an estimated
investment of US$ 40,000. (for Reaction System equipment)
(VI)-Price / Revenue.
Current prices of Styrene Acrylic are US$ 1,250 – 1,350 …. Of Vinyl Veova are LE
9,500 – 10,000.
Accordingly revenues are estimated as US$ 35 – 40 million.

A.3: Silicate Paints
(I) Introduction:-
Inorganic coating with mineral structure, high resistance against UV radiation

and atmospheric influences and with high water Vapor permeation.
Historic Evaluation:-
* 4000 B.C. / Egyptian prepared for the first time the Sodium Silicate.
The Silicate is used as binder of pigments in order to do different paintings

inside the pyramids.
* 200 B.C. Romans continue using Silicate as binder of Pigments in the
Wall paintings.
* 1813 a.c., the German chemist J. Von Fuchs found the use of the
Silicate as binder in paints
* 1879 a.c, Adolph Kim prepared the first Silicate paint in two
Components.
* 1970 a.c, it is developed a new generation of Silicate paints, Silicate
Emulsion paints in one component ready to use with the following

characteristics:-
- One component.
- It can contain hydrophobic agents.
- 5% max. of organic material (Polymeric dispersion).
(II) Technology:-
Composition.
Inorganic products (mineral nature):-
- Stabilized solution of potassium silicate.

- Inorganic pigments (TiO2, and metallic oxides).
- Inorganic fillers (CaCO3 , Talc , Quartz, Kaolin)
- Additives.
Organic products:-
- Polymer dispersion at max. 5%
Properties of the Silicate Emulsion paints
*** *** ***
-Petrifaction process:-
- Strong chemical hard with the mineral substrate (High resistance to

the weather conditional.
- Fixing & reinforcing of mineral structure.
- Nature matt looking.
- Long life.
- Water Vapour permeation:-
The paint forms a micro- Crystalline structure with the substrate to which
it is applied, thereby allowing for the free passage of Vapour whilst
preventing the ingress of moisture.
- No delaminating problems.
- Steam foes not cordless on the surface being held in the substrate and
slowly given back to the atmosphere.
- Resistance against pollution:-
The crystallization process between the silicate and the substrate forms
insoluble silicates that are highly resistant to acids (industry and car
pollution) and alkalis.
- Resistance against UV radiation from the sun:-
- Only inorganic pigments which are stable against UV radiation.

- No loss of colors
- The UV radiation does not affect the bonding between the silicate and
the substrate.
- Silicate paints are Hygienic:-
- No organic nutrients, So no growth of moulds and algae.

- The high alkalinity nature (pH ≈ 2.5) prevents the growth of the spores
of mould / algae on the paint Surface.
- Easy to clean:-
- Its breath ability ensures a clean, Healthy surface and always dry.
- Fire resistant:-
* Non-combustible, class 0 it resists the spread of flame over the
Surface.
* No solvents.
* In case of fire, no toxic gases are released.
- Environmentally Safe :-
• Water born System Odorless and non-toxic.

• Solvent free with inorganic constituents, fully compatible with today
mineral building materials.
• Harmless to the decorator and these are no slow release emission in
Service.
• Production process in low energy consumer.
- Resistance to carbonation :
Protection of the substrate against atmospheric CO2.
(III) – Market / Potential
Coastal areas to protect facades forever in Egypt & Gulf areas.
• Resonation of Historic buildings in Egypt.

• Export to E.C. countries.
(IV) - Raw materials / Suppliers :-

- Anionic surfactants (I.Q.E).
- Cellulose thickener (Aqualone)
- Dispersant (I.Q.E).
- TiO2 (Bayer, Koronas)
- Ca CO3 (Omya).
- Styrene / Acrylic emulsion (BASF).
- Potassium Silicate (I.Q.E).
(V) – Investment :-
A Production line for 5,000 tons/year (one 8 hours shift) needs an estimated
investment of EURO 200,000
(VI) - Price / revenue :-
• Imported price from E.C. is around 8000€ / MT CIF Alex.

• The raw materials prices is around 4000 € / MT.
• The current price in Egypt is ≈ 120,000 L.E. / MT.
Annex B: Manufacturing Process
1 Overview
Paints can be divided into 2 main types: The Decorative Paints (also called Architectural
Paints) & the Industrial Paints.
Architectural Paints
Architectural paints are used for building and decorative purposes.
In general, this type of Paints is divided into four categories and comprises synthetic alkyd-
based paints (Solvent-Based Paints), emulsion paints (Water-Based Paints), synthetic
varnishes and processed oils and oil based paints.
Synthetic alkyd-based paints are based on alkyd resins and are used to coat wood and
substrates, such as windows and masonry, ceilings, metals (after coating with primers) and
walls in bathrooms and kitchens. This category includes: high gloss, semi gloss and matt
finish synthetic paints.
Emulsion paints are based on a latex-soluble binder polymer and are easy to use because they
are water-reducible and dry in the air. They are used for interior and exterior finishing work
for residential and commercial buildings and "do-it-yourself DIY" uses.
Synthetic varnishes are essentially clear pigment-free synthetic paints and are used for
coating wood substrates, flooring and low quality furniture.
Processed oils and oil based paints are used as primers, sealers and undercoats, either alone or
mixed with pigment. They are produced using vegetable oils and were the main paint
products in old days. They are now of reduced importance, but remain less expensive
compared with other paints and are still in use, mainly for interior and exterior finishing work
on buildings where durability and quality of finish is of lesser importance. They are mainly
used by professional painters.
Industrial paints
Industrial paints can be divided into eight categories , which includes automotive OEM
(Original Equipment Manufacturing) stoving paints, automotive refinishing (cellulosic and
polyurethane) paints, stoving (acrylic) electrostatic enamels, metalwork (alkyd-based) stoving
enamels, wood finishes, heavy duty paints, marine paints and general industrial paints.
Automotive OEM stoving paints are based on alkyd resins and are used in the automotive
industry for painting vehicles. Acrylic primers, metallic acrylic paints, polyester and epoxy
paints primers are examples for this type of paints.
Epoxy primer systems are typically used for adhesion and moisture resistance, as well as for
inter-coat adhesion. Polyurethane primer and/or topcoat systems are used for application
flexibility, color and gloss retention, and throughput enhancement, like going wet-on-wet
from the primer to the topcoat. In some cases OEMs use polyurethane on top of epoxy. The
coatings are typically high solids/low volatile content formulations, responding to rising
interest in waterborne and powder technologies among OEMs.
Automotive refinishing paints are based on nitrocellulose and acrylic urethane resins and are
used for car repairs and for the painting of railway stock and commercial vehicles which are
too large to be finished by stoving. Automotive refinishing paints are applied by spraying and
are particularly suitable for such uses because of their quick drying properties.
Stoving electrostatic enamels are based on acrylic resins and are sprayed electrostatically in
order to reduce overspray. They are used for painting domestic appliances.
Metalwork stoving enamels are based on alkyd resins mixed with urea or melamine
formaldehyde and are used for painting metal furniture.
Wood finishes consist of paints and varnishes and are produced from nitrocellulose,
polyurethane and alkyd resins. They are used mainly in the production of wooden furniture.
Heavy duty paints are based on epoxy resins, polyurethane, chlorinated rubber or vinyl. They
are used for the painting of metal structures and in the oil services industry. This type of
paints includes zinc-rich primers for heavy industrial use which have extra anti-corrosive
properties. The heavy duty paints category includes heat-resistant paints for solar heating,
insulating fast dry varnish for electric motors, epoxy-based polyamide primers and
polyurethane paints for aeroplane uses. The coatings for towers &tanks include zinc-rich and
epoxy primers, and polyurethane and polysiloxane topcoats, which are applied in two or
three-step processes, depending on customer specifications and performance expectations.
Marine paints are used for marine applications. They are similar to the heavy duty paints in
formulation with Anti Fouling Agents to be added in order to meet the nature of their uses.
Thinners are produced by the mixing of certain refined petroleum products and are used for
diluting certain paints to obtain an appropriate concentration and viscosity. The customers
modify the concentration of paint by adding thinner according to their particular
requirements.
General purpose industrial paints comprise a wide range of products, including synthetic
primer, heat resistant aluminum based paints, fast drying enamels, polyurethane varnish,
hammer finisher, paint removers, etching primers, high temperature heat resistant silicon
2
based paints, traffic paints, insulating varnishes, leather lacquers and water reducible stoving
paints.
2- Raw Materials
Paints Raw Materials
The raw materials for paints falls into four main categories: binders, pigments, solvents and
other materials.
Binders
The major types of Binders are long oil and medium oil alkyd resins necessary for the
manufacture of gloss and matt decorative paints. These resins are made of local and/or
imported vegetable oils or fatty acids. The second major binder used is acrylic emulsions
(pure acrylic, styrene acrylic & vinyl veova emulsions) which are either locally manufactured
or imported. The acrylic emulsions are used in the production of architectural emulsion
paints.
Other types of binders are imported, such as the industrial resins (epoxy resins, polyurethane
resins, special short alkyd resins and chlorinated rubber fast drying industrial alkyd resins).
Pigments
Pigments can be divided into organic (including anti-corrosive pigment) and inorganic
pigments.
The major inorganic pigments are titanium dioxide (for white), iron oxide (for red) and lead
chromate (for yellow). Organic pigments are more weather resistant and are used for
architectural and general industrial paints. Anti-corrosive paints are produced from mainly
imported inorganic pigments such as zinc chromate, zinc phosphate and zinc dust. High
performance organic pigments are used for automotive OEM finishes.
Solvents
The principal types of solvent used in the paints industry are mineral spirits (which are
aliphatic solvents refined from oil), Xylene and toluene (which are aromatic solvents refined
from crude oil). The major suppliers of solvents are locally based.
Other materials
Other materials include additives, fillers, and raw materials for resins, driers and oils.
Fillers are primarily provided by local suppliers.
The major additives used in the industry include wetting and dispersing agents, anti-foaming,
anti-skinning and Rheology modifiers…. and are sourced overseas.
The major fillers used in the industry include the locally produced calcium carbonate and
talcum powder and the imported synthetic barium sulphate.
3
The major raw materials for alkyd resins are Phthalic anhydride, glycerol, vegetable oils,
fatty acids and monopentaerythritol.
The majority of these raw materials are imported. Pigments are the most important of the
imported products by value (most notably titanium dioxide, the pigment used in the
production of white paints).
3- Production Process, Packaging and distribution
The manufacturing process is broadly similar for all types of paints. The raw materials,
which consist of pigments, solvents, resins and additives, are first mixed and then ground to
achieve the correct grade of fineness(In the case of emulsion paints, grinding is not needed).
Once ground, the paint is transferred to finishing tanks where it is treated with further resins,
solvents and additives as necessary and pursuant to quality control tests.
The finished product is then filled into cans, which are then packed manually into cartons.
The Production Follows the Batches scheme.
Mixing occurs in mixers of various sizes: these are vertical drums with a rotating paddle.
Mixing time varies from one and half to two hours depending on the type of paint and the
size and power of the mixer
Grinding occurs in rollers or bead mills: these are horizontal rotating drums full of steel balls
or glass beads. The mixed ingredients are either transferred from the mixer to the grinder by
pumping. Grinding takes about 30 minutes.
Paint cans are filled using filling machines of different types (manually operated, semi-
automatic or automatic, gravimetric or volumetric).
Alkyd Resins
Alkyd Resins are raw materials needed for manufacturing synthetic architectural paints &
industrial paints. There are number of local manufacturers for the Alkyd Resins. Other resins,
such as acrylic latex for emulsion paints (now, one local manufacturer for acrylic emulsions
exist) and most resins for industrial paints, are imported.
Manufacturing Alkyd Resin include an exothermic, reversible chemical reaction in which a
poly acid (e.g. Phthalic Anhydride) & a polyol (eg. Pentaerythritol) are reacting to form a
honey like mass of alkyd resin.
1. For manufacturing Alkyd Resins, vegetable oil, glycerin, Penta Erythritol and Phthalic
anhydride are pumped according to a prescribed sequence of addition, weights &
temperatures into reactors which are heated either by pumped thermal oil or by direct fire.
The materials are cooked in the reactors for approximately eight hours. The process
requirement includes heating, cooling, vacuum application, continuous remove of one
4
product (the water) in order to force the reaction in the direction of forming the alkyd resin &
purging of an inert gas into the reactor. The resultant hot resin is then transferred to dilution
tanks to be thinned, and then pumped through filters to finishing tanks where quality control
samples are taken and necessary adjustments are made.
4- Quality Assurance
a. National Standard Regulations for Paints (1539/2002 – 1757/2001 – 793/2001)
b. Law No. (4)/1994 for Environments (water - air - soil - sound)
c. International Standardization Organization certificates ( ISO
9001 - ISO 14001 - ISO 17025 )
5- Product development
The effort to comply with VOC regulations without sacrificing quality has created a heavier
workload for paint chemists who are already under tremendous pressure. Consolidation has
taken its toll on R&D departments throughout the paint industry and resins suppliers have
been picking up the slack.
The days of large R&D department that can screen new products are gone. Raw Materials
suppliers are spending more time evaluating new materials before they go to mar¬ket. Paint
manufacturers are seeking solutions, not just products. They are looking for more support. In
some cases, raw materials suppliers are giving them finished formulations."
Chemists of RM suppliers may be placed in customer labs to assist them with formulation
work ranging from short-term projects such as reducing costs without sacrificing quality to
longer-term projects such as readying formulations for future VOC requirements.
In addition to low VOCs, requests also center on improved durability and chem¬ical and
stain resistance. Sometimes, when you go to lower VOC, it requires different technology, and
that means more costs.
R&D activities are looking for products or technolo¬gies that bring value, for example, lower
raw material costs or lower total formulation cost; lower film builds or reduction in overall
coatings layers; increased productivity or reduced application costs. Secondly, R&D activities
are seeking products to solve existing problems or meet a specific performance requirement.
A third consideration would be ecological benefits, VOC reduction, waste elimination and
abil¬ity to recycle. These are the areas of focused prod¬uct and technology developments.
There are several challenges that are affecting the paints market including the rise in raw
materials costs, energy prices and the economic slowdown. The unprecedented escalation in
the price of oil, natural gas and raw materials is having a significant impact on everything
5
from manufacturing to shipping costs. The manufacturing companies should deal with these
challenges by focusing on the development of sustainable and renewable products. The
companies should also pay close attention to results of voice-of-the-customer interviews to
ensure all R&D efforts are being focused on marketable technologies & products.
In order to stay afloat in this challenging environment, paints manufacturers must develop
innovative solutions for their customers. Environmentally responsible and sustainable
products offer the paints market opportunities for growth.
The growth and increased awareness of green building initiatives will continue to require
sustainable coatings solutions. In the aluminum extrusion industry, products which are HAPs
compliant and low VOC coatings have less impact on the environment.
6- Human Resources
The Companies should consider their employees as the most significant asset it owns. Thus,
retaining the employees is a corner stone in the Company strategy to sustain business.
This is achieved through several tools:
- Rewarding & Motivation system.
- Support employees via services, fringe benefits policies (including medical care,
transportation, meals & summer activates).
Employee performance management system
a. The system should cover skills and career progression of employees.
b. An annual employee performance form is to be set to evaluate the individual performance
of each employee. These forms reflect the quantity & quality of work, the ability to work in a
team, the capability to develop the work, the degree of comply with the rules … & many
other parameters. They consider the skills, education, potential career, training courses,
improvement paths, .. etc. These forms are used as an appraisal tool in order to support the
organization objectives.
c. The reward & incentives parameters set some factors of evaluation linked to customer and
business focus.
Hiring and career progression
a. A Human Resource Plan should be prepared.
b. The current employees' knowledge & skills should be assessed & developed according to
the required needs.
c. The recruitment system (Hire & Fire) should be online with legal recruitment principles.
This system should be applied upon executing the Human Resource Plan.
6
d. The diversity of the ideas, culture & thinking is assessed through the hiring interviews with
the candidates.
Employee learning ,education ,training , motivation &development
a. The Companies should set a development plan and incentive programs to support the
employee capabilities.
b. The incentive System should meet the following requirements:
- Link performance with results and objectives.
- Cover the sales objectives.
- Cover bonus for employee of the month.
- Encourage employees to develop their qualifications and performance.
c. The Education & training programs should cover both skills & knowledge areas in order to
support the strategic objectives.
These includes technical & managerial issues (e.g. communication, teamwork, planning,
reducing waste, supply chain management, project management, quality management, legal
compliance, … etc).
d. The findings of performance review sessions play a key role in determining the education
& training needs.
e. Monetary compensations (raises incentive pays,…) should be based on performance &
skill acquisition.
• Employees well being and satisfaction
• Work environment
- The Companies should give special attention to environmental affairs and to be
certified in ISO 14001.
- Occupational & Safety Health regulations should form an integrated part of the
Company's ISO 9001 file.
• Employee support and satisfaction
- The Companies should determine the key factors that affect employees well being
through different tools:
a. Survey forms for employee opinions.
b. Measurement & tracking of employees' turnover.
c. Providing boxes in the workplace for employees' complains.
The companies should use similar tools as formal & informal assessment methods &
measures to determine employees well being, satisfaction & motivation.
7
- The Companies should support employees through providing some sorts of services,
benefits and policies, e.g.
- Incentives system.
- Employees share in net profit dividends.
- Provide all required resources.
- Promotional chances.
- Recognition announcements
- Provide series of benefits in kind:-
a. Medical care.
b. Transportation.
c. Lunch meal.
d. Summer activities.
7- Legislative & Environmental issues
Manufacturing paints involves handling & using many of hazardous materials. Mishandling
of such materials could lead to severe safety or environmental consequences.
• The Products must meet Egyptian standards No. 1539/2002 (Emulsion Paints), No
1757/2001 (Matt Paints) & No. 793/2001 (Gloss & Semi gloss Paints)
• The Companies are legally committed to rules & requirements of " Law of Environment
No. 4 /1994 ", but & self committed to go above & beyond what is legally required.
This commitments form an Ethical milestone in the Company's performance.
• It is recommended for the Companies to give special attention to environmental affairs and
to be certified in ISO 14001.
• The Companies are entitled to hold legal operational permits which allow it to be operative.
These permits are issued by different authorities after close & direct assessment of Safety,
Health & Environmental consideration. Such permits are renewed annually.
Such conformance is subject to oversight by Interior Trade Agencies as well as Egyptian
Standardization authorities.
• Also the Companies are subject to be oversight by other local authorities: Health
administrations (Ministry of Health), Safety Departments (Ministry of Interior), Safety &
Health Administrations (Ministry of Manpower), Environment Administrations (Ministry of
Environmental Affairs) & Developing Departments (Ministry of Habitation, Utilities & New
Communities).
• The European Directive 2004 / 42/ CE, which sets out limitations on emissions of VOC due
to the use of organic solvents in most decorative paint.
8
• European coatings makers continue to face the Biocides Product Directive and increasing
performance requirements.
• Law No. (4)/1994 for Environments (water - air - soil - sound)
• Law of work
• International Standardization Organization certificates (ISO 9001- ISO 14001 - ISO
17025)
8- Requested international certificates
• The EU agreed to carry out a second round of impact assessments on its controversial
Registration, Evaluation and Authorization of Chemicals (REACH) proposal, the mood both
inside and outside the chemicals industry has gradually started to shift, with disparate factions
beginning to coordinate efforts to improve the proposals. REACH was first presented in May
2003 as a solution to EU concerns about the safety and administration of chemicals. The aims
of the proposed new regulations, which would replace 40 separate pieces of current
legislation, are meant to decrease human and environmental exposure to chemicals whilst
simultaneously enhancing the competitiveness and innovative capabilities of the EU
chemicals industry. Under the proposed legislation, the European chemicals industry would
have to register the properties of substances with a central EU database. The process is
expected to take until 2016 to complete. Meanwhile, the availability of chemicals to
consumers, particularly low-volume niche products, will decline.
• International Standardization Organization certificates ( ISO 9001 - ISO 14001 - ISO
17025 )
9- International developments in paints, coating and resins industries (New trends in
paints and resins production process, new types of paints environmentally friendly, new
surface coating products could substitute or compete the paints)
• Benjamin Moore reports that it has made a serious effort to keep costs in check for its
customers, even as it transitioned its premium Moorlife, Moorgard and Moorglo to 100%
acrylic products, improving hide and mildew resistance and offering a lifetime warranty.
• Benjamin Moore has also bolstered its exterior offerings, replacing its existing Moorwood
stain line with its new Benjamin Moore Exterior Stain line. The main factor pushing the
overhaul was VOC laws in order to bring it down to the 250 range, although the cost of raw
materials in the lower VOC formulations can be significantly higher than raw materials used
in older technology.
9
• As U.S.-based companies reformulate based on regional VOC requirements, time is ticking
for European companies to get in compliance with the European Directive 2004 / 42 / CE,
which sets out limitations on emissions of VOC due to the use of organic solvents in most
decorative paint.
• Other issues European coatings makers continue to face include the Biocides Product
Directive and increasing performance requirements.
• The international projects focus is given to innovative solutions to achieve in parallel VOC
compliance together with additional improved product characteristics.
• To create more robust products for exterior applications, there must be a strong focus on
R&D and a willingness to experiment and utilize topnotch materials.
New technology and newly developed binders have helped in developing harder and tougher
paint which will stand up to the harsh climate for an increased number of years.
• Jotun U.A.E. launched Jotashield Thermo, a pure acrylic exterior coating that has been
independently proven by the Dubai Municipality to reduce heat absorbed by walls. Special
glass beads deflect the sun's heat, cooling the interiors and saving energy, according to the
company.
• Among the first smart architectural paints to reach the market in Europe are photocatalytic
paints in which the reactive component is nanosized particles of titanium dioxide (Ti02). But
already it is evident that the successful commercialization of the intelligent coatings will not
be easy.
UV coatings
The basic challenges with automotive refinish coatings are to prepare invisible repairs
These repairs are carried out in several application steps. These steps usually consist of
primer, basecoat and clear coat applications. Generally each of these applications, done at
room temperature, takes a combined amount of time ranging from four hours to several days.
In some instances, there are other steps such as body filler, wash primers, adhesion promoters
and sealers that can add additional time. In all cases, the user needs to wait for the coating to
cure and time is wasted.
Most of the conventional refinish coatings consist of two-component (2K) material and have
limited pot life for applications. This limits the amount of time the coating can be used and
applied. When using two-component chemistry there is also more waste generated from not
knowing how much material is needed for each repair. Waste is also generated from the
clean-up of the application equipment when used. There is also time wasted mixing material
and having to clean application equipment after each of the application steps.
10
There is another concern with conventional refinish coatings dealing with consistency. With
an air-dry coating, temperature and humidity have an effect on the cure of the coating. If the
coating is under-cured in any of the steps, there could be factors such as adhesion loss,
dieback, swelling and appearance imperfections that are not seen for several days. When this
happens, the repairs usually have to be repeated, taking up more valuable time.
With UV technology being applied to automotive refinish applications; the issue of time,
waste and consistency can be overcome. UV technology will assure the user that a repair has
been performed correctly, in a relatively short amount of time with minimal waste.
The common advantages of using UV coatings in automotive refinish are mixing of
materials, unlimited application window, limited waste and less application equipment
cleaning.
• In North America one of the leading trends in the construction industry, including the
commercial, institutional and residential sectors, is the use of energy-saving and
environmentally friendly designs and building materials. Coatings makers have responded
with `greener' products that reflect heat-generating sunlight more efficiently and include more
energy ¬efficient application processes.
Besides developing coatings that help save energy, coatings companies continue to work on
improving the weatherability of coatings used in exterior applications such as metal roofs and
walls, building trim, and garage and entry doors among other applications. Other objectives
include better resistance to abrasion and other kinds of damage, as well as improved color
consistency and color matching.
• ENERGY EFFICIENT TECHNOLOGY….In terms of R&D, the next frontier for industrial
coatings is to further develop greater aesthetic value and energy efficient solutions.
One increasing trend offering energy efficient solutions to the construction industry has been
the development of "cool roof" technology. While many building roofs are coated with hot tar
or black rolled asphalt because of their sturdy nature, these materials do nothing to cool down
temperatures during the hot summer months. Cool roof technology, in contrast, coats the roof
surface with a reflective material that can lower the temperature of a building's roof by up to
100 degrees, producing lower interior temperatures and reducing cooling costs by up to 50%,
according to EPA.
Latest development in cool coatings represents a technological and aesthetic breakthrough.
With a solar reflectivity of at least 25%, the new coating offers the metal roofing market a
new range of dark colors, including a true black that meets cool standards.
11
• Formulators are dealing with the challenges of rising raw material prices and increasingly
strict environmental legislation. These two issues have had a profound impact on the anti-
corrosion market, leading anti-corrosive coating makers to reformulate to reduce the amount
of pricey raw materials, as well as develop products that will meet current and impending
environmental legislation.
• Nanotechnology will play a role in the corrosion inhibitor market as new technologies
develop, such as Sol-Gel Systems. The incorporation of conductive polymers in lieu of
corrosion inhibitors may occur in specialized applications. There are some interesting
approaches of the nanotechnology expected due to the electrochemical properties, but the
cost and handling are obstacles that have to be overcome first.
Nanotechnology will most likely include some interesting future perspectives for paint
formulators, but the feasibility of that technology for industrial use especially in respect to the
handling and costs has not yet been proven. Close contact with different universities and
institutes, who are engaged with nanotechnology is a must in order to participate in these
projects.
• Green chemistry is another major trend….
Companies have invested heavily to develop VOC-compliant, environmentally friendly
coatings. They are normally more expensive than the coatings they replace but they do a
better job and enable industrial companies to meet government regulations, make their plants
better for their employees and improve our environment.
• As efforts by manufacturing companies to reduce VOC emissions from their plants
continues to be a major trend driving the market forward, other industrial coatings market
trends reflect consumer demands for more color choices, lower curing temperatures for bake
enamels, shorter dry times for air dry coatings, increased corrosion and moisture resistance,
resistance to marring and fingerprinting of home appliances, and improved durability of
coated surfaces.
• The use of powder coatings for the coating of architectural metal is well established across
the world. Powder coatings have been used to protect and decorate architectural aluminum
for more than 30 years. Choice of color and gloss appealed to architects, ease of application
and associated environmental benefits encouraged coaters and overall performance in terms
of exterior durability completed the package.
Powder manufacturers, many of whom are global operators, are all working to support
growth by developing the products that will satisfy both today's users and the potential
12
markets of the future. Regional variations however still exist in the extent of substitution by
powder of alternative finishes such as anodizing and liquid coatings.
These include satisfying fashion demands with color service and special finishes,
anticorrosive powders and the new generation of exterior durable products. In addition new
ways of making and applying powder will ensure that it is the most cost effective finish.
In a region such as the Middle East, where climatic conditions increase the demands on
performance, powders with significantly improved exterior durability can replace liquid
paints.
There are a number of developments in powder that are either already commercialized or will
be in the coming years that will address both the geographical and sub-sector demands.
Systems such as Ultra Durable architectural finishes are already in the market. Such products
have now been in use for over 10 years including in the Middle East.
• Automotive OEM coatings suppliers face the challenge of rising raw material and energy
costs by focusing on developing energy-reducing technologies.
Automakers face continuing pressures to cut production costs, automotive OEM coating
suppliers are focusing on developing innovative technologies that meet both environmental
regulations and help reduce overall energy costs.
• Wet on wet two tone process at Ford Kentucky Truck to increase capacity and lower the
cost of two tone production.
• Primer surfacers with improved chip resistance to eliminate the need for an additional chip
protection primer.
• In addition, automakers have developed a primerless waterborne topcoat sys¬tem which is
now in place at two Volkswagen facilities. DuPont's EcoConcept primerless waterborne
basecoat system was recently launched at VW and nominated for an automotive news PACE
award. DuPont's wet on wet solvent borne topcoat technology was initially launched with
basecoat to primer on two tones and also won a PACE award. This concept is now capable of
being used as the main color as well.
• BASF Coatings has recently launched a new automotive OEM coating technology.
Integrated Process II is a novel, highly efficient coating technology. For the new process, the
specially formulated basecoats combine all the functions of the primers, such as stone chip
protection and ultraviolet resistance. The new technology meets the stan¬dards for
automotive finishes with regard to appearance and functional¬ity. For the automotive
industry, this means that the coating process is shortened due to the elimination of the primer
application section of the paint line and the primer oven. Those primer application facilities
13
that are no longer needed can be used to increase capacity. Advantages of the new system
include reduced invest¬ment and operating costs, material and energy savings, improved
pro¬ductivity and eco-efficiency.
The new system has been success¬fully operating and integrated into the Mini production
line at the BMW Group Oxford, UK plant. With the new system all of the basecoats used at
the BMW Group Oxford plant can be applied. With Integrated Process II, auto¬motive paint
lines can be streamlined, costs cut and the overall process sim¬plified, even at existing paint
lines and capacity can be expanded without complicated and costly construction projects.
• PPG has invested considerable R&D time in developing innovative paint processes. These
processes are combining traditional layers of the paint system into one, essentially to reduce
the number of steps and layers to paint a car.
• Another area of interest for PPG is nanotechnology.
PPG is leading the industry in the use of nanotechnology in clearcoats for scratch resistance.
That technology is expanding to other customers and products.
PPG's CeramiClear clearcoat is the first automotive clearcoat to use nanoparticle technology
and combines and combines resistance to scratches, mars and acid etch. The patented
nanoparticle tech¬nology creates a highly cross-linked network at the surface of the coating
for superior resistance to damage caused by day-to-day use, car washes and environmental
hazards such as acid rain and tree sap.
This technology works with an auto¬motive plant's existing waterborne basecoat, primer and
electrocoat lay¬ers and can be used with a conven¬tional circulating system. The coating
does not increase emission levels or introduce new emissions to the waste stream and can
reduce an automaker's total cost by decreasing in-plant dam¬age, buffing and dealership
touch-up, according to the company.
• To further meet the needs of its cus¬tomers, PPG developed an aftermar¬ket refinish
clearcoat, which provides approximately the same level of pro¬tection as the factory-applied
CeramiClear clearcoat, for vehicles requiring body repairs.
• Sartomer's Krasol HLBH¬P 3000 is a hydroxyl-terminated poly¬olefin with a molecular
weight of 3000 that is used in polyurethane systems. This resin brings extreme hydrolysis
resistance (water, steam, acid, and base), good adhesion, low Tg and improved weathering to
coatings applications due to its saturated backbone.
• Akzo Nobel Resins' Setalux 37-6770 (styrene-acrylic) and 37-6779 (all acrylic) are self
crosslinking emulsions based on patented technology that offers the benefits of quick dry,
good block resistance, early blush resistance and chemical resistance. Both can be used in
14
low VOC formulations, with Setalux 37-6770 suited for general industrial and industrial
maintenance applications and Setalux 37-6779 designed for primers and stain sealers for deck
coatings and other specialty architectural applications. Setalux 17¬2450 is a hydroxy-
functional acrylic polyol for two-component vehicle refin¬ish applications. Designed for fast
cur¬ing clearcoat or single-state paint appli¬cations, when combined with appropri¬ate
aliphatic polyisocyanates, Setalux 17-2450 provides fast cure with a longer pot-life for
excellent application and appearance properties and the excellent attributes of DOI. It also
has excellent early hardness development and is buff able in a couple of hours, according to
the company.
• The growth and increased awareness of green building initiatives will continue to require
sustainable coatings solutions like BASF’s Ultra-Cool and Vari-Cool production. In the
aluminum extrusion industry, for instance, products like EcoCeam, which is HAPs compliant
and low VOC flexible polyester coatings, have less impact on the environment.”
15
ANNEX C
Recent Laws, Legislations and regulations of paints and coatings
industry
There are a number of laws and regulations that address the different environmental
violations. The following are the laws applicable to the paints industry.
Concerning Air Emissions
Article 40 of Law 4/1994, article 42 of the executive regulations and annex 6 deal with
gaseous emissions from combustion of fuel. The statutes relevant to the fuel combustion are:
• The use of solar oil and other heavy oil products, as well crude oil shall be prohibited in
dwelling zones.
• The sulfur percentage in fuel used in urban zones and near the dwelling zones shall not
exceed 1.5%.
• The design of the burner and fire-house shall allow for complete mixing of fuel with the
required amount of air, and for the uniform temperature distribution that ensure complete
combustion and minimize gas emissions caused by incomplete combustion..
• Gases containing sulfur dioxide shall be emitted through chimneys rising sufficiently high
in order that these gases become lighter before reaching the ground surface, or using fuel that
contains high proportions of sulfur in power generating stations, as well as in industry and
other regions lying away from inhabited urban areas, providing that atmospheric factors and
adequate distances to prevent these gases from reaching the dwelling and agricultural zones
and regions, as well as the water courses shall be observed.
• Chimneys from which a total emission of wastes reaches 7000 – 15000 kg/hr, shall have
heights ranging between 18 – 36 meters.
• Chimneys from which a total emission of gaseous wastes reaches more than 15000 kg/hour,
shall have heights exceeding at least two and a half times the height of surrounding buildings,
including the building served by the chimney.
• The permissible limits of emissions from sources of fuel combustion in boilers are given in
table (1) (Ministerial decree no. 495, 2001). The permissible limits of emissions from sources
of other fuel combustion sources (Dow-therm oil heater) are given in table (2).
Table 1: Maximum Limits of Emissions from Sources of Fuel Combustion in Boilers
Pollution Maximum limit mg/m3 of Exhaust
Sulfur Dioxide 3400
Carbon Monoxide 250
Smoke 50
Table 2: Maximum Limits of Emission from Fuel Burning Sources
Pollutant Maximum Permissible Limit, mg/ m3
SMOKE 250
DISPERED ASHES 250 (sources existing in urban regions, or close to residential areas)
500 (sources far from habitation)
500 (burning of wastes)
SULPHUR DIOXIDE Existing: 4000 New: 2500
ALDEHYDES Burning of waste: 20
CARBON MONOXIDE Existing: 4000 New: 2500
Concerning Effluents
Limits for pollutants in wastewater vary depending on the type of receiving water body. The
parameters that should be monitored and/or inspected are Oil& grease, BOD, COD, pH,
color, temperature, residual chlorine, TSS, TDS, and heavy metals.
Table (10) presents the permissible limits for discharges to the different recipients (sea, Nile,
canals, agricultural drains, public sewer) according to the different relevant laws.
Spent lube oil has a negative impact on water and soil and therefore its disposal should be
monitored/inspected. A record should be kept for this purpose.
Concerning Solid Wastes
A number of laws address solid waste management. The following laws apply to scrap,
garbage (paper,..), and sludge from the WWTP:
• Law 38/1967 which addresses public cleanliness regulates the collection and disposal of
solid wastes from houses, public places, commercial and industrial establishments.
• Ministry of Housing, Utilities and Urban Communities (MHUUC) decree No. 134 of 1968,
which provides guidelines from domestic and industrial sources, including specifications for
collection, transportation, composting, incineration and land disposal.
• Law 31/1976, which amended law 38/1967.
• Law 43/1979, the Law of Local administration, which provided that city councils are
responsible for “physical and social infrastructure”, effectively delegating responsibility for
infrastructure functions.
• Law 4/1994 regulates incineration of solid waste.
Concerning Work Environment
Violations of work environment could be encountered:
• Gas emissions (VOCs and metal particulates) generated in the production lines, are
regulated by article 43 of Law 4/1994, article 45 of the executive regulations and annex (8),
(table 11).
• In the boiler house: gas emissions, regulated by article 43 of Law 4/1994, article 45 of the
executive regulations and annex 8. The limits for the relevant pollutants are presented in
Table (11).
• Wherever heating is performed: temperature and humidity are regulated by article 44 of
Law 4/1994, article 46 of the executive regulations and annex 9 of the Law (table 12).
• Near heavy machinery: noise is regulated by article 42 of Law 4/1994, article 44 of the
executive regulations and table 1, annex 7 of the Law.
• Ventilation is regulated by article 45 of Law 4/1994 and article 47 of the executive
regulations (tables 13, 14, 15)
• Smoking is regulated by article 46 of Law 4/1994 and article 48 of the executive
regulations, and Law 52/1981.
• Work environment conditions are addressed in Law 137/1981 for Labor, Minister of
Housing Decree 380/1983, Minister of Industry Decree 380/1982
Table (11) Permissible limits as time average and for short periods
Threshold
Material Time average Exposure limits for short periods
ppm mg/m3 ppm mg/m3
Ammonia 25 18 35 27
Carbon dioxide 5000 9000 15000 27000
Carbon monoxide 50 55 400 440
Sulfur dioxide 2 5 5 10
Acetone 750 1780 1000 2375
n- Butyl alcohol 50 150
Butyl acetate 150 710 200 150
Toluene 100 375 150 560
Xylene 100 435 150 655
Ethyl acetate 400 1400
Cadmium salts/ particulates 0.05 0.2
Hexa valent chromium 0.05
Total particulates 200
Table (12) Maximum Permissible Limits for Heat Stress (law 4/1994)
Type of Work Low Air Velocity High Air Velocity
o
Light work 30 C 32.2 o C
Moderate work 27.8 o C 30.5 o C
Severe work 26.1 o C 28.9 o C
Table (13) Maximum Permissible Noise Levels (law 4/1994)

No Type of place and activity Maximum permissible
noise decibel (A)
1 Work place with up to 8 hour and aiming to limit noise hazards on 90 dB
sense of hearing
2 Work place where acoustic signals and good audibility are required 80 dB
3 Work rooms for the follow up, measurement and adjustment of high 65 dB
performance operations
4 Work rooms for computers, typewriters or similar equipment 70 d.B
5 Work rooms for activities requiring routine mental concentration 60 dB
Table (14) Noise Intensity Level Related to the Exposure Period
Noise intensity level decibel (A) 95 100 105 110 115
Period of exposure (hour) 4 2 1 ½ ¼
Table (15) Noise Intensity Level In Intermittent Knocking Places

Noise Intensity db Max Allowable Knocks During Daily Work Period
135 300
130 1000
125 3000
120 10,000
115 30,000
Concerning Hazardous Materials and Wastes

Law 4/1994 introduced the control of hazardous materials and wastes. The paints industry
generates any hazardous wastes, such as chemicals empty containers, spent solvents, sludges
from the solvent recovery unit and WWTP, and spent filters clothes. Hazardous chemicals
such as solvents, and caustic solutions are used for washing vessels. The hazardous chemicals
used in the lab and the fuel for the boilers, fall under the provisions of Law 4/1994. Articles
29 and 33 of the law makes it mandatory for those who produce or handle dangerous
materials in gaseous, liquid or solid form, to take precautions to ensure that no environmental
damage shall occur. Articles 25, 31 and 32 of the executive regulations (decree 338/1995)
specify the necessary precautions for handling hazardous materials. Storing of fuel for the
boilers is covered by the Law 4 as hazardous material There is no explicit articles in Law
4/1994 or in decree 338/1995 (executive regulations), regarding holding a register for the
hazardous materials; article 33 is concerned with hazardous wastes. However, keeping the
register for the hazardous materials is implicit in article 25 of the executive regulations
regarding the application for a license.
The Environmental Register
Article 22 of Law 4/1994 states that the owner of the establishment shall keep a register
showing the impact of the establishment activity on the environment. Article 17 and Annex 3
of the executive regulations specify the type of data recorded in the register. The emergency
response plan and the hazardous materials register will also be part of the environmental
register as stated in part 4.5.
Pollution Abatement Measures
This section deals with pollution abatement (preventions) in the three media air, water and
soil. Three types of interventions will be considered:
• In-plant modifications, which are changes that are performed in the plant to reduce
pollutant concentrations in streams through recovery of materials, segregation and/or
integration of streams, reducing the flow rate of the wastewater streams that need further
treatment to reduce the hold-up of the required WWTP.
• In-Process modifications, which are changes performed on the process such as the
introduction of newer technology, substitution of a hazardous raw material, performing
process optimization and control.
• End-of-pipe (EoP) measures, which involve treatment of the pollutant or its separation for
further disposal. Whereas in-plant and in-process modifications usually have an economic
return on investment, end-of-pipe measures will be performed for the sole purpose of
compliance with the laws without economic.
Egyptian Environmental Laws do not require water and energy conservation measures. These
measures have been considered in this manual since resource depletion and hence
conservation is a worldwide-recognized environmental issue that could be implemented in
Egypt in the near future. Water conservation measures can lead to higher concentrations of
pollutants in the effluent streams. Both energy and water conservation measures will provide
both financial and economic benefits.
The term Cleaner Production (CP) refers to the same concepts of pollution reduction through
in-process, in-plant and resource conservation, in contradistinction to end-of-pipe treatment.
In many cases, the adoption of CP can eliminate the need for (EoP) treatment.
The paints industry sector has a great potential for implementation of cleaner technology
measures. Newly installed factories employing manpower above 100 has acquired relatively
newer technologies, which need little in-process or in-plant modifications and are carrying
out end-of-pipe treatment to meet the requirement of environmental laws. However, medium
size enterprises as well as public sector companies badly need the 3 types of modifications.
Small private enterprises are using primitive technologies.
Mitigation measures in paints industry vary from in-process modification or recovery of
solvents especially used in cleaning purpose.
The following CP and EoP measures have been identified for the paints industry.
Air pollution Abatement Measures
Flue gases Particulate matter in flue (exhaust) gases are due the ash and heavy metal content of
the fuel, low combustion temperature, low excess oxygen level, high flow rate of flue
gases. Sulfur dioxide is due to the sulfur content of the fuel. Nitrogen oxides are formed
when maximum combustion temperature and high excess oxygen. Carbon monoxide is
formed when incomplete combustion occurs at low air to fuel ratio.
The following measures can be adopted to minimize air pollution from flue (exhaust)
gases:
• Replace Mazot by solar or natural gas. Mazot is high in sulfur content.
• Regulate the fuel to air ratio for an optimum excess air that ensures complete
combustion of carbon monoxide to dioxide.
• Keep the combustion temperature at a moderate value to minimize particulate
matter and nitrogen oxides formation.
Work Environment Pollution Abatement Measures

VOCs • Using VOCs control equipment such as; absorbents (activated charcoal)/ biofilters
emissions on exhaust systems, water scrubbers should be implemented where necessary to
achieve acceptable odor quality for nearby residents.
• During equipment cleaning process, solvents are released to air. This emissions
could be minimized through closing off the immediate area around the axles, and
also during operation for dissolvers and stirring equipment.
• Reduction of the use of open strainers (closed filling system).
• Covering of some containers could prevent the evaporation of solvents into air.
• Using mixing system by vibration rather than by stirring. The lake of a shaft
holding a stirrer or a paddle means that the coating and solvent can be gently
blended in a completely sealed vessel.
Particulates • Using control equipment such as; Fabric filters should be used to control
emissions particulates, from the process of charging pigments and fillers to the mixers, to
below 50 milligrams per normal cubic meter (mg/Nm3) .
• Using of pigments in the form of pastes (premixed with resins) could be used
instead of powdered pigments, to minimize particulate emissions during pigments
charging and mixing processes.
• Using of closed equipment (mixers, vessels, mills, and tanks), to prevent the
fugitive emissions (VOCs and particulates) of the raw materials in the work place.
Water Pollution Abatement Measures

Equipment cleaning is considered the major source of pollution (liquid waste) in paints
industry, hence reducing cleaning process is a useful way for pollution control. The following
are some ways for liquid waste control:
In-plant • Elimination of unnecessary intermediate storage tanks, to minimize the amount
modifications of spent solvents generated from the cleaning of these tanks.
• Recycling from intermediate tank directly to the mill instead of using recycling
tank, which lead to reducing the pollution (liquid waste) resulting from cleaning
of the removed tank.
• Using high efficiency mills, which allows no need for recycling tank.
• Using centrifugal clarifier instead of filter press, to minimize losses (spills and
leaks) occur during recycling of the filtrate to the intermediate tank. This will
accordingly improve the quality of the wastewater.
• Using high-pressure jets for cleaning of tanks to enhance cleaning process, so
reducing the amount of liquid wastes (solvents and caustic solutions) generated
from cleaning process.
• Using manual skimmers for removing materials (paints) stuck to the tanks or
container walls, before cleaning with solvent or caustic soda solution. This
reduces the amount of liquid wastes used in cleaning, and the removed sticky
materials could be recycled. Also mechanical skimmers can be used for tubes
cleaning.
• Using Teflon-lined tanks to reduce materials sticking to their walls.
• Segregation of sewer systems for liquid wastes, generated from water- based
paints production line and solvents-based production line, as this leads to more
efficient recycling.
• In all cases, it is recommended the industrial liquid waste discharged separately
from domestic wastes as they differ in the pollutant nature.
• The installation of product-capture systems for filling machines can reduce
product losses.
• Implementation of a quality control system such as HACCP (Hazard Analysis &
Critical Control Point) is recommended to minimize waste.
In-process • In solvent-based paints production line;
modifications - Random choice of the cleaning solvent could be replaced by an evaluation
process, leading to a choice of one single solvent for all tanks and
equipment cleaning.
- Schedule the production runs and modify the manufacturing procedures to
minimize or eliminate the use of wash solvent.
- Reuse of cleaning solvents (spent solvents) many times, hence reducing
the solvent consumption. After that, the solvent can be regenerated
distilled and recycled for use in dilution or cleaning.
- Spent solvent could be recovered through distillation process, with about
90% solvent yield achievable from the still, and 10% sludge (removed
paints). This sludge could be used in the production of a new paint product
(a primer).
• In Water-based paints production line;
- Using washing liquids (caustic solutions), generated from cleaning of mills
and packing machines, in dilution of next batch.
- Scheduling operations to produce light color first then dark color paints to
reduce the need for equipment cleaning. For white paints we can use
intermediate tank to minimize the washing operations.
- In acrylic paints production line; Wash water generated from white acrylic
paint manufacture could be reused in the next production run. Also the
wastewater generated from the colored acrylics could also be stored for
reuse in the next production run.
• In all production line;
- Appling quality assurance to reduce the possibility of errors in paints
preparation.
- Using counter current cleaning operations to reduce the amount of water or
solvent used.
- Cleaning the tanks directly after production step to prevent materials
sticking into walls. This means coordination between the production steps
and cleaning operation.
- Reusing the rejected or off-spec. paints in new batches.
- Raw materials substitution; replacing the toxic pigments or dyes such as
lead and chromium compounds by another non-toxic ones such as organic
dyes or iron oxides.
- Controlling raw materials stock using computerized system, which
facilitate the detection of any leak in the initial stages and indicate the
sources of solid waste pollutants.
- Implementation of a control system involving pressure regulators on the
steam lines, temperature controllers, flow controllers…
- Change from batch processes into continuous ones.
- Modernize the equipment and upgrade the system.
- Introduce new environmentally friendly products (water-bases paints) to
increase sales and minimize pollution.
- Improving raw materials handling, to prevent spills occur during manual
unpacking of sacks and containers, and training of personnel to insure
complete unpacking of containers.
- Integration (acidic and alkaline streams), and segregation of sewer lines of
water and solvent based paints, to minimize treatment needs and ensure
compliance with the environmental laws, can be an option for many
factories. In some cases where there are several discharge points from the
factory, mixing of the streams could lead to compliance. In other cases
where treatment is imperative some streams could be segregated and
discharged without violation. The remaining streams will require a
treatment unit of small capacity.
End-of-pipe Because of the typically high content of suspended solids, TDS, TSS, O&G,
treatment COD, BOD, pH, and temp., in the paints industry waste-streams, end-of-pipe
treatment frequently involves settling tanks and biological treatment.
Pretreatment of effluents is required, it is normally followed by biological
treatment.
1)Water-based The wastewater generated from the water-based paints production line is
paints characterized by high values of BOD, COD, S.S, TSS, and TDS. Therefore,
the end-of-pipe treatment could be as follows:
• Collection and flow equalization,
• Precipitation, using coagulants and flocculants (such as; lime, alum,…), in a
homogenizing tank equipped with mixer, followed by a sedimentation tank to
allow the time needed for reactions of chemicals to precipitate the dissolved
solids.
• Decantation for removal of generated sludge, and drying of sludge using filter
press.
• Filtration using activated carbon filter, to remove any entrained solids.
2) Resins The wastewater generated from the resin production line, contain xylene and
production line other organic compounds, this wastewater could be incinerated in the Dow-
therm oil heaters instead of the fuel (Mazot or Solar).
3) Solvent- The spent solvent generated from equipment cleaning, in the solvent-based
based paints production line, could be recovered by vacuum distillation of the spent
solvent, then condensation of solvent vapors. The solvent can be recycled for
reuse in dilution or cleaning.
The sludge (precipitates) generated from the solvent recovery process could
be dried and safely disposed into a landfill.
Abatement Measures for Solid Waste Pollution

Scrap from • Scrap metals are collected and sold.
workshops
and garage
Hazardous solid wastes sources includes chemicals sacs, packs, empty barrels, filters
cartridge, materials spills, and precipitates from liquid wastes (caustic solutions and
solvents) clarification by settling or distillation. The following are some ways for
Solid wastes reducing solid waste pollution.
from processes
• Planning of packaging systems to avoid solid waste and/or to facilitate recycling
of packages or packaging wastes.
• Separating hazardous solid waste from non-hazardous ones. This means
separating sacs or packs containing hazardous materials such as lead or
chromium compounds, from that free from such compounds.
• Gathering the empty sacs containing hazardous compounds in plastic bags, to
prevent the spread of hazardous dust in the atmosphere.
• Using water-soluble sacs in making water-based paints can reduce the amount of
waste sacs, as the whole sacs can be dissolved in water with their content. This
could be done with pigments containing mercury compounds, or in making paints
containing anti-fungi compounds, but this in turn affect the degree of shininess of
paints.
• Using bag filters instead of cartridge filters, as the spent cartridge should be
safely disposed into a landfill or burned, while the bag filters can be used many
times. In addition, the bag filters can be washed by water or solvents, for
recovery of the toxic material, and recycling of these materials with dilution
liquids (solvents and thinners), then the filter bags can be dried and disposed
safely.
• Using metallic screens for paints filtration process, which can be reused after
cleaning with water or solvent.
• Handling of solid materials spills, by dry cleaning methods such as; vacuum
cleaner, or by wet saw dust, to prevent spreading of these materials. Also the
personnel should be trained to close the grills of the internal sewer system, when
leaks or spills occur, to reduce the pollution load discharged to the sewer.
• Using automatic methods for unpacking of sacs, which prevent dust spreading in
the workplace, also can reduce solid materials spills.
• Cleaning pollutants, from empty sacks and containers by solvent, should be done
before storing or selling.
• Solid wastes, generated from spent solvent distillation or pretreatment of alkali
solutions, used in cleaning and washing, could be safely disposed into a landfill
or burned.
• Generally, recycling of incoming raw materials packaging like steel barrels,
plastic barrels, nonce-use pallets, corrugated, paper bags, shrink plastic (PE) and
transition to storage of raw materials in tanks. The reuse of these packages is a
measure to reduce costs and amounts of waste.
Sludges from • Effluent treatment processes generate sludge. It can also be hazardous to health
water and by absorbing pathogens that multiply in this favorable medium and toxins. It also
wastewater contain traces of heavy metals. Raw sludge is saturated with water, should be de-
treatment watered and disposed of into landfills.
• Sludge also generated from water treatment unit due to addition of lime and
chemicals to water.
Water and Energy Conservation

Water and sewer service costs have been rising, and these increases can cut into profits.
Using water more efficiently can help counter these increases.
Water • Install water meters and monitor water use
Conservation • Use automatic shut-off nozzles and mark hand-operated valves so that open,
close and directed-flow positions are easily identified.
• Use high-pressure, low-volume cleaning systems, such as CIP (clean in place) for
washing equipment.
• Install liquid level controls with automatic pump stops where overflow is likely
to occur.
• Recycle cooling water through cooling towers.
• Minimize spills on the floor minimizes floor washing.
• Repair leaks.
• Handle solid waste dry.
• Recycle steam condensate whenever economically viable.
Energy • Insulation of steam lines.
conservation • Installation of steam traps.
measures
• Repair or replace steam valves.
• Use the optimum excess air to perform efficient combustion process
• Install pressure regulators on steam lines.
• Return steam condensate.
• Improvement of power factor and electrical circuits.
Annex D - 2007 Top Companies Report
# Company Sales # Company Sales
1 Akzo Nobel (The Netherlands) $7.8 Billion 35 Berger (India) $ 306 million
2 Henkel (Germany) $6.921 Billion 36 Helios (Slovenia) $ 303 million
3 ICI Group (UK) $6.387Billion 37 Kelly-Moore (USA) $ 300 million
4 Sherwin-Williams (USA) $6.348Billion* 38 Dunn-Edwards (USA) $ 298 million*
5 PPG Industries $6.324Billion 39 Yasar (Turkey) $ 285 million*
6 DuPont (USA) $4.095Billion 40 Renner (Brazil) $ 282 million*
7 RPM (USA) $ 3.008Billion 41 Dyrup (Denmark) $ 280 million
8 Valspar (USA) $ 2.978Billion 42 Altana (Germany) $ 277 million
9 BASF Coatings (Germany) $2.935Billion 43 National Paints (Jordan) $ 260 million
10 SigmaKalon (The Netherlands) $ 2.386 Billion 44 DIC (Japan) $ 250 million
11 3M (USA) $2.2 Billion* 45 CIN (Portugal) $ 248 million
12 Kansai Paint (Japan) $ 1.795Billion 46 Flugger (Denmark) $ 244 million
13 Nippon Paint (Japan) $ 1.732Billion* 47 Rock Paint (Japan) $ 211 million*
14 Sika (Switzerland) $ 1.5 Billion* 48 Grebe Group (Germany) $ 210 million*
15 H.B. Fuller (USA) $1.472 Billion 49 Tigerwerk (Austria) $ 188 million*
16 Comex (Mexico) $ 1.4 Billion 50 Yung Chi (Taiwan) $ 182 million*
17 Masco (USA) $ 1.277Billion 51 Industrias Titan (Spain) $ 180 million*
18 Jotun (Norway) $ 1.249Billion 52 DPI (South Korea) $ 166 million
19 AB. Wilh. Becker (Sweden) $1.19 Billion* 53 Cloverdale Paint(Canada) $ 165 million*
20 DAW (Germany) $1.13 Billion 54 Shinto Paint (Japan) $ 161 million*
21 Rohm and Haas (USA) $1.055 Billion 55 M.A.B. Paints (USA) $ 155 million*
22 Hempel (Denmark) $ 980 million 56 Ace Paint (USA) $ 150 million*
23 Benjamin Moore (USA) $ 950 million* 57 Vogel Paint (USA) $ 147 million
24 Asian Paints (India) $ 893 million 58 Boero Group (Italy) $ 145 million
25 Kemira Coatings (Finland) $ 707 million 59 Looser Holding AG (Switzerland) $ 141 million
26 Forbo (Switzerland) $584 million 60 Toa Paints (Thailand) $ 140 million*
27 Brillux (Germany) $ 538 million* 61 Tohpe (Japan) $ 133 million*
28 Dai Nippon Toryo (Japan) $ 516 million* 62 Empils (Russia) $ 116.2 million
29 Chugoku Marine Paint (Japan) $453 million* 63 Russian Coatings (Russia) $116.1 million
30 Orica (Australia) $ 403 million 64 Spraylat (USA) $ 110 million
31 Barloworld (South Africa) $400 Billion* 65 Inver SpA (Italy) $ 106 million
32 Arch (USA) $358 million 66 RedSpot (USA) $ 105 million*
33 KCC (South Korea) $ 350 million* 67 Tnemec (USA) $ 96 million
34 Wattyl (Australia) $320 million
* Estimated sales
Source: www.coatings World.com ----July 2007

‫‪Annex E: Paints Exports by HS Codes and countries‬‬
‫ادرات ا

د ا ت ) ‪ /‬دو( ‪ 2005-1-1‬ا ‪ 2007-12-31‬ا!
ور‬
‫ا
‪!$‬‬ ‫ ا‪" #‬‬
‫‪Grand Total‬‬ ‫‪2007‬‬ ‫‪2006‬‬ ‫‪2005‬‬
‫‪6-‬‬
‫‪$‬‬ ‫‪3,354,572‬‬ ‫‪$‬‬ ‫‪1,624,488‬‬ ‫‪$‬‬ ‫‪627,477‬‬ ‫‪$‬‬ ‫‪1,102,608‬‬ ‫&
ا‪ ! %‬‬ ‫‪320810‬‬
‫‪$‬‬ ‫‪1,052,130‬‬ ‫‪$‬‬ ‫‪859,195‬‬ ‫‪$‬‬ ‫‪28,107‬‬ ‫‪$‬‬ ‫‪164,828‬‬ ‫&
أورو‬ ‫‪320810‬‬
‫‪$‬‬ ‫‪62,792‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪45,008‬‬ ‫‪$‬‬ ‫‪17,784‬‬ ‫&
أ ‬ ‫‪320810‬‬
‫‪$‬‬ ‫‪9,612,274‬‬ ‫‪$‬‬ ‫‪3,509,445‬‬ ‫‪$‬‬ ‫‪3,519,612‬‬ ‫‪$‬‬ ‫‪2,583,216‬‬ ‫&
اول ا ‬ ‫‪320810‬‬
‫‪$‬‬ ‫‪14,668‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪34‬‬ ‫‪$‬‬ ‫‪14,634‬‬ ‫دول ا*ي‬ ‫‪320810‬‬
‫‪$‬‬ ‫‪14,096,436‬‬ ‫‪$‬‬ ‫‪5,993,128‬‬ ‫‪$‬‬ ‫‪4,220,238‬‬ ‫‪$‬‬ ‫‪3,883,070‬‬ ‫‪

& 320810‬ا‬
‫‪$‬‬ ‫‪603,055‬‬ ‫‪$‬‬ ‫‪235,061‬‬ ‫‪$‬‬ ‫‪144,408‬‬ ‫‪$‬‬ ‫‪223,586‬‬ ‫&

ا‪ ! %‬‬
‫‪320820‬‬
‫‪$‬‬ ‫‪321,770‬‬ ‫‪$‬‬ ‫‪227,412‬‬ ‫‪$‬‬ ‫‪66,312‬‬ ‫‪$‬‬ ‫‪28,047‬‬ ‫&
أورو‬
‫‪320820‬‬
‫‪$‬‬ ‫‪9,661‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪9,661‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫&
أ ‬
‫‪320820‬‬
‫‪$‬‬ ‫‪2,014,451‬‬ ‫‪$‬‬ ‫‪934,821‬‬ ‫‪$‬‬ ‫‪488,985‬‬ ‫‪$‬‬ ‫‪590,645‬‬ ‫&
اول ا ‬
‫‪320820‬‬
‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪
& 320820‬دول ا*ي‬
‫‪$‬‬ ‫‪2,948,938‬‬ ‫‪$‬‬ ‫‪1,397,294‬‬ ‫‪$‬‬ ‫‪709,366‬‬ ‫‪$‬‬ ‫‪842,278‬‬ ‫‪

& 320820‬ا‬
‫‪$‬‬ ‫‪6,160,050‬‬ ‫‪$‬‬ ‫‪2,126,123‬‬ ‫‪$‬‬ ‫‪3,513,299‬‬ ‫‪$‬‬ ‫‪520,629‬‬ ‫&

أ‪ ! %‬‬ ‫‪320890‬‬
‫‪$‬‬ ‫‪2,144,947‬‬ ‫‪$‬‬ ‫‪1,697,765‬‬ ‫‪$‬‬ ‫‪265,428‬‬ ‫‪$‬‬ ‫‪181,754‬‬ ‫&
اورو‬ ‫‪320890‬‬
‫‪$‬‬ ‫‪771,830‬‬ ‫‪$‬‬ ‫‪28,444‬‬ ‫‪$‬‬ ‫‪742,584‬‬ ‫‪$‬‬ ‫‪802‬‬ ‫&
أ ‬ ‫‪320890‬‬
‫‪$‬‬ ‫‪22,824,830‬‬ ‫‪$‬‬ ‫‪10,277,511‬‬ ‫‪$‬‬ ‫‪8,380,139‬‬ ‫‪$‬‬ ‫‪4,167,180‬‬ ‫&
اول ا ‬ ‫‪320890‬‬
‫&
ا‪#‬ا وآا‬
‫‪$‬‬ ‫‪180,626‬‬ ‫‪$‬‬ ‫‪81,745‬‬ ‫‪$‬‬ ‫‪92,561‬‬ ‫‪$‬‬ ‫‪6,320‬‬ ‫ودول ا*ي‬ ‫‪320890‬‬
‫‪$‬‬ ‫‪32,082,283‬‬ ‫‪$‬‬ ‫‪14,211,588‬‬ ‫‪$‬‬ ‫‪12,994,010‬‬ ‫‪$‬‬ ‫‪4,876,685‬‬ ‫‪

& 320890‬ا‬
‫‪$‬‬ ‫‪242,639‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪19,157‬‬ ‫‪$‬‬ ‫‪223,482‬‬ ‫‪

& 320910‬أ‪ ! %‬‬
‫‪$‬‬ ‫‪104,684‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪104,684‬‬ ‫‪
& 320910‬أورو‬
‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪
& 320910‬أ ‬
‫‪$‬‬ ‫‪1,409,151‬‬ ‫‪$‬‬ ‫‪110,152‬‬ ‫‪$‬‬ ‫‪309,987‬‬ ‫‪$‬‬ ‫‪989,012‬‬ ‫‪
& 320910‬اول ا ‬
‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪
& 320910‬دول ا*ي‬
‫‪$‬‬ ‫‪1,756,473‬‬ ‫‪$‬‬ ‫‪110,152‬‬ ‫‪$‬‬ ‫‪329,144‬‬ ‫‪$‬‬ ‫‪1,317,178‬‬ ‫‪

& 320910‬ا‬
‫‪$‬‬ ‫‪73,895‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪64,160‬‬ ‫‪$‬‬ ‫‪9,735‬‬ ‫&

ا‪ ! %‬‬ ‫‪320990‬‬
‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫&
أورو‬ ‫‪320990‬‬
‫‪$‬‬ ‫‪34,690‬‬ ‫‪$‬‬ ‫‪9,279‬‬ ‫‪$‬‬ ‫‪25,410‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫&
أ ‬ ‫‪320990‬‬
‫‪$‬‬ ‫‪481,837‬‬ ‫‪$‬‬ ‫‪202,043‬‬ ‫‪$‬‬ ‫‪65,257‬‬ ‫‪$‬‬ ‫‪214,537‬‬ ‫&
اول ا ‬ ‫‪320990‬‬
‫‪$‬‬ ‫‪10‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪10‬‬ ‫&
دول ا*ي‬ ‫‪320990‬‬
‫‪$‬‬ ‫‪590,432‬‬ ‫‪$‬‬ ‫‪211,322‬‬ ‫‪$‬‬ ‫‪154,828‬‬ ‫‪$‬‬ ‫‪224,282‬‬ ‫‪

& 320990‬ا‬
‫‪1‬‬
‫‪Annex E: Paints Exports by HS Codes and countries‬‬
‫‪$‬‬ ‫‪12,108,894‬‬ ‫‪$‬‬ ‫‪7,902,467‬‬ ‫‪$‬‬ ‫‪3,717,185‬‬ ‫‪$‬‬ ‫‪489,242‬‬ ‫&

ا‪ ! %‬‬ ‫‪321000‬‬
‫‪$‬‬ ‫‪1,384,976‬‬ ‫‪$‬‬ ‫‪865,545‬‬ ‫‪$‬‬ ‫‪292,904‬‬ ‫‪$‬‬ ‫‪226,527‬‬ ‫&
أورو‬ ‫‪321000‬‬
‫‪$‬‬ ‫‪1,141,034‬‬ ‫‪$‬‬ ‫‪700,902‬‬ ‫‪$‬‬ ‫‪146,749‬‬ ‫‪$‬‬ ‫‪293,383‬‬ ‫&
أ ‬ ‫‪321000‬‬
‫‪$‬‬ ‫‪39,677,693‬‬ ‫‪$‬‬ ‫‪24,818,960‬‬ ‫‪$‬‬ ‫‪10,605,045‬‬ ‫‪$‬‬ ‫‪4,253,689‬‬ ‫&
اول ا ‬ ‫‪321000‬‬
‫‪$‬‬ ‫‪9,548,430‬‬ ‫‪$‬‬ ‫‪4,235,904‬‬ ‫‪$‬‬ ‫‪3,711,928‬‬ ‫‪$‬‬ ‫‪1,600,598‬‬ ‫&
دول ا*ي‬ ‫‪321000‬‬
‫‪$‬‬ ‫‪63,861,027‬‬ ‫‪$‬‬ ‫‪38,523,777‬‬ ‫‪$‬‬ ‫‪18,473,811‬‬ ‫‪$‬‬ ‫‪6,863,439‬‬ ‫‪

& 321000‬ا‬
‫‪$‬‬ ‫‪114,352‬‬ ‫‪$‬‬ ‫‪55,740‬‬ ‫‪$‬‬ ‫‪58,612‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪

& 321410‬ا‪ ! %‬‬
‫‪$‬‬ ‫‪11,610‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪11,610‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪
& 321410‬اورو‬
‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪
& 321410‬أ ‬
‫‪$‬‬ ‫‪100,826‬‬ ‫‪$‬‬ ‫‪30,240‬‬ ‫‪$‬‬ ‫‪43,599‬‬ ‫‪$‬‬ ‫‪26,987‬‬ ‫‪
& 321410‬اول ا ‬
‫‪$‬‬ ‫‪57,194‬‬ ‫‪$‬‬ ‫‪57,194‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪
& 321410‬دول ا*ي‬
‫‪$‬‬ ‫‪283,982‬‬ ‫‪$‬‬ ‫‪143,174‬‬ ‫‪$‬‬ ‫‪113,821‬‬ ‫‪$‬‬ ‫‪26,987‬‬ ‫‪

& 321410‬ا‬
‫‪$‬‬ ‫‪218,688‬‬ ‫‪$‬‬ ‫‪5,202‬‬ ‫‪$‬‬ ‫‪209,344‬‬ ‫‪$‬‬ ‫‪4,143‬‬ ‫&

ا‪ ! %‬‬ ‫‪321490‬‬
‫‪$‬‬ ‫‪210,210‬‬ ‫‪$‬‬ ‫‪150,052‬‬ ‫‪$‬‬ ‫‪38,369‬‬ ‫‪$‬‬ ‫‪21,789‬‬ ‫&
أورو‬ ‫‪321490‬‬
‫‪$‬‬ ‫‪3,254‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪3,254‬‬ ‫&
أ ‬ ‫‪321490‬‬
‫‪$‬‬ ‫‪667,617‬‬ ‫‪$‬‬ ‫‪326,329‬‬ ‫‪$‬‬ ‫‪144,201‬‬ ‫‪$‬‬ ‫‪197,087‬‬ ‫&
اول ا ‬ ‫‪321490‬‬
‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫‪$‬‬ ‫‪-‬‬ ‫&
دول ا*ي‬ ‫‪321490‬‬
‫‪$‬‬ ‫‪1,099,770‬‬ ‫‪$‬‬ ‫‪481,583‬‬ ‫‪$‬‬ ‫‪391,913‬‬ ‫‪$‬‬ ‫‪226,273‬‬ ‫‪

& 321490‬ا‬
‫‪2‬‬
Annex “F”
Table F.1: Paint and Coating Products
HS Code Description Customs Tariff**
32 Tanning or dyeining extracts; Tanning & their derivatives; Dyes, Pigments & other coloring matter; Paints & varnishes; Putty
& other Mastics; Inks
3208 Paints and varnishes (including enamels and lacquers) based on synthetic polymers or chemically modified natural polymers, dispersed
or dissolved in a non-aqueous medium; solutions as defined in Note 4 to this Chapter.
320810 Paints & varnishes (incl. enamels & lacquers) based on polyesters 10%
320820 Paints & varnishes (incl. enamels & lacquers) based on acrylic/vinyl polymers 10%
320890 Paints & varnishes (incl. enamels & lacquers, excl. of 3208.10 & 3208.20) based on synthetic polymers/chemically modified natural 10%
polymers, dispersed/dissolved in a non-aqueous medium; solutions as defined in Note 4 to this Chapter.
3209 Paints and varnishes (including enamels and lacquers) based on synthetic polymers or chemically modified natural polymers, dispersed
or dissolved in an aqueous medium.
320910 Paints & varnishes (incl. enamels & lacquers) based on acrylic/vinyl polymers 10%
320990 Paints & varnishes (incl. enamels & lacquers) based on synthetic polymers/chemically modified natural polymers other than 10%
acrylic/vinyl polymers, dispersed/dissolved in an aqueous medium
3210 Other paints and varnishes (including enamels, lacquers and distempers); prepared water pigments of a kind used for finishing leather.
321000 Paints & varnishes (incl. enamels, lacquers & distempers; excl. of 32.08 & 32.09); prepared water pigments of a kind used for finishing 20%
leather
3214 Glaziers' putty, grafting putty, resin cements, caulking compounds and other mastics; painters' fillings; non-refractory surfacing
preparations for façades, indoor walls, floors, ceilings or the like.
321410 Glaziers' putty, grafting putty, resin cements, caulking comps. & other mastics; painters' fillings 10%
321490 Non-refractory surfacing preparations for facades/indoor walls/floors/ceilings/the like (other?) 10%
** Source: The Presidential Decree No. 39/2007; “Customs Tariff According to the Amendments of the Harmonized System 2007” and its amendment on 2 April 2008,
Ministry of Finance, Arab Republic of Finance.
*** nes= not elsewhere specified
Table F.2: Paint and coating Intermediate Products
HS Code Description Customs
Tariff**
39 Plastics & Articles Thereof
3903 Polymers of styrene, in primary forms
390320 Styrene-acrylonitrile (SAN) copolymers, in primary forms Free
3905 Polymers of vinyl acetate or of other vinyl esters, in primary forms; other vinyl polymers in primary forms
390512 Poly(vinyl acetate), in aqueous dispersion, in primary forms 2%
390519 Poly(vinyl acetate) other than in aqueous dispersion, in primary forms 2%
390521 Vinyl acetate copolymers, in aqueous dispersion, in primary forms 2%
390529 Vinyl acetate copolymers other than in aqueous dispersion, in primary forms 2%
3907 Polyacetals, other polyethers and epoxide resins, in primary forms; polycarbonates, alkyd resin, polyallyl esters and other polyesters, in
primary forms
390720 Polyether's other than polyacetals, in primary forms 2%
390730 Epoxide resins, in primary forms 5%
390750 Alkyd resins, in primary forms
39075010 - of long or medium chain 10%
390791 Polyesters (excl. of 3907.10-3907.60), unsaturated, in primary forms 5%
390799 Polyesters (excl. of 3907.10-3907.91), in primary forms (other?) 5%
3908 Polyamides in primary forms

390810 Polyamide-6/ -11/ -12/ -6,6/ -6,9/ -6,10/ -6,12, in primary forms 2%
390890 Polyamides (excl. of 3908.10), in primary forms 2%
** Source: The Presidential Decree No. 39/2007; “Customs Tariff According to the Amendments of the Harmonized System 2007” and its amendment on 2 April 2008, Ministry of Finance,
Arab Republic of Finance.
Table F.3: Paint and coating Raw materials
32 Tanning or dyeining extracts; Tanning & their derivatives; Dyes, Pigments & other coloring matter; Paints & varnishes;
Putty & other Mastics; Inks
3204 Synthetic organic colouring matter, whether or not chemically defined; preparations as specified in Note 3 to this Chapter based on
synthetic organic colouring matter; synthetic organic products of a kind used as fluorescent brightening agents or as lumin
320417 Pigments & preparations based thereon 2%
3206 Other colouring matter; preparations as specified in Note 3 to this Chapter, other than those of heading 32.03, 32.04 or 32.05;
inorganic products of a kind used as luminophores, whether or not chemically defined
320611 Pigments & preparations based on titanium dioxide, containing 80%/more by weight of titanium dioxide calc. on the dry matter 2%
320619 Pigments & preparations based on titanium dioxide other than those containing 80%/more by weight of titanium dioxide calc. on 2%
the dry matter
3207 Prepared pigments, prepared opacifiers and prepared colours, vitrifiable enamels and glazes, engobes (slips), liquid lustres and
similar preparations, of a kind used in the ceramic, enamelling or glass industry; glass frit and other glass, in the form of
320710 Prepared pigments, prepared opacifiers, prepared colours & similar preparations 10%
320720 Vitrifiable enamels & glazes, engobes (slips) & similar preparations 5%
3211 Prepared driers.

321100 - Prepared driers
32110010 -- in packages of weight not less than 25 K.G. 5%
32110090 -- Other 10%
3212 Pigments (including metallic powders and flakes) dispersed in non-aqueous media, in liquid or paste form, of a kind used in the
manufacture of paints (including enamels); stamping foils; dyes and other coloring matter put up in forms or packing for reta
321290 Pigments (incl. metallic powders & flakes) dispersed in non-aqueous media/in liquid/paste form, of a kind used in the manufacture 2%
of paints (incl. enamels); dyes & other coloring matter put up in forms/packing-RS
38 Miscellaneous Chemical Products

3803 Tall oil, whether or not refined 5%
3805 Gum, wood or sulphate turpentine and other terpenic oils produced by the distillation or other treatment of coniferous woods; crude
dipentene; sulphite turpentine and other crude para-cymene; pine oil containing alpha-terpineol as the main constituent.
380510 - Gum, wood or sulphate turpentine oils 5%
380590 - Other 5%
3806 Rosin and resin acids, and derivatives thereof; rosin spirit and rosin oils; run gums.
380610 - Rosin and resin acids 5%
380620 - Salts of rosin, of resin acids or of derivatives of rosin or resin acids, other than salts of rosin adducts 10%
380690 - other 10%
3814 Organic composite solvents & thinners; prepared paint or varnish removers
381400 Organic composite solvents & thinners, nes***; or prepared paint/varnish removers 2%
3815 Reaction initiators, reaction accelerators and catalytic preparations, not elsewhere specified or included – supported catalysts
381511 -- With nickel or nickel compounds as the active substance 5%
381512 -- With precious metal or precious metal compounds as the active substance 5%
381519 -- other 5%
381590 - other 5%
3823 Industrial mono-carboxylic fatty acids; acid oils from refining; industrial fatty alcohols. – industrial monocarboxylic fatty acids;
acid oils from refining
382311 -- Stearic acid 5%
382312 -- Oleic acid 5%
382313 -- Tall oil fatty acids 5%
382319 -- Other 5%
382370 - Industrial fatty alcohols 5%
39 Plastics & Articles Thereof
3909 Amino-resins, phenolic resins and polyurethanes, in primary forms.

390910 Urea resins, in primary forms; thiourea resins, in primary forms 2%
390920 Melamine resins, in primary forms 390930 - Amino-resins (excl. of 3909.10 & 3910.20), in primary forms 10%
390940 Phenolic resins, in primary forms
39094010 - Phenolic moulding compounds 10%
39094090 - Other 2%
390950 Polyurethanes, in primary forms 2%
3912 Cellulose and its chemical derivatives, not elsewhere specified or included, in primary forms.
391220 Cellulose nitrates (incl. collodions), in primary forms
39122010 - Wet with alchole 10%
39122090 - other 2%
391231 Carboxymethyl cellulose & its salts, in primary forms 5%
** Source: The Presidential Decree No. 39/2007; “Customs Tariff According to the Amendments of the Harmonized System 2007” and its amendment on 2 April 2008, Ministry of Finance,
Arab Republic of Finance.
Annex G: Paints Final and Intermediate Products and Raw Materials
G-1: List of Paints Products

(with HS 1992 codes as a reference)
3208 - Paints and varnishes (including enamels and lacquers) based on synthetic polymers or chemically
modified natural polymers, dispersed or dissolved in a non-aqueous medium; solutions as defined in Note
4 to this Chapter.
320810 - Paints & varnishes (incl. enamels & lacquers) based on polyesters
320820 - Paints & varnishes (incl. enamels & lacquers) based on acrylic/vinyl polymers
320890 - Paints & varnishes (incl. enamels & lacquers, excl. of 3208.10 & 3208.20) based on
synthetic polymers/chemically modified natural polymers, dispersed/dissolved in a non-aqueous
modified natural polymers, dispersed or dissolved in an aqueous medium.
320990 - Paints & varnishes (incl. enamels & lacquers) based on synthetic polymers/chemically
modified natural polymers other than acrylic/vinyl polymers, dispersed/dissolved in an aqueous
medium
3210 - Other paints and varnishes (including enamels, lacquers and distempers); prepared water pigments
of a kind used for finishing leather.
321000 - Paints & varnishes (incl. enamels, lacquers & distempers; excl. of 32.08 & 32.09);
prepared water pigments of a kind used for finishing leather
3214 - Glaziers' putty, grafting putty, resin cements, caulking compounds and other mastics; painters'
fillings; non-refractory surfacing preparations for façades, indoor walls, floors, ceilings or the like.
321410 - Glaziers' putty, grafting putty, resin cements, caulking comps. & other mastics; painters'
fillings
321490 - Non-refractory surfacing preparations for facades/indoor walls/floors/ceilings/the like
G-2: List of Paints Intermediate Products

390320 - Styrene-acrylonitrile (SAN) copolymers, in primary forms
3905 - Polymers of vinyl acetate or of other vinyl esters, in primary forms; other vinyl polymers in
primary forms.
390512 - Poly(vinyl acetate), in aqueous dispersion, in primary forms
390519 - Poly(vinyl acetate) other than in aqueous dispersion, in primary forms
390521 - Vinyl acetate copolymers, in aqueous dispersion, in primary forms
390529 - Vinyl acetate copolymers other than in aqueous dispersion, in primary forms
390610 - Poly(methyl methacrylate), in primary forms
390690 - Acrylic polymers other than poly(methyl methacrylate), in primary forms
3907 - Polyacetals, other polyethers and epoxide resins, in primary forms; polycarbonates, alkyd resin,
polyallyl esters and other polyesters, in primary forms
390720 - Polyether's other than polyacetals, in primary forms
390730 - Epoxide resins, in primary forms
390750 - Alkyd resins, in primary forms
390791 - Polyesters (excl. of 3907.10-3907.60), unsaturated, in primary forms
390799 - Polyesters (excl. of 3907.10-3907.91), in primary forms
390810 - Polyamide-6/ -11/ -12/ -6,6/ -6,9/ -6,10/ -6,12, in primary forms
390890 - Polyamides (excl. of 3908.10), in primary forms
G-3: List of Paints Raw Materials

3212 - Pigments (including metallic powders and flakes) dispersed in non-aqueous media, in liquid or
paste form, of a kind used in the manufacture of paints (including enamels); stamping foils; dyes and
other coloring matter put up in forms or packing's for reta
321290 - Pigments (incl. metallic powders & flakes) dispersed in non-aqueous media/in
liquid/paste form, of a kind used in the manufacture of paints (incl. enamels); dyes & other
colouring matter put up in forms/packing-RS
390910 - Urea resins, in primary forms; thiourea resins, in primary forms
390920 - Melamine resins, in primary forms 390930 - Amino-resins (excl. of 3909.10 & 3910.20),
in primary forms
390940 - Phenolic resins, in primary forms
390950 - Polyurethanes, in primary forms
3805 - Gum, wood or sulphate turpentine and other terpenic oils produced by the distillation or other
treatment of coniferous woods; crude dipentene; sulphite turpentine and other crude para-cymene; pine
oil containing alpha-terpineol as the main constituent.
3815 - Reaction initiators, reaction accelerators and catalytic preparations, not elsewhere specified or
included.
3823 - Industrial mono-carboxylic fatty acids; acid oils from refining; industrial fatty alcohols.
3204 - Synthetic organic colouring matter, whether or not chemically defined; preparations as specified in
Note 3 to this Chapter based on synthetic organic colouring matter; synthetic organic products of
a kind used as fluorescent brightening agents or as lumin
320417 - Pigments & preparations based thereon
3206 - Other colouring matter; preparations as specified in Note 3 to this Chapter, other than those of
heading 32.03, 32.04 or 32.05; inorganic products of a kind used as luminophores, whether or not
chemically defined.
320611 - Pigments & preparations based on titanium dioxide, containing 80%/more by weight of
titanium dioxide calc. on the dry matter
320619 - Pigments & preparations based on titanium dioxide other than those containing
80%/more by weight of titanium dioxide calc. on the dry matter
3207 - Prepared pigments, prepared opacifiers and prepared colours, vitrifiable enamels and glazes,
engobes (slips), liquid lustres and similar preparations, of a kind used in the ceramic, enamelling
or glass industry; glass frit and other glass, in the form of
320710 - Prepared pigments, prepared opacifiers, prepared colours & similar preparations
320720 - Vitrifiable enamels & glazes, engobes (slips) & similar preparations
2
Annex G: Paints Final and Intermediate Products and Raw Materials
G-1: List of Paints Products

modified natural polymers, dispersed or dissolved in a non-aqueous medium; solutions as defined in Note
4 to this Chapter.
320810 - Paints & varnishes (incl. enamels & lacquers) based on polyesters
320890 - Paints & varnishes (incl. enamels & lacquers, excl. of 3208.10 & 3208.20) based on
synthetic polymers/chemically modified natural polymers, dispersed/dissolved in a non-aqueous
modified natural polymers, dispersed or dissolved in an aqueous medium.
320990 - Paints & varnishes (incl. enamels & lacquers) based on synthetic polymers/chemically
modified natural polymers other than acrylic/vinyl polymers, dispersed/dissolved in an aqueous
medium
3210 - Other paints and varnishes (including enamels, lacquers and distempers); prepared water pigments
of a kind used for finishing leather.
321000 - Paints & varnishes (incl. enamels, lacquers & distempers; excl. of 32.08 & 32.09);
prepared water pigments of a kind used for finishing leather
3214 - Glaziers' putty, grafting putty, resin cements, caulking compounds and other mastics; painters'
fillings; non-refractory surfacing preparations for façades, indoor walls, floors, ceilings or the like.
321410 - Glaziers' putty, grafting putty, resin cements, caulking comps. & other mastics; painters'
fillings
321490 - Non-refractory surfacing preparations for facades/indoor walls/floors/ceilings/the like
G-2: List of Paints Intermediate Products

390320 - Styrene-acrylonitrile (SAN) copolymers, in primary forms
3905 - Polymers of vinyl acetate or of other vinyl esters, in primary forms; other vinyl polymers in
primary forms.
390512 - Poly(vinyl acetate), in aqueous dispersion, in primary forms
390519 - Poly(vinyl acetate) other than in aqueous dispersion, in primary forms
390521 - Vinyl acetate copolymers, in aqueous dispersion, in primary forms
390529 - Vinyl acetate copolymers other than in aqueous dispersion, in primary forms
390610 - Poly(methyl methacrylate), in primary forms
390690 - Acrylic polymers other than poly(methyl methacrylate), in primary forms
3907 - Polyacetals, other polyethers and epoxide resins, in primary forms; polycarbonates, alkyd resin,
polyallyl esters and other polyesters, in primary forms
390720 - Polyether's other than polyacetals, in primary forms
390730 - Epoxide resins, in primary forms
390750 - Alkyd resins, in primary forms
390791 - Polyesters (excl. of 3907.10-3907.60), unsaturated, in primary forms
390799 - Polyesters (excl. of 3907.10-3907.91), in primary forms
390810 - Polyamide-6/ -11/ -12/ -6,6/ -6,9/ -6,10/ -6,12, in primary forms
390890 - Polyamides (excl. of 3908.10), in primary forms
G-3: List of Paints Raw Materials

3212 - Pigments (including metallic powders and flakes) dispersed in non-aqueous media, in liquid or
paste form, of a kind used in the manufacture of paints (including enamels); stamping foils; dyes and
other coloring matter put up in forms or packing's for reta
321290 - Pigments (incl. metallic powders & flakes) dispersed in non-aqueous media/in
liquid/paste form, of a kind used in the manufacture of paints (incl. enamels); dyes & other
colouring matter put up in forms/packing-RS
390910 - Urea resins, in primary forms; thiourea resins, in primary forms
390920 - Melamine resins, in primary forms 390930 - Amino-resins (excl. of 3909.10 & 3910.20),
in primary forms
390940 - Phenolic resins, in primary forms
390950 - Polyurethanes, in primary forms
3805 - Gum, wood or sulphate turpentine and other terpenic oils produced by the distillation or other
treatment of coniferous woods; crude dipentene; sulphite turpentine and other crude para-cymene; pine
oil containing alpha-terpineol as the main constituent.
3815 - Reaction initiators, reaction accelerators and catalytic preparations, not elsewhere specified or
included.
3823 - Industrial mono-carboxylic fatty acids; acid oils from refining; industrial fatty alcohols.
3204 - Synthetic organic colouring matter, whether or not chemically defined; preparations as specified in
Note 3 to this Chapter based on synthetic organic colouring matter; synthetic organic products of
a kind used as fluorescent brightening agents or as lumin
320417 - Pigments & preparations based thereon
3206 - Other colouring matter; preparations as specified in Note 3 to this Chapter, other than those of
heading 32.03, 32.04 or 32.05; inorganic products of a kind used as luminophores, whether or not
chemically defined.
320611 - Pigments & preparations based on titanium dioxide, containing 80%/more by weight of
titanium dioxide calc. on the dry matter
320619 - Pigments & preparations based on titanium dioxide other than those containing
80%/more by weight of titanium dioxide calc. on the dry matter
3207 - Prepared pigments, prepared opacifiers and prepared colours, vitrifiable enamels and glazes,
engobes (slips), liquid lustres and similar preparations, of a kind used in the ceramic, enamelling
or glass industry; glass frit and other glass, in the form of
320710 - Prepared pigments, prepared opacifiers, prepared colours & similar preparations
320720 - Vitrifiable enamels & glazes, engobes (slips) & similar preparations
2
Annex H
Arab Republic of Egypt ‫

א‬
The Cabinet of Ministries ‫
אא‬
Egyptian Environmental Affairs Agency ‫ א‬
()

Environmental Screening Form B
(General Information )
: ! "#$ .1
(Project Title)
( 123 / 0 / /# / ,-. / )*#) : ! &'( .2

( Residential / Commercial / Touristic / Industrial/ others) ( Nature of project)
(89: ;<=) 567! .3

( Investor / applicant )
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(Project Developer or applicant)
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(reference)
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( Address)
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( Fax No.) (Phone No.)
& @E FGH I7 &:# J5*# "D 9'

Information to be completed by the EEAA officials
/ / : M- KD-L / / :89: ;<= KD-L
Receival Date Date of application
: <= N797 "A-
Serial No.
(,
! P) &DD<= I! O- &?9*L ♦
( Estimated Capital Investment, L.E.)
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( Project phases and expected starting dates)
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construction
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Technological systems (Accompanied as much as possible with layout and
Operational charts and diagrams showing inputs & outputs (including wastes)
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(alternatives considered)
(sites) WA!
(technologies) H *
(designs) 55

(materials) &<V7! M!
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(Please attach a detailed map with a suitable scale to indicate clearly the site,
transportation routes and pipelines, its boundaries and neibouring uses)
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(A brief description of the construction phases and basic construction methods)
3
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Inputs of water, energy, and manpower , see table 1
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wastes
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other information deemed important particularly with regard to safeguarding
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7
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Brief description of the environment (Baseline information)
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General area description and most important features as
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Hospitals
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Fragile or sensitive ecosystems ( critical or high valued ecosystems) that are
present
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(Description of archeological & historical areas )
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( Description of protected areas )
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( Description of recreational & touristic areas)
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project sites
(as hospitals, schools, residential areas ....etc)
9
Water Quality 1! & 3
1! & p- &H-M t^
t&lP 1! t;<V#Y tpl / h 1! 9 e9 N* _ j# N_
(Will the activity cause a significant change on the water availability, use, hydrology,
drainage, temperature or quality?)
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( Are there existing hazads probabilities - explain type, quantity and impact )
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( Will the activity affect surface water use?)
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(Fisheries)
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( Tourism and recreation )
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Soil Quality & & 4

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( Would the activity provoke a significant change on landuse, landscape,
fertility, vegetation cover, biodiversity or quality?)
10
Please identify the effect of changes soil 9 & & i 2Z2jgL ,< <D< XH
quality on
: l &/7 .
(Tourism and recreation)
: 123 .
Others
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(Please explain if there are any other potential or significant impacts resulting from this
activity)
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( Is there a posibility that local community would object to the project?
( Mitigating measures ) &97 -jY h ?V XH$ .M
(Air emissions) XJ j' 1
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(Solid and hazardous wastes) p:] &9
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involvment)
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I hereby certify that the information given is accurate and true to
the best of my knowledge, and in case of any consequent changes,
prompt notification will be made to the EEAA.
: =5
Certified by
: ?7 FH/&A: "A-
I.D No. / pasport No.
: ?0
reference
/ / : KD-
Date
12
Annex I
Egyptian Environmental Affairs Agency
(EEAA)
Egyptian Pollution Abatement Project
(EPAP)
Self-
Self-Monitoring Manual
Paints Industry
Final Version
Prepared by:
Environics
Management of Environmental Systems
Month year Consultant Name

Paints Industry- Self-Monitoring Manual
September 2002
Egyptian Environmental
Environmental Affairs Agency
(EEAA)
Egyptian Pollution Abatement Project
(EPAP)
Self-
Self- Monitoring Manual
Paints Industry
Final Version
Prepared by:
Environics
Management of Environmental Systems
6 Dokki Street , Dokki - Giza

Tel: 7495686-7495696-7601595
Fax: 3360599
E-mail: environics@link.net
September 2002
2 September 2002 Environics

Table of Contents
Page
1. Introduction 1
1.1 Preface 1
1.1.1 Project Objectives 1
1.1.2 Organization of the Manual 2
2. Description of the Industry 3

2.1 Raw Materials and Utilities 3
2.1.1 Main Raw Materials 3
2.1.2 Other raw Materials 6
2.1.3 Utilities 6
2.1.4 Equipment used in paint industry 6
2.2 Production Lines 14
2.2.1 Solvent-based Paint (household/ industrial) Production Line 17
2.2.2 Water-based Paint Production Line 20
2.2.3 Printing Inks Production Line 22
2.2.4 Varnishes Production Line 24
2.2.5 Alkyd Resin Production Line 26
2.3 Service Units: Description and Potential Pollution Sources 29
2.3.1 Boilers 29
2.3.2 Water Treatment Units 29
2.3.3 Cooling Towers 30
2.3.4 Laboratories 30
2.3.5 Workshops and Garage 31
2.3.6 Storage Facilities 31
2.3.7 Wastewater Treatment Plants 31
2.3.8 Dow-therm Oil Heater 31
2.3.9 Solvent Recovery Unit 31
2.3.10 Restaurant and Housing Complex 32
2.4 Emissions, Effluents and Solid Wastes 34
2.4.1 Air Emissions 34
2.4.2 Effluents 34
2.4.3 Solid Wastes 38
2.4.4 Work Environment 38
2.5 Characteristics Specific to the Paint Industry 38
3. Environmental and Health Impacts of Pollutants 39

3.1 Impact of Air Emissions 39
3.2 Impact of Effluents 45
3.3 Environmental Impact of Solid Wastes 46
4. Egyptian Laws and Regulations 47

4.1 Concerning Air Emissions 47
4.2 Concerning Effluents 48
4.3 Concerning Solid Wastes 48
4.4 Concerning Work Environment 49
4.5 Concerning Hazardous Materials and Wastes 53
4.6 The Environmental Register 54
5. Pollution Abatement Measures 56

5.1 Air Pollution 57
5.2 Work Environment 57
5.3 Water Pollution Abatement Measures 58
5.4 Abatement Measures for Solid Wastes Pollution 62
5.5 Water and Energy Conservation 63

6. Self-Monitoring, Definition and Link to EMS 65

6.1 Benefits of SM 65
6.2 Scope and Objectives of SM 65

6.3 SM and Environmental Management System (EMS) 66
6.3.1 The Environmental Management System (EMS) 66
6.3.2 Link Between Self-Monitoring and EMS 68
6.3.3 SM Link to Pollution Prevention and Cleaner 70
Production
6.4 Regulatory Aspects 70
6.4.1 SM and Environmental Register 70
6.4.2 SM and Inspection 71
7. Planning of SM 73
7.1 Assessment of existing monitoring capacity 75
7.2 Identification of key parameters 75
7.3 General data required 76
7.4 Data collection, manipulation and reporting 76
7.5 Criteria for selecting monitoring method 77
7.5.1 Direct or indirect measurement 78
7.5.2 Mass balance 80
7.5.3 Emission factor 81
7.5.4 Engineering calculations 81
8. Monitoring of Raw Materials, Utilities and Products 82

8.1 Raw materials and chemicals 82
8.2 Utilities 84
8.3 Products 85
9. Operation Control 86
9.1 Monitoring process parameters 86
9.2 Planned maintenance 98
10. Environmental Monitoring 100
10.1 Emission to air 100
10.2 Effluents (wastewater) 101
10.3 Monitoring of solid waste 103
10.4 Monitoring of hazardous waste management 103

11. Data Collection, Processing and Usage 109
11.1 Data collection and processing 109
11.2 Using SM outputs 109

11.2.1 Techniques for summarizing and illustrating data 111
11.2.2 Environmental register 111
11.2.3 Reporting 111
11.2.4 Internal auditing and conclusions on results 112
11.2.5 Feedback and decision making 112
11.2.6 Using outputs in public relations 112
References
Annex A Data collection and processing

Annex B Register for environmental conditions

List of Acronyms
BOD Biological Oxygen Demand
COD Chemical Oxygen Demand
O&G Oil and Grease
CO Carbon Monoxide
CO2 Carbon Dioxide
VOCs Volatile Organic Compounds
MEK Methyl ethyl Ketone
MIBK Methyl Iso Butyl Ketone
SOx Sulfur Oxides
NOx Nitrogen Oxides
TDS Total Dissolved Solids
EMS Environmental Management System
EoP Treatment End-of-Pipe Treatment
CP Cleaner Production
P2 Pollution Prevention
SIC Standard Industrial Classification
SM Self-Monitoring
SMS Self-Monitoring System
WWTP Wastewater Treatment Plant
µm Micro meter 10-6 m
MHUUC Ministry of Housing, utilities and urban Communities
HACCP Hazardous Analysis& Critical Control Point

CIP Clean in Place
SM Self-Monitoring
SMS Self-Monitoring System

1. Introduction
The Egyptian Pollution Abatement Project (EPAP) sponsored by

FINIDA has assigned Finish and Egyptian consultants for the task of
developing sector-specific inspection and monitoring guidelines.
A General Inspection Manual, GIM, has been developed covering

inspection aspects common to all sectors. The manual :
Discusses the strategy, objectives and tasks of the inspectorate
management.
Identifies the team leader responsibilities and tasks.
Presents a methodology for performing all types of inspection.
Tasks during the various phases of planning, performing field
inspection, report preparation and follow-up are discussed.
Several checklists are included.
Sector specific inspection manuals have been developed for the

following industries:
Textile industry
Pulp and paper industry
Food industry
- Grain milling industry
- Dairy industry
- Carbonated beverages industry
- Confectionery industry
- Fruits and vegetables industry
Metallurgical industry
Fabricated metal industry
Motor vehicle assembly
The developed manuals were tested through a number of training

programs that targeted RBOs and EMUs.
The inspectors involved in the training used these manuals to inspect a

number of industrial facilities. Feedback from the concerned parties led
to the improvement of these manuals and their continuous update.
1.1 Preface
As a continuation of the previous effort, the following Inspection and

self-monitoring manuals are being developed as part of this project.
Inspection manuals:
Paint industry
Detergent oil and soap industries
Cement and ceramic industry
Fertilizer industry
Self-monitoring manuals:
Paint industry

1.1.1 Project Objectives

The project aims at the development of sector-specific guidelines for
inspection and self-monitoring to be used by inspectors and pant
personnel respectively. These manuals are meant to be simplified but
without abstention of any information necessary to the targeted users.
Flowcharts, tables and highlighted notes are used for easy
representation of information.
1.1.2 Organization of the Self-Monitoring Manual

The self-monitoring manual for the paints industry includes eleven
chapters. The first chapter represents an introduction to the whole
project and to the specific sub-sector of the industry. Chapters two to
five deal with the paints industry and its environmental impacts.
The description of the industry in chapter 2 includes the inputs and

outputs, a description of the different production lines with their
specific inputs and outputs, a brief description of the service and
auxiliary units that could be present at the industrial establishment with
their potential sources of pollution and the various emissions, effluents
and solid wastes generated from the different processes.
Chapter three describes the environmental and health impacts of the

various pollutants whereas chapter four gives a summary of the articles
in the Egyptian environmental laws relevant to the paints industry.
Chapter five gives examples of pollution abatement techniques and
measures applicable to the paints industry.
Chapters 6 to 11 describe self monitoring activities and start with

defining self- monitoring (SM) and its link to environmental
management systems (EMS). The stages of the EMS are described and
their relation to the corresponding stages of the SMS defined. The link
between pollution prevention and SM is explained in the context of the
Egyptian regulations. Inspection of SM results by competent
inspection authorities is considered with respect to the benefits that can
be achieved for the inspection process as well as the role of the
inspectors in checking the results.
Planning for SM is described in chapter 7 and includes the assessment

of existing monitoring capacity, the identification of key parameters,
the collection of basic information and data, the organization and
reporting of results and the criteria for selecting monitoring method.
Chapter 8 is concerned with monitoring of inputs and outputs whereas

chapters 9 and 10 are devoted to the process monitoring and
compliance monitoring respectively. Using SM outputs is described in
chapter 11.

2. Description of the Industry
Products of the surface-coating (paints) are essential for the preservation of all types of
architectural structures, including factories, from ordinary attacks of weather. Uncoated wood and
metal are particularly susceptible to deterioration, especially in cities where soot and sulfur dioxide
accelerate such action. Aside from their purely protective action, paints, varnishes, and lacquers
increase the attractiveness of manufactured goods, as well as the aesthetic appeal of a community
of homes and their interiors. Coatings that are used to cover building, furniture, and the like are
referred to as trade sales or architecture coatings in contrast to industrial coatings which are used
on materials being manufactured. Industrial finishes are applied to a wide variety of materials,
such as metal, textiles, rubber, paper, and plastics, as well as wood. Architectural coatings are
usually applied to wood, gypsum wall-board, or plaster surfaces.
The paints industry is a branch of the chemical industries sector. Surface coating (paints) have
been divided into:
• Solvent-based paints
• Water-based paints
• Varnishes; clear coatings.
• Printing inks.
• Resins (for paints and varnishes manufacture).
Therefore, there are different production lines, plants can have as few as one or two production
lines or all of them.
Service units (utilities) provide water and energy requirements as well as maintenance, storage,
packaging, testing, and analysis needs.
The batch process is common in paints industry, old plants use open equipment, while modern
plants use the closed one. Equipment cleaning is necessary, and required between batches.
2.1 Raw Materials and Utilities
2.1.1 Main Raw Materials

Liquid paints is a composite of a finely divided pigment dispersed in a liquid composed of a resin
or binder and a volatile solvent. Therefore, paints are manufactured from three main constituents;
pigments, binders, and solvents (thinners), in addition to many other additives to give the paints
specific properties for specific purposes or applications.
The liquid portion of the paints is known as the vehicle. Vehicles are composed of nonvolatile and
volatile parts:
• Nonvolatile;
- Solvent-based paints: oils and/ or resins plus driers
and additives.
- Lacquers: celluloses, resins, plasticizers, and
additives.
- Water-based paints: styrene-butadiene, polyvinyl
acetate, acrylic, other polymers and emulsions,
copolymers plus additives.
• Volatile

Ketones, esters, alcohol, aromatics, and aliphatics.
The pigment is one of the main and important constituent of the paint. In general, pigments should
be opaque to ensure good covering power and chemically inert to secure stability, hence long life.
Pigments should be nontoxic, or at least of very low toxicity, to both the painter and the
inhabitants. Finally, pigments must be wet by the film-forming constituents and be of low cost.
Different pigments possess different covering power per unit weight. Table (1) shows the different
paints constituents.
Table (1) Paints Constituents

Constituent Function
Main constituents
Pigments are usually: The function of pigments and fillers is to provide
simply a colored surface, pleasing for its aesthetic
appeal. The solid particles in paint reflect light rays,
• An inorganic and thus help to prolong the life of the paints, and
substance, such as protect metals from corrosion.
titanium dioxide,
chrome pigment,
earths, lead pigments,
zinc pigments.
• A pure, insoluble
organic dye known as
a toner.
• An organic dye
precipitated on an
inorganic carrier such
as aluminum
hydroxide, barium
sulfate or clay.
Binders or vehicles. Those are Its function is binding the pigment to the substrate.
resins or oils.
Thinners and solvents; such as It is the volatile part of the vehicle. Its function is to
petroleum ether, toluene, xylene. dissolve the binders, adjust the paint viscosity, and give
homogeneous, regular, and uniform thickness on the
coated surface.
Fillers; such as clay, talc, gypsum, Pigment extender, or fillers, reduce the paint cost and
and calcium carbonate. control the rheorological properties (viscosity) of
paints.

Table (1) Paints Constituents (continue)

Constituent Function
Other additives
Driers, as cobalt, lead, zinc, To accelerate the drying of the paints.
zirconium, manganese, calcium,
barium.
Anti-skinning agents It is added to the paints (unsaturated), to prevent the
solidification of paints surface during storage.
Anti-settling agents To improve the dispersion efficiency of the pigments
into the vehicle, to prevent the settling of pigments
during storage.
Plasticizers; These materials are To improve the elasticity of paint films, and to
special types of oils, phthalate minimize the paint films tendency for cracking.
esters or chlorinated paraffins.
Dispersants, wetting agents, fire To give the paint specific property for specific purpose
retarding, anti-floating, anti- or application.
foaming,…etc.
Paint Formulations
Proper paint formulations depend upon raw materials selection and accurate calculation of the
amounts of its constituents. Generally, paint is a blend, in which pigments and fillers are
suspended in a liquid. The paint formulations are related to their applications. Generally paints are
used to hide the original surface, providing a certain color, resisting the weathering conditions,
washability, gloss, and protecting surface from corrosion. The selection of pigments, fillers, and
carrying liquids (vehicles) is necessary for a proper paint. In general, pigments should be opaque to
ensure good covering power, and chemically inert to secure stability, and non toxicity. To predict
some properties of paints such as ease of painting, gloss, washability for a certain formulation, the
pigment volume concentration (PVC) in paint is used as indicator.
volume of pigment in paint

Pigment volume concentration (PVC) =
(Volume of pigment in paint + volume of
nonvolatile vehicle constituents in paint)
Indicator values for pigment volume concentration in paints, is shown in table (2).
Table (2) Pigments Volume Concentration (PVC)
Paints Type Indicator Values
Matt paints 50-75%
Semigloss paints 35-45%
Gloss paints 25-35%
Exterior household paints 27-36%
Metal primers 25-40%
Wood primers 35-40%
2.1.2 Other Raw Materials
Chemicals; are consumed at the facility for different purposes:
• Chemicals used are organic solvents (ether, chloroform, ketones,

esters, xylene, toluene, hexane, ethyl and methyl alcohol’s), acids
(acetic, boric, oxalic, benzoic, hydrochloric, sulfuric), alkalis (sodium,

potassium and ammonium hydroxides), potassium chloride, sodium

sulfate, sodium thiosulphate potassium iodide. These chemicals are
used in the production processes, and in the quality control
laboratories for raw materials and products.
• Biocides and antifouling agents are used in the manufacture of the
antifouling and wood preservatives paints, and they are also used in
the manufacture of water-based paints to prolong their life time.
• Water-alkali solutions, and solvents for equipment cleaning and
washing, between batches.
• Detergents and antiseptics for floor cleaning.
Lube oil; is used in the garage and workshops.
Packaging materials; different types of packaging materials are used (aluminum foil, metallic and
plastic containers, tin sheets, and cartons).
2.1.3 Utilities
Steam; is generated in boilers that use either Mazot (fuel oil), solar (gas oil) or natural gas as fuel.
Steam is used for providing heat requirements and in some large facilities for electric power
generations.
Water; is used as process water, as rinse water for equipment and floor, as boiler feed water, as
cooling water and for domestic purposes. Boiler feed water is pretreated in softeners to prevent
scale formation. Water may be supplied from public water lines, wells or canals. The type of water
supply will dictate the type of pretreatment.
Note: Defining the inputs and outputs helps to predict the

expected pollutants.
2.1.4 Equipment Used in Paints Industry

1. Mixers
Mixers are used to achieve homogeneity between different components, specially in the production
of varnishes or water-based paints. Mixers are used in the following operations:
• Mixing oils or resins.

• Mixing pigments and fillers with coating materials.
• Decreasing the viscosity of resins, and varnishes.
• Mixing additives with paints or varnishes.
• Adding solvents or diluting agents (thinner) to paints, to adjust the viscosity.
• Preparing emulsion (water-based) paints.
There are many types of mixers used in paint industry, they differ in their suitability for different
applications. Choice of mixer type depends on the following:
• Viscosity: mixers types used in preparing pastes differ from those used in the
production of low viscosity paints.

• Density difference between components: achieving the desired homogeneity

depends on the type of impeller, blades design, mixing speed, and inclination of
impeller axis with respect to mixing tank axis.
• Solid particle size: Some components, such as pigments agglomerates, have
relatively large particle size compared to other components. Also volatility of
solvents affects the design of mixers and the need for cooling.
The following are different types of mixers:
• Manual mixers.
• Automatic mixers.
• Kneaders.
• Colloid mills.
• Rotary churns.
• Mixing by air streams.
Figures (1-14) shows the types of impellers or mixers used in paints industry.
The mixers usually consists of mixing tank, usually vertical, and one or more impeller(s) driven by
electrical motor, the mixing tank may also have vertical baffles. The impeller consists of a shaft
assembled with one or more mixing blades propellers. Propellers can be divided into two main
types, axial and radial flow propellers.
Figures (1-6) show axial flow propellers, the type shown in Figure (1) is considered the most
common type in paints industry. The impeller in figure (4) is fixed in the wall of mixing tank with
suitable inclination, it can be also fixed vertically at the axis of mixing tank using vertical baffles.
Such impellers rotate at speeds between 1150-1750 rpm. The vertical type shown in Figure (5)
usually rotate at speeds between 350-420 rpm via gearbox and it is used in preparing colloids. The
inclined high-speed type is used for the preparation of emulsions. The type shown in Figure (6),
which fixed in the side of mixing tank, is used in mixing solid particles free liquids.
Figures (7- 10) show radial flow propellers, which have blades parallel to propeller shaft axis.
Turbine propellers in figures (7, 8) rotate the mixing tank contents in circular motion in both
vertical and axial directions. The diameter of paddle propellers shown in Figure (9), reaches 60%
of mixing tank diameter and rotates with relatively low speeds.
Figures (11 and 12) show paddle stirrers, which are used in mixing high viscosity liquids or pastes,
whereas Figure (13) shows anchor stirrers which are used for very high viscosity liquids or pastes.
This type has a small clearance between the mixing propeller and mixing tank walls. Figure (14)
shows the multiple vane stirrer, and figures (15 and 16) the motion of the inclined propellers.
Figures (17) shows kneaders used in the production of putties. The kneader consists of a separate
tank which can be fixed in the mixer or transferred with its contents to the packing unit. This
system helps in weighing the tank content before mixing and to clean the mixing vessel in the
cleaning unit. In this system the mixers can be elevated vertically or laterally as shown in Figure
(18).
Figure (19) shows a horizontal kneader consisting of a U-shaped vessel in which two mixers with
special shape rotate in different directions with small clearance between them. There are other
types of kneaders which can be heated by steam or cooled by water in order to control the viscosity
of the mixture.
2. Mills

Paints industry uses different types of mills such as roller mills or ball mills, etc.. Figure (20)
shows three-roller mills in which each roller rotates in the opposite direction of the others and with
different speeds with ratio 1:3:9. The clearance between each two rollers must be controlled
accurately to maintain the desired finesse of dyes. This type of mills leads to the desired
homogeneity as the dye is dispersed into its particles. This type of mills is open and therefore
cannot be used in grinding of paints which contain high volatility solvents as solvent emissions to
the atmosphere could occur.
Another type of mills is the ball mills. This type consists of a cylinder rotating about its horizontal
axis and containing the grinding balls which may be made of steel or pebbles. If steel balls are
used the cylinder lining will be also made of steel and is used only with dark color paints. But if
the balls are made of pebbles or ceramics the cylinder lining will be made of ceramic or silica and
can be used with white or light color. The grinding efficiency and fineness of particle depend on
the dimensions of the cylinder, speed of rotation, balls size and balls density. In some mills the
length of the cylinder is equal to its diameter, but to maintain higher degree of fineness mills with a
length larger than diameter are used. There are other types in which the grinding operation is made
in steps inside the mill, as the cylinder is separated into sections with screens with suitable sizes
separating the sections. The initial grinding is done in the first section and the final grinding is
done in the final section. In some types of theses mills bars are used instead of balls in order to
obtain particles with slightly different sizes. This type of mills is suitable for dry grinding or
grinding of colloidal particles.
The roller mill and ball mill are used in small factories. Presently, the most common used mills, in
large modern factories, are sand mills (vertical or horizontal) and dyno mills.
The relations between the internal diameter of ball mills and the diameter of balls are shown in
table (3).
Table (3) Relations between the internal diameter of ball mills and the ball diameter
Internal diameter Ball diameter (cm) & their percentage
30 – 60 1.5 (70%), 2.5 (30%)
90 – 120 1.5 (30%), 2.5 - 4 (60%), 4 - 5 (10%)
120 – 150 2 – 2.5 (85%), 5 – 6.5 (15%)
3. Filters
During the manufacturing steps in paints or varnishes industry or during the oil heating process the
liquids are contaminated by foreign matters that fall into them. Moreover the paint may contain
particles that were not ground to the required size or some polymers that didn’t dissolve. Some
surface hardness may also exist. For all the previous reasons, paints and varnished liquids must be
purified by one of the following methods:
• Single cylinder mill: It can work as a screen as all large pigments particles and
foreign particles will be separated in the mill hopper.
• Fine screens.
• Filter press.
• Centrifugal separator for varnishes purification.
• Settling for varnishes purification.
4. Packing machines

The packing may be manual, semi-automatic, or automatic according to the size of production.
There is a number of packing machines differing in speed and packs handling.

Fig. (2)
Fig. (1)
Fig. (3)
Fig. (4)

Fig. (5) Fig. (6)
Fig. (7) Fig. (8)
Fig. (9)
Fig. (10)

Fig. (11) Fig. (12)
Fig. (14)
Fig. (13)
Fig. (15) Fig. (16)

Fig. (18)
Fig. (17)
Input
Knife
Output
Low Medium High
speed speed speed
Fig. (19) Fig. (20)

2.2 Production Lines

Table (4) presents the various production lines and service units that
could be present in a facility.
Note: Knowledge of the processes involved in each production line and service
unit allows the prediction of pollution hazards and expected violations and
helps determine possibilities for implementing cleaner technology.
Table (4) Production lines and service units in paints industry
Production Lines Service Units

Water-based paints Heating furnaces (Dow-therm oil heater)
Solvent-based (household) paints Cooling towers
Solvent-based (industrial) paints Solvent recovery unit
Printing inks production line Compressors
Varnishes production line Boilers
Resins production line Generators
Laboratories
Mechanical & electrical workshops
Garage
Storage facilities
Wastewater Treatment Plant
Restaurant and Housing complex
Large plants use huge number of raw materials and chemicals, and produce a multitude products
for different applications. Paints industry is characterized by batch processing, which helps adjust
the color and properties of paints.
The unit operations used for paints manufacture are shown in Figure (21). These unit operations
are mainly physical (mixing, grinding, filtration and packaging).
Chemical conversions are involved in the manufacture of the constituents of paints as well as in
the drying of the film on the substrate. These constituents are either exported or purchased from
another chemicals production plant, therefore, the chemical processes involved in the production
of these constituents will not be addressed in this manual.
The manufacture procedures illustrated in Fig. (21) are for a mass-production of paints. The
weighing, assembling, and mixing of the pigments and vehicles take place on the top floor. The
mixer may be similar to a large dough kneader with sigma blades. The batch masses are conveyed
to the next operation, where grinding and further mixing take place. A variety of grinding mills
may be used. One of the oldest methods is grinding, or dispersion, between two buhrstones;
however, ball-and-pebble mills and steel roller mills were the principal grinding mills used until
recently. Sand mills, high-speed agitators, and high-speed stone mills are being used increasingly
to grind paints and enamels.
The types of pigments and vehicles are dominant factors in the choice of the equipment used. The
mixing and grinding of pigments in oil require skill and experience to secure a smooth product.

After mixing, the paint is transferred to the next operation, where it is thinned and tinted in agitated
tanks, which may hold batches of several thousand liters. The liquid paint is strained into a transfer
tank or directly into the hopper of the filling machine. Centrifuges, screens, or pressure filters are
used to remove nondispersed pigments. The paint is poured into cans or drums, labeled, packed,
and moved to storage, each step being completely automatic

23 Paints Industry- Self-Monitoring Manual
Solvents
Driers
Plasticizers
Thinning Labeling
Mixing Milling Filling
Tank Machine
Additives except driers Machine
Feed Hopper
Belt conveyor
Binder (oils or resins)
Tank Tank
Screens
Weigh
Pigments & Fillers Plate form Tank Packaging Storage
Scale Sludge
Fig. (21) Flowchart of Paints Manufacturing Steps

2.2.1 Production of solvent-based (household/ industrial) Paints

The solvent-based paints differ according to their applications and therefore the raw materials
and additives (adhesives, driers, heat resisting agents, …) used in their production. They
include industrial and household paints. The industrial paints are used for industrial purposes
such as motor vehicle, washing machine, and pipelines painting operations. The household
paints are used to cover buildings and furniture.
Figures (22, 23) present the main operations in the solvent-based household/ industrial paints
production lines, the input to the units and the pollution sources.
Mixing Alkyd resins or vegetable oils (boiled linseed oil), fatty acids,
pigments (titanium dioxide), fillers (talc, and calcium carbonate), and
plasticizers are weighed, and fed automatically to the mechanical
mixers.
Grinding After mixing, the mixture (batch) is transferred to the mills for further
mixing, grinding, and homogenizing. The type of used mill is related
to the type of pigments, vehicles, and fillers.
Intermediate storage In some plants, after grinding, the batch is transferred to an

intermediate storage tank, because the batch may need further
grinding to obtain the required degree of homogeneity.
Thinning/ dilution The batch is then transferred from the intermediate storage tank to a
mixer for thinning and dilution, where solvents, and other additives
are added.
Filtration and After thinning, the batch is filtered in a filter, to remove nondispersed
finishing pigments and any entrained solids. Metal salts are added to enhance
drying (cobalt, lead, zirconium).
Packaging and The paint is poured into cans or drums, labeled, packed, and moved to
storage storage, each step being completely automatic.

Figure (22) Solvent-based (household) Paints Production Line
Inputs Processing Steps

Pollution Sources
Pigments
Titanium dioxide (TiO2)

Raw Materials Spills or
Filler (Talc, Calcium Carbonate) leaks
Linseed Oil
Alkyd resin
Mixing
Solvent (Turpentine) Spent solvent (Mixers
washing & cleaning)
Spent Cooling Water (closed

or open circuit)
Rollers Cooling Water Spent Solvent (mills
Grinding
washing & cleaning)
Cobalt drier Spent solvent (vessels & tanks

Lead drier washing or cleaning)
Finishing
Zirconium drier
Solid waste
(sludge from filter press)
Filtration
Packages Leaks or spills

Packaging &
Storage
Solvent – based
paints (building)
* Work place pollution parameters are VOCs, particulates, and noise.

** Spills or leaks could occur through the whole process, and may contaminate the water if
discharged to the sewer.
*** Chemicals empty containers are generated, and considered hazardous. Those hazardous
solid waste should be safely disposed into a landfill.

Figure (23) Solvent-based (Industrial) Paints Production Line

Pollution Sources
Styrenated alkyd resin

Filler (Talc, Calcium Carbonate) leaks
Ti O2
Acrilamide Resin
Mixing
Epoxy Resin Spent solvent (Mixers
Phenolic Resin washing & cleaning)
Iron Oxide pigment
Vinyl Resin
or open circuit)
Rollers Cooling Water

Spent Solvent (mills
Grinding
washing & cleaning)
Toluene Spent solvent (vessels & tanks

washing or cleaning)
Finishing
Xylene
Solid waste
(sludge from filter press)
Filtration
Packages Leaks or spills

Packaging &
Storage
Industrial Paints
* Work place pollution parameters are VOCS, particulates, and noise.


2.2.2 Production of Water-based Paints

Figure (24) presents the main operations in the water-based production line, the input to the
units and the pollution sources. The water-based paints manufacturing steps are similar to
those of the solvent-based paints production, except that the raw materials are added to the
mixture in different order, and water is used instead of solvent as thinner.
Mixing and thinning/ Mixing in water-based occurs in two steps. In the first step (very high
dilution speed mixing) all inorganic materials dispersing agents, and wetting
agents are mixed thoroughly. In the second one, polymer, glycol,
freeze thaw agent, etc… are added and mixed at low speed.
The pigments, acrylic resins, and extenders most used are water-
dispersible grades of titanium dioxide, zinc sulfide, lithophone, and
regular grades of barium sulfate, mica, diatomaceous silica, clay, and
magnesium silicate.
Grinding After mixing, the batch is transferred to the mills for further mixing,
grinding, and homogenizing. The type of used mill is related to the
type of pigments, vehicles, and fillers.
Mixing of additives The batch is then transferred to a mixer, where ammonia and
dispersants are added to water, followed by pigments (premixed and
ground in a mill). plastisizers, anti-foaming agents, preservative
solution (usually chlorinated phenols) and polyvinyl acetate to give
the required characteristics. Other additives are needed for specific
purposes.
Intermediate storage In some plants, after that, the batch is transferred to an intermediate
storage tank, because the batch may need further grinding to obtain
the required degree of homogeneity.
Filtration and The batch is then filtered in a filter to remove nondispersed pigments
finishing and any entrained solids.

Figure (24) Water-based Paints Production Line

Pollution Sources
Water
leaks
Titanium dioxide (TiO2)
Talc
Defoamer Mixing
Mixers Washing & Cleaning
Calcium Carbonate/ other fillers
Wastewater
Silica

or open circuit)
Rollers Cooling Water Grinding Mills Washing & Cleaning
Wastewater
Water + Ammonia
Vessels or tanks washing &
Emulsion polymer cleaning wastewater
Finishing
Coalescents & other additives
Solid waste
(sludge of filter press)
Filtration
Packages Packaging & Spills or leaks

Storage
Water – based paints
* Work place pollution parameters are ammonia, particulates, and noise.


2.2.3 Production of Printing Inks

Figure (25) presents the main operations in the printing inks production line, the input to the
units and the pollution sources. The printing inks manufacturing steps are similar to those of
the paints production.
Printing inks consist of a fine dispersion of pigments or dyes in a vehicle which may be a
drying oil with or without natural or synthetic resins. Drying oils or petroleum oils and resins
are used, although the newer synthetic resin systems are finding great favor because they are
quick-drying and their working properties are excellent. There are three main types of printing
inks; black inks, paste inks, and liquid inks. The paste inks are used in manufacturing of pens,
and the black inks in newspaper print, and the liquid inks for printing on metals, plastics,
carton.
Mixing Binder (resins/ oils), pigments (in paste, and liquid inks) or carbon
black (in black inks), and solvent or water are used according to the
type of ink manufactured. These raw materials are fed automatically
to the mechanical mixers.
Grinding After mixing, the batch is transferred to the mills for further mixing,
grinding, and homogenizing. The type of used mill is related to the
type of pigments, vehicles, and fillers.
Intermediate storage In some plants, after grinding, the batch is transferred to an

intermediate storage tank, because the batch may need further
grinding to obtain the required degree of fineness.
Filtration and After thinning, the batch is filtered in a filter (usually filter press) to
finishing remove nondispersed pigments and any entrained solids. Other
additives are added to the batch for special purposes.

Figure (25) Printing Inks Production Line

Pollution Sources
Paste inks
Pigments Spent Solvent
(Mixers Cleaning)
Binder (oil/ resin) Mixing
Spent Cooling
Cooling Water (Open or Closed Circuit)
Grinding
Intermediate storage
Packages
Filtration &
Packaging
Paste inks
Carbon Black Black Inks Spent Solvent

(Mixers Cleaning)
Binder (oil/ resin)
Mixing
Plasticizer
Cooling Water Spent Cooling Water

Grinding
Packages
Filtration&
Packaging
Black inks
Liquid Inks
Carbon Black Spent Solvent(Mixers Cleaning)
Binder (oil/ resin)
Mixing
Plasticizer Carbon black particulates
(work place)
Cooling Water Spent Cooling Water

Grinding
Spent Solvent
Additives (adhesives,
(vessels Cleaning)
heat resistant) Finishing
Packages
Filtration&
Packaging
Liquid inks
* Work place pollution parameters are VOCS, particulates, and noise.
solid waste should be safely disposed into a special landfill.

2.2.4 Production of Varnishes

Figure (26) presents the main operations in the varnishes production line, the input to the units
and the pollution sources. A varnish is an unpigmented colloidal dispersion or solution of
synthetic and/or natural resins in oils or urethenated oils dissolved in true solvents. These are
used as protective or decorative coating for various surfaces specially wood.
Mixing Only one production step occurs, in which the binders (natural resin +
oil, nitro cellulose + short alkyd resin, urethenated oil, synthetic
resins,…etc.) are thoroughly mixed with true solvents. After thorough
mixing, the required additives are added. These raw materials are fed
automatically to a mixing container.
Filtration and After mixing has been finished, the batch is filtered in a filter, to
finishing remove any entrained solids.
Packaging and The varnish is poured into cans or drums, labeled, packed, and moved
storage to storage, each step being completely automatic.

Figure (26) Varnishes Production Line

Pollution Sources
Binder (oil/ resin)
Aromatic & aliphatic Solvents Mixing Caustic Wash wastewater from
reactor cleaning
Additives
Sludge
(Solid Waste)
Filtration
Packages Packaging & Spills or leaks

Storage
Varnishes
* Work place pollution parameters are VOCS, and particulate.


2.2.5 Production of Alkyd Resins

Figure (27) presents the main operations in the resins production line, the input to the units
and the pollution sources.
Reaction Any resin that is a polymer of an ester type monomer is a polyester

resin. In this broad sense alkyds are polyesters, however, general
usage restricts the term alkyd to polyesters that are modified with a
triglyceride oil or the acids of such an oil.
Generally alkyd resin means the reaction product of a polybasic acid,

a polyhydric alcohol, and a monobasic fatty acid or oil. Alkyds differ
according to the type of oil which depends on whethere it is oxidized
or nonoxidized, and on the length of the chain short, medium, or long.
The reaction basic to all polyester resins, including alkyds, is a
condensation reaction of carboxyl groups with hydroxyl groups,
splitting out water and forming an ester.
In this process raw oils (linseed, soybean, safflower, sunflower,

dehydrated castor), glycerol ( or penta erythretol), phthalic anhydride
(or maleic anhydride), and solvents are fed to a catalytic reactor using
heavy metal oxides (lead oxides) as catalyst. The acids typified by
phthalic anhydride, contain two carboxylic acid groups, this gives
them a reactive capacity or potential functionality of two glycerols.
The reaction conditions (temperature and pressure) depend on the

specifications of the final product as short, medium, or long alkyd
resin. Since the reaction is reversible, its completion requires removal
of water. The addition of solvents (e.g. xylene) facilitates the removal
of water by forming an azytropic vapors mixture.
Xylene Recovery (Xylene/ Xylene recovery can be performed by one of the following operations:
water Separation)
Condenser/ decanter, where the xylene/ water vapors are first cooled
in a condenser and the resulting liquid allowed to separate in a
decanter into a water rich layer and a xylene rich layer. The latter is
recycled to the reactor.
Gas/ liquid separator, where the water/ xylene vapors mixture is

introduced to a gas-liquid separator, which is fed with make-up
xylene. Cooling to the dew point of the vapors allows the separation
of the xylene rich vapor from the water solution. The Xylene rich
vapor is recycled to the reactor, and the contaminated water is
discharged to the internal sewer system of the plant.
Cooling The produced resin is cooled to about 200oC, by cooling water circuit.
Dilution The batch is transferred to tanks, where it is diluted with suitable

solvent.
Filtration After dilution, the batch is filtered in a filter (usually plate and frame

filter press), to remove any entrained solids.
Properties adjustment After filtration, additives are added to adjust the properties of the
resin.
Packaging and The produced resin is then stored in barrels (for sale) or in tanks to be
storage used in the solvent-based paints manufacturing.

Figure (27) Alkyd Resins Production Line

Pollution Sources
Oil or fatty acids Humidity & heat stress
Alcohols (Penta earithritol, or glycerol) (work place)
Phathatic anhydride or maleic

anhydride Reactor
250-300ºC Caustic wash wastewater from
Solvents (e.g. xylene) reactor cleaning
(Heating by
Lead Oxide (catalyst) Dowtherm oi1
Heater)
Xylene Recycled
Additives (driers; Mg, Co, pb, Ba)
Resin Water/
Wastewater contains traces
Xylene vapors
Xylene (make-up) of Xylene
Separation G/L
Separator
Spent solvent from tanks

Cooling, Dilution, cleaning
Solvent (Turpentine) Adjustment
Sludge
(Solid waste)
Filtration
Intermediate
Storage
Alkyd Resin to Solvent-

based paints, inks and
varnishes production lines
* Work place pollution parameters are VOCS, and particulates.

** Spills or leaks could occur through the whole process, and may contaminate the water if discharged
to the sewer.

2.3 Service Units, Description and Potential Pollution Sources

Medium and large size plants will have some/all of the following service and
auxiliary units. These units can be pollution sources and therefore should be
inspected and monitored. Figure (28) shows the various service units with their
corresponding raw materials and potential pollution sources.
2.3.1 Boilers
Boilers are used to produce steam which is used to supply heat to the processes.
Although, processes in the production lines do not require steam, some paints
facilities have boilers to supply heat to the solvent recovery unit.
The gaseous emissions, due to fuel (Mazot or solar) burning, contain primarily
particulates (including heavy metals if they are present in significant concentrations
in the fuel), sulfur and nitrogen oxides (SOx, and NOx), carbon oxides (CO, and
CO2), and volatile organic compounds (VOCs). The concentration of these pollutants
in the exhaust gases depends on firing configuration (nozzle design, chimney height),
operating practices and fuel composition.
Wastewater is generated as blow-down purged from boilers to keep the concentration
of dissolved salts at a level that prevents salt precipitation and consequently scale
formation. The blow-down will be high in (TDS)
Also large quantities of water is used for cooling the turbines, therefore, spent cooling
water is generated. Also steam condensate is generated as wastewater. The amount of
wastewater generated depends on whether cooling is performed in open or closed
cycle, and on the recycling of steam condensate (may return to the boiler).
Wastewater contamination may arise from lubricating and fuel oil.
The heat stress may be high, in work place, in case of absence of thermal insulation
for boilers and steam pipelines.
2.3.2 Water Treatment Units

There are different treatment processes, depending on the water source and the
application in the industry.

i) Water softening for medium hardness water

calcium and magnesium ions are removed from hard water by using cation
exchange resin (sodium form). When the exchange resin has been loaded
with Ca and Mg ions, it is regenerated to the sodium form by using a salt
solution (sodium chloride) in the pH range of 6-8. This is performed by
backwashing with the salt solution. The treated water has a hardness level of
less than 1 ppm expressed as calcium carbonate.
ii) Water softening for very high bicarbonate hardness

Water from wells and canals is pre-treated before softening. Water is treated
first by the lime process, then by cation exchange resin. The lime process
reduces dissolved solids by precipitating calcium carbonate and magnesium
hydroxide from the water. It can reduce calcium hardness to 35 ppm if
proper opportunity is given for precipitation. A coagulant such as aluminum
sulfate (alum) or ferric sulfate is added to aid magnesium hydroxide
precipitation. Calcium hypochlorite is added in some cases.
Currently the use of organic polyelectrolytes is replacing many of the

traditional inorganic coagulant aid. Sludge precipitates and is discharged to
disposal sites whereas the overflowing water is fed to a sand filter followed
by an activated carbon filter that removes any substances causing odor and
taste. A micro filter can then be used to remove remaining traces.
A successful method to accelerate precipitation is contacting previously

precipitated sludge with the raw water and chemicals. The sludge particles
act as seeds for further precipitation. The result is a more rapid and more
complete reaction with larger and more easily settled particles.
iii) Desalination (Reverse Osmosis/ Electro-dialysis)

Desalination can also be performed by reverse osmosis. In this process water
is forced through a semi-permeable membrane by applying pressure.
2.3.3 Cooling Towers

Moderate quantities of cooling water is used for cooling furnaces and the formation
equipment in this industry. Cooling towers provide the means for recycling water and
thus minimizing its consumption. The cooling effect is performed through partial
evaporation. This causes an increase in the concentration of dissolved salts which is
controlled by purifying some water (blow-down). The blow-down will be high in
TDS and will represent a source of pollution to the wastewater to which it is
discharged.
2.3.4 Laboratories
Laboratories, in paint industry, are responsible for:
• Testing raw materials for compliance with required standards.

• Quality control of products to check agreement with standard

specifications.
• Check the physical, chemical, and mechanical properties of final products.
Chemicals, including hazardous materials, are used in laboratories. Storage and handling should be checked by the
inspectors, in addition to the disposal of chemicals empty containers, which is considered as hazardous waste.
2.3.5 Workshops and Garage

Workshops are very important in the paint industry, where they are divided into
mechanical and electrical workshops. They are responsible for repairing and
maintenance of the equipment. Environmental violation could be due to:
• Noise
• Rinse water contaminated with solvents and lube oil
Pollution in the garage will depend upon the services offered. The presence of
a gasoline or diesel station implies fuel storage in underground or over the
ground tanks that require leak and spill control plans. Replacing lube oil
implies discharge of spent oil to the sewer system or selling it to recycling
facility.
2.3.6 Storage Facilities

The specifications for the storage facilities depend on the nature and properties of the
stored material:
• Environmental laws stipulate that special system should be applied for

handling and storing hazardous chemicals.
• Fuel is kept in under/or above ground tanks. Storage requires proper
preventive plans for spills and leaks.
2.3.7 Wastewater Treatment Plants

Although a WWTP is a pollution abatement measure, it has to be inspected and
monitored for potential pollution. Pollution may be due to malfunctioning or
improper management. A paints production facility discharges wastewater, high in
organic load. From time to time, due to batch processing, peak load will be
discharged. They may be due to internal processes, to seasonal fluctuations, to lack of
control or a “force majeur” situation such as power collapse. The potential pollution
sources are:
• Sludge which represents a solid waste problem.

• Treated water could represent a water pollution problem if not
complying with relevant environmental laws.

2.3.8 Dow-therm Oil Heater

Heating oil is heated in a furnace, where fuel is burned to produce the
necessary energy. The pollution is expected to be generated from oil leaks or
spills, which may contaminate the wastewater, if discharged to the sewer
system. The gaseous emissions generated from stacks, due to fuel (Mazot or
solar) burning in the heater.
2.3.9 Solvent Recovery Unit

The spent solvent generated from equipment cleaning, in the solvent-based
production line, could be recovered by vacuum distillation of the spent
solvent, then condensation of solvent vapors. Spent solvent could be recovered
through distillation process, with about 90% solvent yield achievable from the
still, and 10% sludge (removed paints). The solvent can be recycled for reuse
in dilution or cleaning.
The sludge (precipitates) generated from the solvent recovery process could be
dried and safely disposed into a landfill, or used in the production of a new
paint product (a primer).
2.3.10 Restaurants, Washrooms and Housing Complex

These facilities will generate domestic wastewater as well as domestic solid waste.

Figure (28) Service Units and their Related Pollution Sources

Inputs Service Units Pollution
Water Treatment Sludge

Lime + chemicals
Softening Units Back- wash w.w
Boiler Blow Down (TDS)

Fuel Boilers
Flue Gases
Steam
Cooling Cooling Tower Blow-

Hot Water Towers down (TDS)
Wastewater Hazardous
Laboratory
Chemicals Materials (handling)
Lube Oil
Electrical & Mechanical
Floor and workshops Oily Rinse Water
equipment rinse
water Solid Wastes
Cleaning Chemicals
Fuel Oily rinse water

Oil Garage
Rinse Water Solid wastes
Raw materials Spills
Fuel Storage Raw material

Chemicals
Hazardous
Products material
Wastewater Treated wastewater

WWTP Sludge

Figure (28) Service Units and their Related Pollution Sources (continue)
Inputs Service Units Pollution
Fuel Flue Gases

Dow-therm oil heater
Spent cleaning solvens
Solvent Recovery Sludge (removed
Unit
paints)
2.4 Emissions, Effluents and Solid Wastes

Table (5) summarizes the major polluting processes, process inputs, their outputs, the
pollution parameters and corresponding impact.
2.4.1 Air emissions

There are two sources of air emission in the paints industry.
• Exhaust gases, resulting from fuel consumption used to generate steam from
boilers, and to heat oil in the heater (Dow-therm oil heater).
The violating parameters would be; particulate matters (PM10), sulfur
oxides, nitrogen oxides, carbon monoxide.
• Fugitive emissions; volatile organic compounds (VOCs) as solvents and other

low molecular weight compound (in solvent-based paints, inks, alkyd resins
and varnishes), ammonia (in water based paints), solvents, particulate matters
(PM10), these emissions resulting from the operation processes (mixing,
grinding, packaging,…) in the workplace.
2.4.2 Effluents
The major pollution load of the paints industry is the wastewater from the various
sources. Liquid effluent is generated from equipment, vessels, tanks, mixers, mills,
and packages, cleaning or washing process, between batches.
The cleaning process is performed using water (in water-based paints), or using
solvent (in solvent-based paints). This effluent contains oil& grease, BOD, COD,
ammonia, solvents, and heavy metals (lead, chromium, and mercury), and is
considered hazardous waste.
Specific effluents are:

• Caustic wash wastewater generated from vessels and reactors cleaning. This
effluent contains caustic soda, BOD, COD, heavy metals, and oil& grease. It is
usually pretreated (precipitation and pH adjustment), and recycled for reuse.
The pretreatment process generates sludge, which is considered hazardous
waste.
• Equipment (mixers, mills, tanks, and vessels) and filling machines are
responsible for raw materials and products spills, these leaks could contaminate
the wastewater if discharged to the internal sewer system. (BOD, COD, oil&
grease, and heavy metals).
• Spent solvents used for equipment cleaning in the solvent-based paints

production line. The solvent is recovered by distillation and recycled back. The
nonvolatile materials, sludge (containing paints, solvents, and heavy metals) is
disposed as solid waste, and considered hazardous.
• Blow-downs from the cooling tower and boilers as well as back-wash of

softeners are high in TDS and TSS.
• Spent lube oil from garage and workshops if discharged to sewer will give oily
wastewater (O&G).
• Floor washing and sanitation produces a wastewater containing organic matter,
oil and grease, and traces of the chemicals used for sanitation.
• Out-dated, off-spec, and refused or rejected products.
Typical effluent characteristics of the Egyptian paints industry are shown in

table (6) Typical pollution loads per ton of production are given in table (7).

Table (5) Pollutants Per Process

MAJOR PROCESS PROCESS POLLUTION IMPACT
POLLUTING INPUTS OUTPUTS PARAMETERS
PROCESS
Solvent-based Pigments Accepted product
paints Resins Fugitive VOCs, particulates Work Environment
Fillers emissions
Binding agents Solid waste Chemicals empty Land
containers, paints filters
Solvents sludge
Additives
Spent cooling Contaminated with traces Water
water of chemicals ( O&G,
BOD, COD, TDS, TSS,
S.S, color, pH, heavy
metals )
Spent solvent Contaminated with Water, if
from equipment paints discharged to sewer
cleaning
Losses or leaks to O&G, BOD, COD, TDS, Water

Sewer TSS, S.S, color, pH,
heavy metals
water-based Pigments Accepted product
paints Fillers Fugitive particulates, ammonia Work Environment
Binders (resins/ emissions
oils) Solid waste Chemicals empty Land
Water containers, paints filters
sludge
Ammonia
BOD, COD, TDS, TSS,
metals )
Wastewater from O&G, BOD, COD, TDS, Water
equipment wash TSS, S.S, color, pH,
heavy metals
Losses or leaks to O&G, BOD, COD, color, Water
Sewer pH, TDS, TSS, S.S,
heavy metals
Printing inks Pigments Accepted product
Binder (resins/ oils) Fugitive VOCs, particulates Work Environment
ٍSolvents emissions
BOD, COD, TDS, TSS,
metals )
cleaning


PROCESS
heavy metals
Solid waste Chemicals empty Land
containers, paints filters
sludge
Resins Vegetable oils Accepted product
Binders (resins/ Fugitive VOCs, particulates Work Environment
oils) emissions
Solvents
BOD, COD, TDS, TSS,
metals )
cleaning

heavy metals
containers, filters sludge
Accepted product
Vegetable oils Fugitive VOCs, particulates, acids Work Environment
Oil free Fatty acids emissions vapor
Alcohols/ Glycero Wastewater from Contaminated with Water, if
the reaction xylene discharged to sewer
Penta erythrito
Solvents (Xylene)
Caustic wash O&G, BOD, COD, color, Water
Phthalic anhydride
wastewater from pH, TDS, TSS, S.S,
Maleic anhydride equipment heavy metals
Metal oxides cleaning
heavy metals
BOD, COD, TDS, TSS,
metals )
containers, filters sludge
Packaging Paints products Losses in O&G, BOD, COD, color, Water
wastewater pH, heavy metals
Softeners Raw Water Treated Water
Back-wash TDS, TSS Water


PROCESS
Boilers Treated Water + Blow-down TDS, TSS Water
Condensate recycle
Fuel Flue Gasses PM10, CO2, CO, NOx, Air
SOx
Cooling Towers Water Blow-down TDS, TSS Water
Dow-therm oil Fuel Flue Gasses PM10, CO2, CO, NOx, Air
heater SOx
Solvent Recovery Spent solvents Sludge Solvents and heavy Land
Unit metals
Air emissions solvents Air
(VOCS)
WWTP Process W.W Treated effluent O&G, BOD, COD, TDS, Water
TSS, S.S, color, pH,
heavy metals
Sludge O&G, heavy metals, TSS Soil
Table (6) Typical chemical analysis of paints factory waste effluents
Oil&
pH BOD COD TSS TDS S.S Color
Parameter Grease
mg/1 mg/1 mg/1 mg/1 mg/1 Pt/CO
mg/1
Solvent-based
7.7 66 221 39 353 - 15 28
paints line
Water-based Out-of-
7.7 3000 5930 1485 1659 - 402
paints line range
Printing inks 7.1 220 680 123 403 0.5 40 168
Resins 7.4 615 1344 218 790 3 55 89

Table (7) Typical organic pollution loads in

Egyptian paints industry per ton of
production
Effluent COD TSS TDS Oil&
Plants BOD S.S
flow rate Kg/d Kg/d Grease
kg/d Kg/d
m3/d kg/d Kg/d
Solvent-based
paints line 150 9.9 33.15 5.85 53 - 4.2
Water-based
paints line 2.5 7.5 14.83 3.7 4.15 - 1
Printing inks
2 0.44 1.4 0.25 0.81 0.001 0.34
Resins
90 55.4 121 19.6 71 0.27 8
2.4.3 Solid and Hazardous Wastes

The main sources of hazardous and solid wastes are:
• Empty containers of raw materials and chemicals, contaminated with traces of
chemicals, are considered as hazardous waste.
• Spent bags of the Bag-Filters, contain pigments particulates. This solid waste is
considered as hazardous waste.
• Sludge generated from the solvent recovery unit, and filter press, containing
paints, solvents, and heavy metals, are considered as hazardous waste.
• Outdated, rejected, and off-spec. products. These solid wastes are considered
hazardous wastes.
• Sludge generated from the biological wastewater treatment plant, may contain
heavy metals, and could be considered hazardous.
• Oil separators could be used as a pretreatment before the WWTP or in the

garage, workshops, and storage area. Sludge is generated from the oil
separators and considered hazardous waste.
• Scrap metals generated from workshops and garage.

• Packaging wastes, paper, plastic,…

2.4.4 Work Environment

There are many sources of air emission in the paints industry. These emissions
resulting from the operation processes (mixing, grinding, packaging,…) in the
workplace.
Fugitive emissions; volatile organic compounds (VOC) as solvents and other low
molecular weight compound (in solvent-based paints), ammonia (in water based
paints), particulate matters (PM10) of pigments during unpacking and mixing.
Noise could occur during grinding (near mills).
2.5 Characteristics Specific to the Paints Industry
Proper inspection and monitoring of the paints industry should take into
consideration the following aspects:
• Production lines operate on batch mode, therefore, equipment cleaning and
washing are performed between batches.
• Shock loads are expected and are caused by discharging equipment wash
wastewater, in water-based paints production lines.
• Paints products production rate is seasonal, it increases in summer and

decreases in winter.
• Pollution loads are expected to be higher during start-up and shut-down.
3. Environmental and Health Impacts of Pollutants
3.1 Impact of Air Emissions

Particulates
Particulate matters Recent epidemiological evidence suggests that much of the health damage
from fuel combustion caused by exposure to particulates is associated with particulate matters
and other smaller than 10µm (PM10). These particles penetrate most deeply into the
manufacturing lungs, causing a large spectrum of illnesses (e.g. asthma attack, cough,
processes bronchitis).
Emissions of particulates include ash, soot and carbon compounds, which
are often the result of incomplete combustion.
Lead, cadmium, Chromium, and other metals of pigments, can also be

detected in the production processes.
Chromium pigments Chromium is steel-gray, lustrous metal; body-centered cubic

structure, gray crystals and blue-white hard metal. It is also an
odorless element, insoluble in water. Under strongly oxidizing

conditions, may be converted to hexavalent state & occur as

chromate anions. Chromium is soluble in acids (except nitric)
and strong alkalies.
Chromium is causing irritation to the upper respiratory tract,
severe nasal irritation. Chromium (III), the naturally occurring
form, has low toxicity due to poor membrane permeability and
non-corrosivity, while Cr (VI), from industrial emissions, is
highly toxic due to strong oxidation characteristics and ready
membrane permeability.
Occupational exposure to trivalent chromium and other
chromium compounds by inhalation has been studied in the
chromate manufacturing and ferrochromium industries;
however, exposures all include mixed exposures to both Cr (III)
and Cr (VI). Cr (VI) species is the likely etiological agent in
reports of excess cancer risk in chromium workers. Data
addressing exposures to Cr (III) alone are not available and data
are inadequate for an evaluation of human carcinogenic
potential. Hexavalent chromium is known to be carcinogenic in
humans by the inhalation route of exposure. Hexavalent
chromium compounds are carcinogenic in animal bioassays.
There is sufficient evidence for increased incidence of lung
cancer among workers.
Chromium occurs in nature mostly as chrome iron ore (feo.cr
203). Chromium is present in small quantities in all soils &
plants. Movement from the soil surface to a depth of 10 cm was
observed for all of the seven metals; cadmium, chromium,
copper, molybdenum, nickel, lead and zinc, but most of the
metal (60%-100%, mean 87%) remained in the upper 5 cm of
soil.
Although most of the soluble chromium in surface waters may
be present as Cr (VI), a small amount may be present as Cr (III)
organic complexes. Hexavalent chromium is the major stable
form of chromium in seawater; however, Cr (VI) may be
reduced to Cr (III) by organic matter present in water, and may
eventually deposit in sediments.
Nickel pigments Nickel is a silvery metal, odorless, Excellent resistance to

corrosion and insoluble in water, ammonia; soluble in diluted
nitric acid; slightly soluble in hydrochloric acid and sulfuric
acid.
Nickel metal is well known cause of contact dermatitis in
sensitized individuals. Instances of dermatitis in region of eyes
has resulted from contact with nickel spectacle frames, but eye
itself has not been involved. Histological changes in nasal
mucosa of nickel workers were studied. Nickel is considered
toxic as dust or powder. Nickel is the most frequent metal,

which induces allergic contact sensitization. Nickel

hypersensitivity dermatitis may be initiated by contact with
nickel on the skin. Exposure to industrial nickel dust causes
nickel dermatitis. Sensitivity to nickel may be exhibited from
skin contact … divalent nickel ions can penetrate skin at sweat-
duct & hair follicle ostia, & bind with keratin.
There is sufficient evidence in humans for the carcinogenicity
of nickel sulfate, and of the combinations of nickel sulfides and
oxides. There is inadequate evidence in humans for the
carcinogenicity of metallic nickel and nickel alloys. There is
sufficient evidence in experimental animals for the
carcinogenicity of metallic nickel, nickel monoxides, nickel
hydroxides and crystalline nickel sulfides.
No data was found to suggest that nickel is involved in any
biological transformation in the aquatic environment.
Lead pigments Chronic exposure to lead has been found to produce infertility,
germinal epitheleium damage, oligospermia and testicular
degeneration, decreased sperm motility, and prostatic
hyperplasia. The subjective symptoms of lead poisoning in
working adults are diffuse and include weariness at the end of
the day. The patient is moody and irritable and may fall asleep
watching T.V. Often he loses his interest in leisure- time
activities. Lead poisoning is due to inhalation of lead dust, upon
inhalation, absorption takes place easily from the respiratory
system tract and symptoms develop relatively quickly than oral
ingestion.
Cadmium Cadmium and cadmium compounds are carcinogenic to
humans. They are highly toxic, inhalation (dust or fumes), and
cause throat dryness, cough, headache, vomiting, chest pain,
extreme restlessness and irritability, penumonitis, possibly
bronchopneumonia, and it is irritating to nose and throat.
Inhalation of cadmium dust, fumes, or salts over a number of
years result ion chronic cadmium poisoning, a disease
characterized by distinctive, non-hypertrophic emphysema with
or without renal tubular injury, in which urinary execration of a
protein occurs. Other toxic effects include anemia, eosinophilia,
anosmia, chronic rhinitis, yellow discoloration of teeth, and
bone changes.
Gases
Air pollution by sulfur oxides is a major environmental problem. This compound is harmful to
Sulfur Oxides plant and animal life, as well as many building materials. Another problem of great concern is
acid rain which is caused by the dissolution of sulfur oxides in atmospheric water droplets to
form acidic solutions that can be very damaging when distributed in the form of rain. Acid rain
is corrosive to metals, limestone, and other materials, also deteriorates the agriculture land.

Nitrogen Oxides Nitrogen oxides also dissolve in atmospheric water droplets to form acid
rain.
Carbon Dioxide Combustion of fossil fuels to produce electricity and heat

contribute to the green house effect caused by the formation of
carbon dioxide. The greenhouse phenomenon occurs when heat
radiation from earth is absorbed by the gases causing a surface
temperature increase.
Water Vapor Humidity in workplace is regulated by law 4/1994 due to its

(Humidity) effect on the respiratory system especially for people suffering
from asthma.
Vapors
Ammonia Ammonia is a corrosive and severely irritating gas with a

pungent odor.
Anhydrous ammonia is irritating to the skin, eyes, nose, throat,
and upper respiratory system. Ecologically, ammonia is a
source of nitrogen (an essential element for aquatic plant
growth), and may therefore contribute to eutrophication of
standing or slow-moving surface water, particularly in nitrogen-
limited waters such as the Chesapeake Bay. In addition,
aqueous ammonia is moderately toxic to aquatic organisms.
There is currently no evidence to suggest that this chemical is
carcinogenic.
Ammonia combines with sulfate ions in the atmosphere and is
washed out by rainfall, resulting in rapid return of ammonia to
the soil and surface waters. Ammonia is a central compound in
the environmental cycling of nitrogen. Ammonia in lakes,
rivers, and streams is converted to nitrate.
Toluene Toluene is a volatile organic chemical.

Inhalation or ingestion of toluene can cause headaches,

confusion, weakness, and memory loss. Toluene may also

affect the way the kidneys and liver function. Reactions of
toluene in the atmosphere contribute to the formation of ozone
in the lower atmosphere. Ozone can affect the respiratory
system, especially in sensitive individuals such as asthma or
allergy sufferers. Some studies have shown that unborn animals
were harmed when high levels of toluene were inhaled by their
mothers, although the same effects were not seen when the
mothers were fed large quantities of toluene. Note that these
results may reflect similar difficulties in humans.
There is currently no evidence to suggest that this chemical is carcinogenic.
A portion of releases of toluene to land and water will evaporate.
Microorganisms may also degrade toluene. Once volatilized, toluene in the
lower atmosphere will react with other atmospheric components
contributing to the formation of ground-level ozone and other air pollutants.
Xylene Xylene are rapidly absorbed into the body after inhalation,
ingestion, or skin contact. Short-term exposure of humans to
high levels of xylene can cause irritation of the skin, eyes, nose,
and throat, difficulty in breathing, impaired lung function,
impaired memory, and possible changes in the liver and
kidneys. Both short- and long-terms exposure to high
concentrations can cause effects such as headaches, dizziness,
confusion, and lack of muscle coordination. Reactions of
xylene in the atmosphere contribute to the formation of ozone
in the lower atmosphere. Ozone can affect the respiratory
system, especially in sensitive individuals such as asthma or
allergy sufferers.
There is currently no evidence to suggest that this chemical is
carcinogenic.A portion of releases to land and water will
quickly evaporate, although some degradation by
microorganisms will occur. Xylene are moderately mobile in
soils and may leach into groundwater, where they may persist
for several years. Xylenes are volatile organic chemicals. As
such, xylene in the lower atmosphere will react with other
atmospheric components, contributing to the formation of
ground-level ozone and other air pollutants.
Methyl Ethyl Ketone Methyl ethyl ketone is a flammable liquid. Methyl ethyl ketone
(MEK) (MEK) is used as a solvent. Its extremely volatile characteristic
makes fugitive emissions its primary source of releases to the
environment.
Breathing moderate amounts of methyl ethyl ketone (MEK) for
short periods of time can cause adverse effects on the nervous
system ranging from headaches, dizziness, nausea, and
numbness in the fingers and toes to unconsciousness. Its vapors
are irritating to the skin, eyes, nose, and throat and can damage
the eyes. Repeated exposure to moderate to high amounts may

cause liver and kidney effects.

No agreement exists over the carcinogenicity of MEK. One
source believes MEK is a possible carcinogen in humans based
on limited animal evidence. Other sources believe that there is
insufficient evidence to make any statements about possible
carcinogenicity.
Most of the MEK released to the environment will end up in the
atmosphere. MEK can contribute to the formation of air
pollutants in the lower atmosphere. It can be degraded by
microorganisms living in water and soil.
Methyl Isobutyl Ketone Acute inhalation can cause nose, eye, and throat irritation,
(MIBK) nausea headatche, vertigo, incoordination,…
Methanol is highly flammable. Methanol is readily absorbed from the

Methanol gastrointestinal tract and the respiratory tract, and is toxic to humans in
moderate to high doses. In the body, methanol is converted into
formaldehyde and formic acid. Methanol is excreted as formic acid.
Observed toxic effects at high dose levels generally include central nervous
system damage and blindness. Long-term exposure to high levels of
methanol via inhalation cause liver and blood damage in
animals. Ecologically, methanol is expected to have low toxicity to aquatic
organisms. Concentrations lethal to half the organisms of a test population
are expected to exceed one mg methanol per liter water. Methanol is not
likely to persist in water or to bioaccumulate in aquatic organisms.
Liquid methanol is likely to evaporate when left exposed. Methanol reacts in

air to produce formaldehyde which contributes to the formation of air
pollutants. In the atmosphere it can react with other atmospheric chemicals
or be washed out by rain. Methanol is readily degraded by microorganisms
in soils and surface waters.
Long-term inhalation exposure to low levels of ethylene glycol may cause

Ethylene Glycol throat irritation, mild headache and backache. Exposure to higher
concentrations may lead to unconsciousness. Liquid ethylene glycol is
irritating to the eyes and skin. Toxic effects from ingestion of ethylene
glycol include damage to the central nervous system and kidneys,
intoxication, conjunctivitis, nausea and vomiting, abdominal pain, weakness,
low blood oxygen, tremors, convulsions, respiratory failure, and coma.
Renal failure due to ethylene glycol poisoning can lead to death.
Ethylene glycol readily biodegrades in water. No data are available that

report its fate in soils; however, biodegradation is probably the dominant
removal mechanism. Should ethylene glycol leach into the groundwater,
biodegradation may occur. Ethylene glycol in water is not expected to
bioconcentrate in aquatic organisms, adsorb to sediments or volatilize.
Atmospheric ethylene glycol degrades rapidly in the presence of hydroxyl
radicals.

Acetone is a volatile and flammable organic chemical. Acetone is irritating

Acetone to the eyes, nose, and throat. Symptoms of exposure to large quantities of
acetone may include headache, unsteadiness, confusion, lassitude,
drowsiness, vomiting, and respiratory depression. Reactions of acetone (see
environmental fate) in the lower atmosphere contribute to the formation of
ground-level ozone. Ozone (a major component of urban smog) can affect
the respiratory system, especially in sensitive individuals such as asthmatics
or allergy sufferers.
If released into water, acetone will be degraded by microorganisms or will
evaporate into the atmosphere. Degradation by microorganisms will be the
primary removal mechanism.
Acetone is highly volatile, and once it reaches the troposphere (lower
atmosphere), it will react with other gases, contributing to the formation of
ground-level ozone and other air pollutants.
Petroleum ether is a mixture of hydrocarbons having carbon numbers in the

Petroleum Ether range of C5 through C6, it is used as solvent. Petroleum ether is classified as
reactive and volatile, and it participate in smog formation. Occupational
exposure to petroleum ether can occur through inhalation, dermal contact,
and ingestion. Petroleum ether applied to the skin may induce severe
irritation, its vapor is an irritant of the mucous membranes and respiratory
tract. It also affect the central nervous system, and may cause headache,
fatigue, poor concentration, emotional instability, and impaired memory.
Chloroform is an irritant, its main effect is as a central nervous system and

Chloroform cardiac depressant. Delayed renal and hepatic toxicity may also occurs. It
can be a poison by ingestion and inhalation. General symptoms of exposure
include nausea, vomiting, anorexia, salivation, a sensation of bodily warmth,
headache, chest pain, fatigue, giddiness, drowsiness, and disorientation.
Butyl acetate vapors can affect central nervous system and cause headache,
Butyl Acetate muscle weakness, giddiness, ataxia, confusion, delirium, coma. It also has
and irritating effect to skin, eyes, throat. It causes cough and dyspnea. It may
result to death by respiratory failure.
Butyl acetate has moderate mobility is soil, ans its volatilization is expected
from moist and dry soil, and water surfaces.
The inhalation of ethyl acetate may be damaging to lung, liver, kidney, and
Ethyl Acetate heart. It is also toxic by ingestion. It may cause irritation of the eyes, nose,
and throat. It is expected to have high mobility in soil and it is volatile from
moist soil and water surfaces, its biodegradation in soil is also expected.
Cellosolve can affect the central nervous system causing headache,

Cellosolve drowsiness, and weakness. Long term exposure may affect semen quality.
Cellosolve has a very high mobility in soil, and its biodegradation may occur
rapidly in water.
Butyl cellosolve can affect the central nervous system causing headache,
Butyl Cellosolve drowsiness, and weakness. It penetrates skin easily and has toxic action by
excessive skin exposure. It is also irritating to eyes, nose, and throat. It is
expected to have high mobility in soil and to biodegrade rapidly in soil.
Butyl alcohol vapors irritate and cause cough, it may cause irritation to eyes,
Butyl Alcohol nose, throat, and mucous membrane, headache, dizziness, and drowsiness. In
high concentration it can cause central nervous system depression. It has
high mobility in soil, and it is expected to volatilize from water surfaces

3.2 Impact of Effluents

The environmental impact of the wastewater depends on the receiving water body. The
Ministry of Irrigation has set limits for the pollutants in the wastewater discharged into
agriculture canals and drains as well as the Nile river for their detrimental effect on
agriculture. The parameters of relevance to the paints industry are O&G, BOD, COD, TSS,
TDS, S.S, heavy metals, temp., color, and pH.
Discharge of polluted wastewater high in BOD, O&G, and COD into lakes and sea can cause
eutrofication and impact bio-diversity. Eutrofication is a natural aging process in which the
water becomes organically enriched, leading to increasing domination by aquatic weeds,
transformation to marsh land, and eventually to dry land. Eutrofication can be accelerated by
human input of nutrients. Die-off and settling of plant growth results in sediment oxygen
demand, which tend to decrease dissolved-oxygen levels. The organic material in wastewater
stimulates the growth of bacteria and fungi naturally present in water which then consume
dissolved oxygen. In addition heavy metals could be toxic to the plants and aquatic life
because they interfere with many beneficial uses of the water..
Discharge of high O&G, BOD, and COD loads to the public sewer system will
have an indirect environmental impact. Increased loads can cause malfunction
of the domestic wastewater treatment plant.
Spent lube oils from garage and workshops could be a cause for concern if
discharged into the sewer system because they tend to coat surfaces causing
maintenance problems. Also, if they discharged to surface waters, they can
interfere with the aquatic life in these surface waters and create unsightly
floating matter and films.
In addition, spent solvent and caustic wash wastewater generated from

equipment washing and cleaning could make corrosion of the internal sewer
system of the plant, if discharged.
3.3 Environmental Impact of Solid and Hazardous Wastes

Most of the generated solid waste is considered hazardous waste, and should be dumped in
disposal sites for hazardous waste.
Sludges generated from the filters, solvent recovery unit, and WWTP (if exist) containing
heavy metals, could contaminate the soil, surface water and underground water, if disposed.
Empty containers of raw materials and chemicals, may be sold to contractor. This solid
hazardous waste could affect the human health, if used domestically (food packaging,…).

Egyptian Laws and Regulations
There are a number of laws and regulations that address the different environmental
violations. The following are the laws applicable to the paints industry.
Concerning Air Emissions
Article 40 of Law 4/1994, article 42 of the executive regulations and annex 6 deal with
gaseous emissions from combustion of fuel. The statutes relevant to the fuel combustion are:
• The use of solar oil and other heavy oil products, as well crude oil shall be prohibited in
dwelling zones.
• The sulfur percentage in fuel used in urban zones and near the dwelling zones shall not
exceed 1.5%.
• The design of the burner and fire-house shall allow for complete mixing of fuel with the
required amount of air, and for the uniform temperature distribution that ensure complete
combustion and minimize gas emissions caused by incomplete combustion..
• Gases containing sulfur dioxide shall be emitted through chimneys rising sufficiently high
in order that these gases become lighter before reaching the ground surface, or using fuel
that contains high proportions of sulfur in power generating stations, as well as in industry
and other regions lying away from inhabited urban areas, providing that atmospheric
factors and adequate distances to prevent these gases from reaching the dwelling and
agricultural zones and regions, as well as the water courses shall be observed.
• Chimneys from which a total emission of wastes reaches 7000 – 15000 kg/hr, shall have
heights ranging between 18 – 36 meters.
• Chimneys from which a total emission of gaseous wastes reaches more than 15000
kg/hour, shall have heights exceeding at least two and a half times the height of
surrounding buildings, including the building served by the chimney.
• The permissible limits of emissions from sources of fuel combustion in boilers are given
in table (8) (Ministerial decree no. 495, 2001). The permissible limits of emissions from
sources of other fuel combustion sources (Dow-therm oil heater) are given in table (9).

Table (8) Maximum Limits of Emissions from Sources of Fuel Combustion in Boilers
Pollution Maximum limit mg/m3 of Exhaust
Sulfur Dioxide 3400
Carbon Monoxide 250
Smoke 50
Table (9) Maximum Limits of Emission from Fuel Burning Sources

Pollutant Maximum Permissible Limit, mg/ m3
SMOKE 250
DISPERED ASHES 250 (sources existing in urban regions, or close to
residential areas)
500 (sources far from habitation)
500 (burning of wastes)
Existing 4000
SULPHUR DIOXIDE
New 2500
ALDEHYDES Burning of waste 20
Existing 4000
CARBON MONOXIDE
New 2500
Concerning Effluents
Limits for pollutants in wastewater vary depending on the type of receiving water body. The
parameters that should be monitored and/or inspected are Oil& grease, BOD, COD, pH, color,
temperature, residual chlorine, TSS, TDS, and heavy metals.
Table (10) presents the permissible limits for discharges to the

different recipients (sea, Nile, canals, agricultural drains, public
sewer) according to the different relevant laws.
Spent lube oil has a negative impact on water and soil and therefore its
disposal should be monitored/inspected. A record should be kept for this
purpose.

Concerning Solid Wastes
A number of laws address solid waste management. The following laws apply
to scrap, garbage (paper,..), and sludge from the WWTP:
• Law 38/1967 which addresses public cleanliness, regulates the collection

and disposal of solid wastes from houses, public places, commercial and
industrial establishments.
• Ministry of Housing, Utilities and Urban Communities (MHUUC) decree
No. 134 of 1968, which provides guidelines from domestic and industrial
sources, including specifications for collection, transportation, composting,
incineration and land disposal.
• Law 31/1976, which amended law 38/1967.
• Law 43/1979, the Law of Local administration, which provided that city
councils are responsible for “physical and social infrastructure”,
effectively delegating responsibility for infrastructure functions.
• Law 4/1994 regulates incineration of solid waste.
Concerning Work Environment

Violations of work environment could be encountered:
• Gas emissions (VOCs and metal particulates) generated in the production
lines, are regulated by article 43 of Law 4/1994, article 45 of the executive
regulations and annex (8), (table 11).
• In the boiler house: gas emissions, regulated by article 43 of Law 4/1994,
article 45 of the executive regulations and annex 8. The limits for the
relevant pollutants are presented in Table (11).
• Wherever heating is performed: temperature and humidity are regulated
by article 44 of Law 4/1994, article 46 of the executive regulations and
annex 9 of the Law (table 12).
• Near heavy machinery: noise is regulated by article 42 of Law 4/1994,
article 44 of the executive regulations and table 1, annex 7 of the Law.
• Ventilation is regulated by article 45 of Law 4/1994 and article 47 of the
executive regulations (tables 13, 14, 15)
• Smoking is regulated by article 46 of Law 4/1994 and article 48 of the
executive regulations, and Law 52/1981.
• Work environment conditions are addressed in Law 137/1981 for Labor,
Minister of Housing Decree 380/1983, Minister of Industry Decree
380/1982

Table (11) Permissible limits as time average and for short periods
Threshold
Material Time average Exposure limits for short
periods
ppm mg/m3 ppm mg/m3
Ammonia 25 18 35 27
Carbon dioxide 5000 9000 15000 27000
Carbon 50 55 400 440
monoxide
Sulfur dioxide 2 5 5 10
Acetone 750 1780 1000 2375
n- Butyl alcohol 50 150
Butyl acetate 150 710 200 150
Toluene 100 375 150 560
Xylene 100 435 150 655
Ethyl acetate 400 1400
Cadmium salts/ 0.05 0.2

particulates
Hexa valent 0.05
chromium
Total particulates 200
Table (12) Maximum Permissible Limits for Heat Stress (law 4/1994)
Type of Work Low Air Velocity High Air Velocity
Light work 30o C 32.2 o C
Moderate work 27.8 o C 30.5 o C
Severe work 26.1 o C 28.9 o C

Table (13) Maximum Permissible Noise Levels (law 4/1994)

No Type of place and activity Maximum
permissible
noise decibel
(A)
1 Work place with up to 8 hour and aiming to limit noise 90 dB
hazards on sense of hearing
2 Work place where acoustic signals and good audibility 80 dB
are required
3 Work rooms for the follow up, measurement and 65 dB
adjustment of high performance operations
4 Work rooms for computers, typewriters or similar 70 d.B
equipment
5 Work rooms for activities requiring routine mental 60 dB
concentration
Table (14) Noise Intensity Level Related to the Exposure Period
Noise intensity level decibel (A) 95 100 105 110 115

Period of exposure (hour) 4 2 1 ½ ¼
Table (15) Noise Intensity Level In Intermittent Knocking Places

Noise Intensity db Max Allowable Knocks During Daily Work Period
135 300
130 1000
125 3000
120 10,000
115 30,000
Concerning Hazardous Materials and Wastes

Law 4/1994 introduced the control of hazardous materials and wastes. The
paints industry generates any hazardous wastes, such as chemicals empty
containers, spent solvents, sludges from the solvent recovery unit and WWTP,
and spent filters clothes. Hazardous chemicals such as solvents, and caustic
solutions are used for washing vessels. The hazardous chemicals used in the
lab and the fuel for the boilers, fall under the provisions of Law 4/1994.
Articles 29 and 33 of the law makes it mandatory for those who produce or
handle dangerous materials in gaseous, liquid or solid form, to take
precautions to ensure that no environmental damage shall occur. Articles 25,
31 and 32 of the executive regulations (decree 338/1995) specify the necessary
precautions for handling hazardous materials. Storing of fuel for the boilers is
covered by the Law 4 as hazardous material There is no explicit articles in
Law 4/1994 or in decree 338/1995 (executive regulations), regarding holding a

register for the hazardous materials; article 33 is concerned with hazardous

wastes. However, keeping the register for the hazardous materials is implicit in
article 25 of the executive regulations regarding the application for a license.
The Environmental Register
Article 22 of Law 4/1994 states that the owner of the establishment shall keep
a register showing the impact of the establishment activity on the environment.
Article 17 and Annex 3 of the executive regulations specify the type of data
recorded in the register. The emergency response plan and the hazardous
materials register will also be part of the environmental register as stated in
part 4.5.

Pollution Abatement Measures

This section deals with pollution abatement (preventions) in the three media
air, water and soil. Three types of interventions will be considered:
• In-plant modifications, which are changes that are performed in the plant
to reduce pollutant concentrations in streams through recovery of
materials, segregation and/or integration of streams, reducing the flow rate
of the wastewater streams that need further treatment to reduce the hold-up
of the required WWTP.
• In-Process modifications, which are changes performed on the process
such as the introduction of newer technology, substitution of a hazardous
raw material, performing process optimization and control.
• End-of-pipe (EoP) measures, which involve treatment of the pollutant or
its separation for further disposal. Whereas in-plant and in-process
modifications usually have an economic return on investment, end-of-pipe
measures will be performed for the sole purpose of compliance with the
laws without economic.
Egyptian Environmental Laws do not require water and energy conservation

measures. These measures have been considered in this manual since resource
depletion and hence conservation is a worldwide-recognized environmental
issue that could be implemented in Egypt in the near future. Water
conservation measures can lead to higher concentrations of pollutants in the
effluent streams. Both energy and water conservation measures will provide
both financial and economic benefits.
The term Cleaner Production (CP) refers to the same concepts of pollution reduction
through in-process, in-plant and resource conservation, in contradistinction to end-of-
pipe treatment. In many cases, the adoption of CP can eliminate the need for (EoP)
treatment.
The paints industry sector has a great potential for implementation of cleaner
technology measures. Newly installed factories employing manpower above
100 has acquired relatively newer technologies, which need little in-process or
in-plant modifications and are carrying out end-of-pipe treatment to meet the
requirement of environmental laws. However, medium size enterprises as well
as public sector companies badly need the 3 types of modifications. Small
private enterprises are using primitive technologies.
Mitigation measures in paints industry vary from in-process modification or

recovery of solvents especially used in cleaning purpose.
The following CP and EoP measures have been identified for the paints
industry.

Air pollution Abatement Measures

Flue gases Particulate matter in flue (exhaust) gases are due the ash and
heavy metal content of the fuel, low combustion temperature,
low excess oxygen level, high flow rate of flue gases. Sulfur
dioxide is due to the sulfur content of the fuel. Nitrogen
oxides are formed when maximum combustion temperature
and high excess oxygen. Carbon monoxide is formed when
incomplete combustion occurs at low air to fuel ratio.
The following measures can be adopted to minimize air

pollution from flue (exhaust) gases:
• Replace Mazot by solar or natural gas. Mazot is high in
sulfur content.
• Regulate the fuel to air ratio for an optimum excess air
that ensures complete combustion of carbon monoxide to
dioxide.
• Keep the combustion temperature at a moderate value to
minimize particulate matter and nitrogen oxides
formation.
Work Environment Pollution Abatement Measures

VOCs
• Using VOCs control equipment such as; absorbents
emissions
(activated charcoal)/ biofilters on exhaust systems, water
scrubbers should be implemented where necessary to
achieve acceptable odor quality for nearby residents.
• During equipment cleaning process, solvents are released to
air. This emissions could be minimized through closing off
the immediate area around the axles, and also during
operation for dissolvers and stirring equipment.
• Reduction of the use of open strainers (closed filling
system).
• Covering of some containers could prevent the evaporation
of solvents into air.
• Using mixing system by vibration rather than by stirring.
The lake of a shaft holding a stirrer or a paddle means that
the coating and solvent can be gently blended in a
completely sealed vessel.
Particulates
• Using control equipment such as; Fabric filters should be
emissions
used to control particulates, from the process of charging
pigments and fillers to the mixers, to below 50 milligrams
per normal cubic meter (mg/Nm3) .
• Using of pigments in the form of pastes (premixed with

resins) could be used instead of powdered pigments, to

minimize particulate emissions during pigments charging
and mixing processes.
• Using of closed equipment (mixers, vessels, mills, and
tanks), to prevent the fugitive emissions (VOCs and
particulates) of the raw materials in the work place.
Water Pollution Abatement Measures
Equipment cleaning is considered the major source of pollution (liquid waste)

in paints industry, hence reducing cleaning process is a useful way for
pollution control. The following are some ways for liquid waste control:
In-plant • Elimination of unnecessary intermediate storage tanks, to

modifications minimize the amount of spent solvents generated from the
cleaning of these tanks.
• Recycling from intermediate tank directly to the mill
instead of using recycling tank, which lead to reducing the
pollution (liquid waste) resulting from cleaning of the
removed tank.
• Using high efficiency mills, which allows no need for
recycling tank.
• Using centrifugal clarifier instead of filter press, to
minimize losses (spills and leaks) occur during recycling of
the filtrate to the intermediate tank. This will accordingly
improve the quality of the wastewater.
• Using high-pressure jets for cleaning of tanks to enhance
cleaning process, so reducing the amount of liquid wastes
(solvents and caustic solutions) generated from cleaning
process.
• Using manual skimmers for removing materials (paints)
stuck to the tanks or container walls, before cleaning with
solvent or caustic soda solution. This reduces the amount of
liquid wastes used in cleaning, and the removed sticky
materials could be recycled. Also mechanical skimmers can
be used for tubes cleaning.
• Using Teflon-lined tanks to reduce materials sticking to
their walls.
• Segregation of sewer systems for liquid wastes, generated
from water- based paints production line and solvents-based
production line, as this leads to more efficient recycling.
• In all cases, it is recommended the industrial liquid waste
discharged separately from domestic wastes as they differ
in the pollutant nature.

• The installation of product-capture systems for filling

machines can reduce product losses.
• Implementation of a quality control system such as HACCP
(Hazard Analysis & Critical Control Point) is recommended
to minimize waste.
In-process • In solvent-based paints production line;

modifications
- Random choice of the cleaning solvent could be
replaced by an evaluation process, leading to a choice
of one single solvent for all tanks and equipment
cleaning.
- Schedule the production runs and modify the
manufacturing procedures to minimize or eliminate
the use of wash solvent.
- Reuse of cleaning solvents (spent solvents) many
times, hence reducing the solvent consumption. After
that, the solvent can be regenerated distilled and
recycled for use in dilution or cleaning.
- Spent solvent could be recovered through distillation
process, with about 90% solvent yield achievable
from the still, and 10% sludge (removed paints). This
sludge could be used in the production of a new paint
product (a primer).
• In Water-based paints production line;
- Using washing liquids (caustic solutions), generated

from cleaning of mills and packing machines, in
dilution of next batch.
- Scheduling operations to produce light color first then
dark color paints to reduce the need for equipment
cleaning. For white paints we can use intermediate
tank to minimize the washing operations.
- In acrylic paints production line; Wash water
generated from white acrylic paint manufacture could
be reused in the next production run. Also the
wastewater generated from the colored acrylics could
also be stored for reuse in the next production run.
• In all production line;
- Appling quality assurance to reduce the possibility of

errors in paints preparation.
- Using counter current cleaning operations to reduce
the amount of water or solvent used.

- Cleaning the tanks directly after production step to

prevent materials sticking into walls. This means
coordination between the production steps and
cleaning operation.
- Reusing the rejected or off-spec. paints in new
batches.
- Raw materials substitution; replacing the toxic
pigments or dyes such as lead and chromium
compounds by another non-toxic ones such as organic
dyes or iron oxides.
- Controlling raw materials stock using computerized
system, which facilitate the detection of any leak in
the initial stages and indicate the sources of solid
waste pollutants.
- Implementation of a control system involving
pressure regulators on the steam lines, temperature
controllers, flow controllers…
- Change from batch processes into continuous ones.
- Modernize the equipment and upgrade the system.
- Introduce new environmentally friendly products
(water-bases paints) to increase sales and minimize
pollution.
- Improving raw materials handling, to prevent spills
occur during manual unpacking of sacks and
containers, and training of personnel to insure
complete unpacking of containers.
- Integration (acidic and alkaline streams), and
segregation of sewer lines of water and solvent based
paints, to minimize treatment needs and ensure
compliance with the environmental laws, can be an
option for many factories. In some cases where there
are several discharge points from the factory, mixing
of the streams could lead to compliance. In other
cases where treatment is imperative some streams
could be segregated and discharged without violation.
The remaining streams will require a treatment unit of
small capacity.
End-of-pipe Because of the typically high content of suspended solids,

treatment TDS, TSS, O&G, COD, BOD, pH, and temp., in the paints
industry waste-streams, end-of-pipe treatment frequently
involves settling tanks and biological treatment.
Pretreatment of effluents is required, it is normally followed
by biological treatment.
1)Water-based The wastewater generated from the water-based paints

paints production line is characterized by high values of BOD,
COD, S.S, TSS, and TDS. Therefore, the end-of-pipe

treatment could be as follows:

• Collection and flow equalization,
• Precipitation, using coagulants and flocculants (such as;
lime, alum,…), in a homogenizing tank equipped with
mixer, followed by a sedimentation tank to allow the time
needed for reactions of chemicals to precipitate the
dissolved solids.
• Decantation for removal of generated sludge, and drying of
sludge using filter press.
• Filtration using activated carbon filter, to remove any
entrained solids.
2) Resins The wastewater generated from the resin production

production line, contain xylene and other organic compounds, this
line wastewater could be incinerated in the Dow-therm oil
heaters instead of the fuel (Mazot or Solar).
3) Solvent- The spent solvent generated from equipment cleaning,

based paints in the solvent-based production line, could be recovered
by vacuum distillation of the spent solvent, then
condensation of solvent vapors. The solvent can be
recycled for reuse in dilution or cleaning.
The sludge (precipitates) generated from the solvent
recovery process could be dried and safely disposed into
a landfill.

Abatement Measures for Solid Waste Pollution

Scrap • Scrap metals are collected and sold.
from
workshop
s and
garage
Hazardous solid wastes sources includes chemicals sacs,
Solid packs, empty barrels, filters cartridge, materials spills, and
precipitates from liquid wastes (caustic solutions and solvents)
wastes clarification by settling or distillation. The following are some
from ways for reducing solid waste pollution.
processes • Planning of packaging systems to avoid solid waste and/or
to facilitate recycling of packages or packaging wastes.
• Separating hazardous solid waste from non-hazardous ones.
This means separating sacs or packs containing hazardous
materials such as lead or chromium compounds, from that
free from such compounds.
• Gathering the empty sacs containing hazardous compounds
in plastic bags, to prevent the spread of hazardous dust in
the atmosphere.
• Using water-soluble sacs in making water-based paints can
reduce the amount of waste sacs, as the whole sacs can be
dissolved in water with their content. This could be done
with pigments containing mercury compounds, or in
making paints containing anti-fungi compounds, but this in
turn affect the degree of shininess of paints.
• Using bag filters instead of cartridge filters, as the spent
cartridge should be safely disposed into a landfill or burned,
while the bag filters can be used many times. In addition,
the bag filters can be washed by water or solvents, for
recovery of the toxic material, and recycling of these
materials with dilution liquids (solvents and thinners), then
the filter bags can be dried and disposed safely.
• Using metallic screens for paints filtration process, which
can be reused after cleaning with water or solvent.
• Handling of solid materials spills, by dry cleaning methods
such as; vacuum cleaner, or by wet saw dust, to prevent
spreading of these materials. Also the personnel should be
trained to close the grills of the internal sewer system, when
leaks or spills occur, to reduce the pollution load discharged
to the sewer.
• Using automatic methods for unpacking of sacs, which
prevent dust spreading in the workplace, also can reduce

solid materials spills.

• Cleaning pollutants, from empty sacks and containers by
solvent, should be done before storing or selling.
• Solid wastes, generated from spent solvent distillation or
pretreatment of alkali solutions, used in cleaning and
washing, could be safely disposed into a landfill or burned.
• Generally, recycling of incoming raw materials packaging
like steel barrels, plastic barrels, nonce-use pallets,
corrugated, paper bags, shrink plastic (PE) and transition to
storage of raw materials in tanks. The reuse of these
packages is a measure to reduce costs and amounts of
waste.
Sludges from
• Effluent treatment processes generate sludge. It can also be
water and
hazardous to health by absorbing pathogens that multiply in
wastewater
this favorable medium and toxins. It also contain traces of
treatment
heavy metals. Raw sludge is saturated with water, should be
de-watered and disposed of into landfills.
• Sludge also generated from water treatment unit due to
addition of lime and chemicals to water.
Water and Energy Conservation
Water and sewer service costs have been rising, and these increases can cut
into profits. Using water more efficiently can help counter these increases.
Water
• Install water meters and monitor water use
Conservation
• Use automatic shut-off nozzles and mark hand-operated
valves so that open, close and directed-flow positions are
easily identified.
• Use high-pressure, low-volume cleaning systems, such as
CIP (clean in place) for washing equipment.
• Install liquid level controls with automatic pump stops
where overflow is likely to occur.
• Recycle cooling water through cooling towers.
• Minimize spills on the floor minimizes floor washing.
• Repair leaks.
• Handle solid waste dry.
• Recycle steam condensate whenever economically viable.
Energy
• Insulation of steam lines.
conservation
measures • Installation of steam traps.

• Repair or replace steam valves.

• Use the optimum excess air to perform efficient combustion
process
• Install pressure regulators on steam lines.
• Return steam condensate.
• Improvement of power factor and electrical circuits.

6. Self-Monitoring, Definition and Link to EMS
The Self-Monitoring System (SMS) primarily relates to measurements of process inputs,

releases and environmental pollution levels, as well as process conditions (operation controls)
that are directly related to the monitored emissions. Self monitoring is necessary for the plant
to improve its economic performance by identifying the sources of wastes in raw materials,
water and energy, which represent the main source of pollution. Thus, the plant would be able
to implement pollution prevention techniques that could reduce production costs and minimize
compliance costs that lead to an improved economic and environmental performance of the
plant.
In addition, self-monitoring may include reporting of the results to the competent authorities.
Monitoring can be carried out by the industrial establishment or carried out on behalf and paid for
by the industrial establishment. The information obtained from the sampling component of the
monitoring system must be recorded and the results reported to the appropriate internal and
external decision-makers.
6.1 Benefits of SM
In general, the benefits of self-monitoring results to the operators include:
• To raise awareness about the process performance and efficiency.
• To have them ready for inspection by authorities.
• To provide inspectors with more reliable data to verify the single unrepresentative
samples and/or measurements.
• To raise their awareness about impact of pollutants.
• To implement corrective actions if non-compliance occurs.
• To decide on raw materials, additives, fuels, and investment strategies.
• To identify trends in plant performance and setting alarms.
• To improve process efficiency.
These benefits refer to implementing an integrated environmental self-monitoring plan that

comprises:
• Emissions monitoring, which covers releases to air, wastewater, soil, and solid and
hazardous waste as well as regulated work conditions.
• Monitoring of process parameters (operations controls) that are directly related to the
releases e.g. temperature, pressure and humidity. In addition, process conditions e.g.
shutdowns, maintenance operations and spills need to be monitored, linked to
emissions and reported.
6.2 Scope and Objectives of SM
As previously indicated, environmental self- monitoring comprises the

monitoring of environmental releases (emissions) as well as the monitoring of
process parameters (operation controls) that affect the environmental impact of
the facility. The objectives of each type are separately detailed as follows:
a) Emissions Self-Monitoring
The basic objective of self-monitoring is to provide information to ensure compliance with
environmental regulations. As the inventory for hazardous materials and wastes is
mandatory with procedures for handling and storage as regulated by law 4/1994, self-
monitoring should assist in covering that area. The objectives of emission monitoring may
go beyond monitoring compliance, to assist in improved environmental performance. In
other words, monitoring of emissions at the process level is necessary to minimize
emissions at the source through pollution abatement and prevention measures. While
Egyptian regulations consider only concentration of the pollutants, self-monitoring may

include pollution loads as well as the environmental impact on the receiving media. These
data are required to assess the improvement of the environmental performance.
b) Process Self-Monitoring (Operation Control)

In most industrial facilities monitoring of process operations already exists. Some process
operation controls should be monitored for improved environmental benefits. The main
objectives of process self-monitoring (operation control) is:
• Optimization of process operation an controlling the operating conditions

• Maximization of profit through:
- Product development and operation
- Energy and water conservation
- Minimization of losses
• Planned maintenance and repair as opposed to emergency maintenance and shutdown
6.3 SM and Environmental Management Systems (EMS)
Aside or the regulatory aspects, SM has shown to be a necessary tool for the
plant to manage its releases, control its environmental impacts and improve its
environmental performance. Such achievements represent the main objectives
of the Environmental Management Systems (EMS), which in turn constitute a
requirement for internal monitoring, checking and implementing the corrective
actions. Also, EMS encourages the industrial plants to adopt Cleaner
Production (CP) and Pollution Prevention measures as the main tools for
continual improvement. This can be achieved by implementing a
comprehensive and effective SM plan.
The following sections highlight the concept of EMS, link to SM and link
between SM and cleaner production.
6.3.1 The Environmental Management System (EMS)

An Environmental Management System (EMS) is a framework that helps a company achieve
its environmental goals through consistent control of its operations. The EMS itself does not
dictate a level of environmental performance of the company; each company tailors its EMS
to its specific business goals. Compliance with environmental laws and regulations has
become a major goal that has to be attained with minimum cost. This is the minimum level for
environmental performance achieved through the EMS. In general, an EMS comprises five
phases leading to continual improvement; commitment and policy, planning, implementation,
evaluation and review.
These phases will be herein explained within the context of the standard system “ISO 14000”,
which is internationally recognized. With regard to Egypt, this system is being gradually
implemented by the Egyptian Industry. The different stages of the EMS form a cycle (Fig. 29)
that allows feedback of information and continuous improvement. This system includes the
following elements:
1. Environmental policy. Top management commits to an

environmental policy that comprises, as a minimum, compliance
with laws and regulations, pollution prevention and continual
improvement.. The policy is the foundation of the EMS.
2. Planning: A company first identifies environmental aspects of its

activities. Environmental aspects are those items such as air
pollutants or hazardous wastes that can have negative impacts on

people and/or the environment. Once the relevant laws and

regulations are determined, the company sets objectives and targets.
An objective is an overall environmental goal (e.g. minimize use of
chemical x). A target is a detailed, quantified requirement that
arises from the objective (e.g. reduce use of chemical x by 25% by
September 2002). The final part of the planning stage is devising an
action plan for meeting the targets. This includes the schedule, and
the clearly defined steps to meet the targets.
3. Implementation. This phase comprises the establishment of the

structure, assignments and responsibilities of the designated
personnel. An important component is employee training and
awareness for all employees. Other steps in the implementation
stage include documentation, document control, implementing
operation procedure, and setting up internal and external
communication lines. In addition, an emergency and preparedness
plan has to be developed.
4. Checking and Corrective Action. The company monitors its

operations activities to ensure that targets are being met. If not, the
company takes corrective action and keeps records for the
emissions and environmental performance. Internal audit is a key
element to improve the system.
5. Management Review. Top management reviews the results of the

evaluation to see if the EMS is efficient and effective. Management
determines whether the original environmental policy is consistent
with company values. The plan is then revised to optimize the
effectiveness of the EMS. The review stage creates a feedback of
information necessary for continuous improvement.
Environmental
Policy
Management Planning
Review
Continuous
Improvement
Checking and Implementation

Corrective Action

Fig. (29) Phases of EMS Cycle (ISO 14000)
6.3.2 Link between Self-Monitoring and (EMS)

As previously explained an EMS e.g. ISO 14000, comprises 5 stages;
environmental policy, planning, implementation, checking and corrective
actions. By analogy, the self-monitoring system (SMS) can be looked at using
the same concept. Taking into consideration the definition, concept and
principles of self-monitoring, as stated in the “Guide Book on Self Monitoring,
the elements of SMS can be rearranged as follows:
Commitment: In general, an effective self-monitoring requires the

management of the plant be committed to environmental compliance, as a
minimum. However, this commitment will be an integrated part of the
environmental policy in the EMS, if exists.
Planning: The planning of the SM is mainly based on objective (s) that have
been set. For a basic SMS, the objective would be monitoring of regulated
parameters to assist in achieving regulatory compliance e.g. end-of-pipe
emissions and discharges. In an advanced SMS, the objectives may include
monitoring of operation controls as well as emissions and wastes at the source,
to help in implementing pollution prevention and cleaner production measures.
In all cases, the objectives of self-monitoring should be in line with the
objectives of EMS, if exists. In such case, the self-monitoring plan can be part
of the EMS plan and includes:
• Description of the regulatory limits for compliance
• Brief description of the actual situation of existing monitoring activities (processes and
parameters monitored):
- Devices, and equipment used (type of devices, and frequency of measurements)
- Available resources.
• Objectives and targets with time frame for implementation.
• Identification of parameters monitored, location of monitoring points and preparation of
a self-monitoring schedule.
• Description of methods and procedures used for sampling, analyses, measurements,
calculations, recording and data manipulation.
• Description of tasks and responsibilities.
• Training program.
• Information flow.
Implementation: The implementation of SM means that the tools and

mechanisms for collecting the relevant data are functioning. On the other
hand, the implementation phase in EMS means that the environmental
performance of the plant is improved.
The implementation of SM results in large amount of data that need

representation, interpretation and reporting in order to be useful as tools for
decision making for corrective actions. The decision making requires
knowledge about the status of:

• Control and optimization of process performance (Process operating parameters)

• Emissions, effluents, solid waste, toxic and hazardous releases: concentration, load,
handling procedures and transfers and comparison with environmental limit values
(ELVs)
• Maintenance and repair.
• Percentage losses of raw materials, products and utilities.
Evaluation: Evaluation of the self-monitoring plan through regular auditing

will allow its continuous improvement. Evaluation should include all aspects
of the plan (training, meeting targets, reliability of data, efficiency of
devices,…etc). On the other hand, the evaluation of the EMS involves
checking and taking corrective actions of all system components, including the
monitoring activities.
Review: On the basis of the evaluation of the monitoring plan, a review can be
made of the monitoring objectives and targets. In case of EMS, the
management review covers all the involved procedures, including monitoring
activities.
It is clear from the above explanation that self-monitoring is an integral part of

any EMS. More specifically, self-monitoring is the tool for the evaluation
function of an EMS. Figure (30) illustrates relationship and interaction among
the main elements of EMS and SMS.
6.3.3 SM Link to Pollution Prevention and Cleaner Production

With the growing understanding that escaping raw materials, chemicals and products constitute
major pollution sources, industry has opted to implement pollution prevention measures at the
source. These measures include in-plant and in-process modifications as well as resource
conservation (minimization of water and energy consumption). The implementation of these
measures will decrease the end-of-pipe treatment cost. However, plant management will have to
undertake a cost-benefit analysis to determine which measures are economically viable.
Self-monitoring is the tool that helps undertake these analyses by providing the necessary
information about process inputs and outputs as well as the framework for performing the required
tasks.
The introduction of emission monitoring for the purpose of improved environmental performance
through the application of cleaner technology widens the objectives of the plant EMS beyond
compliance with relevant laws and should be met with economic incentives from the part of the
competent authorities.
6.4 Regulatory Aspects
In developed industrial countries e.g. Europe, the competent authorities must

approve the monitoring program, specify the standards and quality
requirements for self-monitoring that are to be achieved by the operator, and
ensure those possibilities for cheating and fraud are minimized. The
competent authorities will receive self-monitoring reports periodically from
the operator. These should provide summary information, following data

reduction, in a format facilitating easy comparison with permit limits.

Additionally, the competent authorities should inspect the operator’s self-
monitoring records, including log sheets covering sampling, analysis,
instrumental monitoring, and data-reduction calculations.
6.4.1 SM and Environmental Register

According to law 4/1994, industrial facilities (operators) are required to keep a record of their
inputs, outputs and releases in the environmental register as stated by which implicitly requires
some sort of self-monitoring. The Egyptian Environmental Affairs Agency (EEAA) is
mandated to check the validity of the data in the Environmental Register. The responsibilities
of the operator and the competent authority are not affected by who carries out the monitoring.
It is the responsibility of the operator to comply with laws and regulations. On the other hand,
the competent authorities (inspector) are responsible for assessing and ensuring the operator’s
compliance.
When combined with Self-monitoring, Environmental inspection competent authorities

benefits from combination of inspection with SM through:
• Utilizing the operator’s knowledge and experience of his process in planning and
carrying out a monitoring program that can lead to improved control over releases to the
environment.
• Self-monitoring will normally provide more information than may be obtained by
periodic inspection by the competent authorities.
• Providing a mechanism for educating the operator about the requirements for complying
with relevant laws, regulations and permits and for increasing of management
responsibility for compliance and the impact of process releases on the environment.
6.4.2 SM and Inspection

Self-monitoring does not constitute self-regulation. SM provides additional
information on which the competent authorities can judge whether an operator
is complying with relevant legislation and conditions of permits. It does not
change the duty of the competent authority to assess compliance by means of
inspection and by performing its own monitoring or choose to rely on the
operator’s monitoring data or a combination of both. The competent authority
continues to be responsible for enforcement.
As mentioned above, SM provides a wealth of information that can be utilized

by the competent authority in reviewing standards and developing applicable
environmental policies.
However, the competent authority will have to check the reliability of the SM
data. Thus, inspectors may be required to check the SMS plan, Quality
Assurance and Quality Control (QA/QC) procedures, data handling and
documentation. In this context, it is expected that inspectors may perform the
following tasks:
• Check the SM program.

• Check and verify the specified measurement standards.
• Check the reliability of the data (by carrying out independent monitoring).
• Inspect SM arrangements such as:
- The positioning and serviceability of fixed instrumentation and check representative
ness of the monitoring.
- Records confirming the maintenance and calibration of instrumentation and sampling
equipment.
- Manual sampling and analytical procedures.

This expected interaction will help both partners i.e. the operator and the
competent authority in achieving their objectives in terms of reliability of
emissions data and environmental performance.

EMS PolicySMS
Statement
Policy Statement Policy Statement
Planning
Planning • Define Scope
• Environmental Aspects • Identify Monitored Parameter
• Regulatory Requirements
• Establish Monitoring Program
• Objectives and Targets
• Environmental program
Implementation Implementation
• Structure & Responsibilities • Environmental Monitoring
• Training awareness • Operation controls
• Documentation • Development of Person skills
• Documents control • Internal & External Reporting
• Operations control • Q/A & Q/C of data
• Communications • Documentation
• Emergency response
Evaluation of EMS Evaluation of SMS
Review of EMS: policy, Review Objective & SM

objectives, program and Plan
procedures
Fig. (30) Relationship between EMS and SMS

7. Planning of SM
Planning for SM starts by setting the objectives. It should be clear that a

number of process control parameters needs to be monitored, along with
environmental monitoring. For the purpose of this manual environmental self-
monitoring will be considered in addition to monitoring of process parameters
that are related to emissions (operation controls).
Compliance monitoring requires measurements, analysis and data on end-of-

pipe releases, whereas operation controls target the production units that offer
pollution prevention opportunities. The environmental manager with the help
of various sector managers should carry out the planning activities.
With reference to ”Guidebook for Industrial Self-Monitoring”, the main

elements of the Self-Monitoring Plan, that describes the SMS, include:
• Objectives and results required from the self-monitoring system

• Organization and share of responsibilities and tasks
• Planning activities and design of an implementation schedule
• Definition of the parameters and relevant monitored indicators to reach the objectives
• Design of an appropriate measurement and sampling program
• Data processing and reporting procedures
• System for follow-up of decisions, actions and monitoring development
• Quality assurance and control
With reference to the Guidebook for Industrial Self-Monitoring the objective

of the SMS can be limited to provide the data required for the Environmental
Register which is mandated by the Environmental Law, e.g. total inputs,
outputs and emissions on the plant level. This objective ”compliance with
regulations” requires the ”Basic Self-Monitoring System” which comprises the
minimum requirements. In these cases where self-monitoring is not
mandatory, operator can build a ”basic” self-monitoring system that focuses
on the regulated emissions, as a minimum. Then, the system can be gradually
upgraded, ”continual improvement” through internal auditing of all system
components. Other objectives, e.g. waste minimization, pollution prevention
and improved environmental performance require upgraded SMS that includes
monitoring of inputs, outputs and releases on the level of operations and
detailed processes. In all cases, the established SMS should be gradually
improved and upgraded, considering the plant financial and economic
constrains.
The following sections are detailing the stepwise activities that are needed to
develop a viable realistic, and applicable plan for a self-monitoring system.
Fig. (31) presents the various steps for the preparation and implementation of
a self-monitoring plan.

Identify standard Methods for

Sampling, Analysis and
Measuring
Selection of In-
House Responsible
Person(S) Process and Pre- Select Write Self-
Management Awareness
and Commitment Monitoring Parameter to be Monitoring
Objectives
Existing Survey Monitored Plan
Contract Outside Monitoring
Assistance
Select Monitoring
Location
Laboratory Consultants
Define Monitoring
Schedules
Review and Modify the
SM Plan
Continual Execute Self-

Operation Monitoring Plan
- Measurements
- Samplings
- Analysis
- Data collection
Fig. (31) Steps for the Preparation and Implementation of a Self-Monitoring Plan
- Data evaluation
- Data reporting
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7.1 Assessment of Existing Monitoring Capacity
Assessment of existing monitoring capacity includes the following aspects:
• Management system: presence of an EMS, existing system for data collection and
reporting.
• Human resources: available personnel, level of training; motivation.
• Technical resources: monitoring equipment and laboratory, status of equipment
• Financial resources: available budget for self-monitoring activities.
Table (17) presents an example of a checklist for existing self-monitoring

activities.
Table (17) Example for Assessing the Status of

Existing Monitoring Activity
Monitored Location Parameter Associated Person in Time schedule
activity tasks charge
Wastewater Final Flow rate Recording flow Operator X Daily
discharge on flow meter
Inspect meter Supplier
Calibrate Operator Y
Data analysis, Lab staff
representation
BOD, COD, Grab sample Lab technician Once a week

TDS, TSS, S.S, Sample Lab staff
O&G, pH, preservation
color, heavy
metals Analysis Lab staff
Review results Chief of Lab
and reporting
7.2 Identification of Key Parameters

The identification of key monitoring parameters requires an understanding of the
manufacturing processes and the operation of the various units. The brief description provided
in section 2 and the relevant tables can help identify some of these parameters. However, a
pre-monitoring audit is necessary to determine sampling and measurement locations and
schedules needed to design the self-monitoring plan. Priority should be given to parameters
that determine compliance with environmental laws. A table describing the monitoring
activities can be prepared for process and compliance monitoring.
The exact positions of the monitoring points within the production line have to be determined
on a case by case basis by production experts, according to the following criteria (SM
Guidebook, EPAP 1999):
• Representativeness of the monitoring point.

• Criticality of the monitoring point
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• Accessibility of the monitoring points
The choice of the parameters is determined by the type of production, the legal requirements,
the nature of the pollutant and its load, and the importance of the parameter for decision
making. For each of the proposed parameters the trends and variations should be monitored in
addition to the value of the parameter at a given time.
7.3 General Data Required

When assessing the performance of the operation and its impacts on the environment, some
basic information is needed to put the monitoring data into the context of interpretation. Such
information is about:
• Identification : Name, address, plant location, name of owner, manager and head of
environmental department.
• Inputs name, type and amount: Raw materials, chemicals, fuels, water, steam,
electricity.
• Technology: Description of process, applied technology, operating conditions
(temperature, pressure, …etc.), maximum capacity, operating capacity during
monitoring.
• Outputs name, type and rate: Products, by-products.
• Abatement techniques: Air pollution prevention, wastewater treatment, solid and
hazardous waste management, noise abatement.
• Emissions and their sources: receiving media, pollutant type, concentration and load,
pollutant impact.
• Existing EMS system, analyses and measurement results, relevant environmental laws
and allowable pollutant levels.
• Assessment of legislative and regulatory requirements.
7.4 Data collection, Manipulation and Reporting
Data collection and analysis should be carefully planned according to the

following principles:
• Base the analysis on trends over a long period to take into consideration the shock
loads that characterize the paints industry.
• Determine the causes and degree of variability of a parameter. A dramatic change of a
low-variability parameter may be interpreted as a sign of anomaly of the process. This
will require an investigation to find the potential source of the problem and take the
right corrective action.
• Study the correlation between different parameters. The cause of variation for a highly
variable parameter may be correlated to another parameter.
A considerable amount of data may be generated by the operator carrying out

self-monitoring especially when continuous monitoring instrumentation are
used. Data reduction is necessary to calculate time-averaged means, percentile
values and the like. When compliance data are recorded in the environmental
register the relevant calculations for data reduction should be specified.
Measured values are used to form half-hourly mean values for each successive
half-hour to generate frequency distribution. For each calendar day a daily
mean value, related to the daily operating time, is calculated from the half-
hourly mean values and kept on file.
Measurement results should be kept in the environmental register for at least

10 years (Article 22 of law 4/1994 and 17 of its executive regulations).
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An annual report is prepared on the outcome of the measurements including

information on:
• Measurement planning
• The outcome of each individual measure
• Measurement methods used
• Operating conditions that are important for the assessment of individual data and
measurement results.
7.5 Criteria for Selecting Monitoring Method
The choice of monitoring method used to determine the value of the parameter
depends on the specific features of the process, the emission sources, the
physical state and properties of the sample and the nature of emissions from
the operation. The latter can be classified as:
End-of-pipe Normal Occur during normal operation and normal process and
emissions (point abatement technique conditions. These emissions are
source) generated from point sources (e.g. flue gases from
stacks (boilers, and Dow-therm oil heaters), process
vents (reactors), boilers blow-down, softeners back-
wash, spent solvents (equipment cleaning), …etc.
Diffuse and fugitive These are emissions from a certain process but from
emissions scattered points such as emissions from ventilation
ducts, barrels, pumps, valves, compressors, scattered
small storage’s. The diffuse emissions are
calculated/estimated by monitoring the source
periodically and assessing the long term emission from
the measurement results or by mass balance
calculations.
Exceptional Exceptional emissions refer to varying input or process

emissions (start-up, conditions, start-ups, shut-downs, by-pass of a process
shut-down, for malfunctioning and accidental causes, and
maintenance, maintenance operations.
malfunction) The emissions can differ from those of normal
operation in their volume and/or concentration. These
emissions can be multiple compared to normal
emissions. It can be impossible to measure the
concentration or volume of the exceptional emissions
as the measuring device is calibrated according to the
normal operating conditions. Estimation techniques
should then be performed.
There are four basic methods that may be used to develop estimates:
• Direct or indirect measurement
• Mass balance
• Emission factors
• Engineering calculations
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7.5.1 Direct or Indirect Measurement

a) Direct measurements: Using monitoring data or direct measurements is
usually the best method for developing chemical release and/or other waste-
management activity quality estimates. Data may have also been collected for
the facility through an occupational health and safety assessment. If only a
small number of direct measurement data is available or if the monitoring data
are not based on a representative sample, another estimation method should be
used to give a more accurate result.
Note : Treatment Efficiencies

Supplier data on treatment efficiencies often represent ideal operating conditions, should
be adjusted to account for downtime and process upsets during the year that would result in
lower efficiencies. Efficiencies reported by supplier are often general and may not apply
to specific chemicals. For example, an incinerator or flare may be 99.99% efficient in
destroying organic chemicals, but will have a 0% efficiency in destroying heavy metals.
For successful measurements the following considerations should be satisfied:

• The frequency of measurement and sampling must cover temporal variations of the
process and specifically the period during which harm occurs.
• Continuous monitoring is suitable for large emission sources, such as stacks and
wastewater canals except in cases where high temperature or corrosive substances are
involved. At smaller sites the cost of continuous monitoring is weighed against the
value of the monitoring results and the possibility of obtaining representative results
from periodic measurements.
• Utilization rate (percentage of continuous monitoring time to total operation time)
should be known when performing continuous monitoring.
• The process conditions must be specified when monitoring takes place (e.g. start-up,
shut-down, production rate, operating production lines, failure of abatement
equipment).
b) Indirect measurements: These are performed through surrogate parameters.

Surrogate parameters are variables that can be closely related to conventional
direct measurements of pollutant releases or impacts and which may therefore
be monitored and used instead of direct values for some practical purposes.
Surrogates are commonly used in operation control as they give an early
warning of possible abnormal conditions or emissions. Surrogates may
provide a relative measurement rather than an absolute value and may only be
valid for a restricted range of process conditions. On the other hand, surrogates
can provide more continuous information than direct measurements. It is also
often cost-effective as it allows more discharge positions to be monitored for
the same resources. Table (18) summarizes the advantages and disadvantages
of surrogate parameters. A surrogate can be used for compliance monitoring
purposes if all the following conditions are met:
• It is closely and consistently related to a required direct value (e.g. fuel sulfur vs.
directly measured SO2, relationship between opacity and particulate concentration,
condenser temperature and VOCs emissions).
• It is regularly calibrated against the direct value.
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• It is cheaper or easier to monitor than the direct value, or gives more frequent
information
• Its value can be related to specific limits
• The process conditions where it is measured matches the conditions where direct
measurements are required.
• Any extra uncertainty due to use of surrogate is not significant for regulatory decisions
or process management.
Table (18) The Advantages and Disadvantages of Surrogate Parameters

Advantages Disadvantages
• Cost savings. • Need cost for calibration
• More continuous information e.g. against direct values.
continuous opacity vs. periodic • May provide relative
dust sampling. measurement rather than an
• Allow more positions form absolute value.
discharge monitoring. • May not valid only for a
• Sometimes more accurate e.g. restricted range of process
fuel sulfur vs. SO2 . conditions.
• Give early warning of possible • May not command as much
abnormal emissions e.g. public confidence as direct
combustion temperature warns values.
for increase in dioxin emissions. • Sometimes less accurate.
• Causes disruption to process
operation.
• May combine information from
several direct measurements e.g.
temperature indicates energy
efficiency, emissions and process
control.
7.5.2 Mass Balance

A mass balance involves determining the amount of chemical entering and
leaving an operation. The mass balance is written as follows:
Input + Generation = Output + Consumption
• Input refers to the materials (chemicals) entering an operation. For

example, caustics added to equipment wash water would be
considered an input to the wastewater treatment operation.
• Generation identifies those chemicals that are created during an

operation. For example, when nitrogen sources are used in biological
wastewater treatment systems, additional ammonia may be produced
(generated).
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• Output means any stream by which the chemical leaves the operation.
Output may include on-site releases and other waste management
activities to the environment, storage, or disposal ; or the amount of
chemical that leaves with the final products. In paints manufacturing
operations, for example, pigments in the paint may leave the operation
as product losses and leakages, on the ground that could be sent to
sewer, and in the cleaning solvents/ solutions (waste effleuent), or
emissions in the work environment that could be collected into the
filters and sent for disposal.
• Consumption refers to the amount of chemical that is converted to

another substance during the operation (i.e., reacted). For example,
caustic soda would be consumed by a neutralization process during
wastewater treatment.
The mass balance technique may be used for manufactured, processed, or

otherwise used substances. It is typically most useful for chemical that do not
become part of the final product, such as catalysts, cleaning solvents and
alkalis. For large inputs and outputs, a mass balance may not be the best
estimation method, because slight uncertainties in mass calculations can yield
significant errors in the release and other waste management estimates.
Therefore mass balance is not accurate enough method for estimating process
and combustion emissions.
Material balance calculations are also used to examine the effects of emission
reduction on the material balances of the plant. A material balance calculation
gives an impression of the magnitude of the emission of a specific substance
but can not show accurate emission amounts, nor their division between
emissions into the air, water discharges, or solid wastes. Material balance
calculations are often based on evaluated process flows and concentrations.
Calculating a reliable average emission level for a factory means long term
monitoring of the processes and statistical examination.
7.5.3 Emission Factors

An emission factor is a representative value that attempts to relate the quantity
of an emission released with an associated activity. These factors are usually
expressed as the weight of emission released divided by a unit weight, volume,
distance, or duration of the activity (e.g. kg of emission released per kg of
product). Emission factors have been developed for many different industries
and activities. Emission factors depend on the technology used, raw materials ,
and pollution control devices. Emission factors can be obtained from industrial
database e.g. DSS (available at EEAA).
Note
Sources of information on emission factors should be carefully evaluated and the conditions for using
the factors reviewed to determine if it is applicable to the situation at the facility.
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7.5.4 Engineering Calculations

Engineering calculations are assumptions and/or judgments used to estimate
quantities of listed chemicals released or managed. The quantities are
estimated by using physical and chemical properties and relationships (e.g.
Raoult’s law, Ideal gas law) or by modifying an emission factor to reflect the
chemical properties of the toxic chemical in question. Engineering calculations
rely on the process parameters; thorough knowledge of the operation is
required to complete these calculations.
Engineering calculations can also include computer models. Several computer

models are available for estimating emissions from landfills, wastewater
treatment, water treatment and other processes.
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8. Monitoring of Raw Materials, Utilities and Products

Inputs and outputs data is needed for estimating the nature and amount of the releases when
assessing the reliability of the monitoring results. The input data includes the quantity and quality
of raw materials, chemicals, fuel and water used.
8.1 Raw Materials and Chemicals

The amount of raw materials received per day and cost/kg are important monitoring parameters.
The quality of raw materials is assessed by chemical tests before acceptance. Some factories store
the rejected raw materials until it sent back to the contractor (Table 19).
Table (19) Monitoring of Raw Materials and Chemicals

Parameter Monitoring Method Indication
Amount of raw materials and Weighting, measuring, calculation and Rationality in the use of
chemicals (pigments, fillers, material balance, book keeping and raw materials.
binders, solvents, driers, recording.
plasticizers, …etc.) necessary to
produce 1 ton of product.
Quantity of rejected raw Weighting, measuring, calculation and - Losses.

materials per unit of product. material balance, book keeping and - process efficiency.
recording. - storing or handling
problems.
Quality of raw material Specific criteria (Analysis): - Avoiding possible

• Pigments production problems due
− Assay (metal content to bad quality.
− Oil absorption
− Fineness (grindness) - Maximize productivity.
− Color (full, reduced)
− Moisture content - Minimize the quantity of
refuse products.
− pH
− Specific gravity
- Identifying raw
− Coverage
materials harmful for the
• Fillers (extenders) environment if discharged
− Oil absorption with the wastes generated.
− Fineness (grindness)
− Color (full, reduced)
• Resins/polymers/oils
− Non-volatile %
− Acid value
− Iodine number
− Viscosity
− Color
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Table (19) Monitoring of Raw Materials and Chemicals (continue)

Parameter Monitoring Method Indication
• Emulsions
− Non-volatile %
− pH
− Viscosity
• Solvent
− Specs distillation range
− Boiling point
− Refractive index
− Color
• Dryers
− Metal contents
− Evaluation of drying speed (non-
volatile percent)
• Dispersing agents
− Wet ability
− Refractive index
volatile %)
• Antifoaming agents
volatile percent)
Cost of the raw material Book keeping Assess economical burden due to non
necessary to produce 1 ton rational use of raw material and
of product. possible avoidable extra costs.
Proportion of the cost of Book keeping Assess economical burden due to non
raw material in the cost of rational use of raw material.
product & its variation
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8.2 Utilities
Monitoring of energy consumption takes into account the different forms of

energy. It is important to note that heat and electricity cannot be summed up,
as they are not commensurate. The energy efficiencies of heat and electricity
should therefore be dealt with separately (Table 20).
Table (20) Monitoring of Utilities

Parameters Monitoring Method Indication
Energy consumption Consumption Energy use efficiency
per ton produced measurements and book keeping
• Electricity
Fuel flow
• Fuel
(gauge accumulator)
Repartition between Recording and book keeping Energy use efficiency

the different types of
energy used (steam,
heating oil).
Water consumption Flow measurements, book Water use efficiency, most of the
per ton of product and keeping and recording discharge related parameters are
calculated
its variability.
Quality of the
utilities
Steam :
Pressure level
Degree of saturation.
Wash water : According to the specific Impact on the smooth running and
Pressure, temperature criteria efficiency of processes
Boiler water:
quality
Electric power :
Voltage level
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8.3 Products
The most important parameters that need monitoring are presented in table
(21)
Table (21) Monitoring of Products

Parameters Monitoring Method Indication
Amount produced Recording and book keeping: Production statistics

• Final product (water- • Paints
based paints, solvent-based − Viscosity
paints, resins, varnishes, and − Density
inks) − Grindness
− Gloss
− Drying time
− Coverage
− Mechanical hardness
− Bending
− Impact on metals
− Cross-cut adhesion
− Film application
− Color
• Resins
− Non-volatile %
− Color
− Viscosity
− Acid value
− Iodine value
− Drying time
− Gloss
− Hardness
− Flexibility
− Packaging stability
Rejects as a percentage of the Recording (quality control) Production quality,

total production, per unit of avoidable expenses
time
• Final product ( out of
specification, expired
date)
• In- line rejects
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9. Operation Control
Processes should be operated at the optimum operating conditions to ensure

disturbance-free operation, safety, highest yield and productivity as well as
product quality. Operation control deals with the control and monitoring of
key parameters that affect environmental performance. These key parameters
are monitored to minimize losses and therefore pollution.
Planned maintenance (regular) is important to facilitate disturbance-free
operation as well as minimize pollution and improve environmental
performance.
9.1 Monitoring Process Parameters

Tables (22) a and b present the major processes in each production line and utility
respectively, and the parameters that should be monitored to minimize losses, maximizing
productivity and predict maintenance and repair needs.
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Table 22 (Attached below)
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9.2 Planned Maintenance

Maintenance can be classified broadly into planned and emergency
maintenance. Various types of planned activities (preventive, predictive) are
undertaken with the basic objective of avoiding the need for emergency
(breakdown) maintenance and the corresponding loss of plant profitability.
The cost of an unscheduled breakdown resulting in loss of production can be
substantial, and the cost of repairs may also be considerably higher than the
cost of routine, planned maintenance of the equipment. A PM (preventive
maintenance) program must include the following basic elements (Table 23):
• Inventory of equipment with detailed design and operating parameters. The operating
parameters are monitored and are indicators for predictive maintenance.
• A record of failure rate and causes
• Evaluation of condition of equipment using the following criteria:
- Maintenance cost per unit of product.
- Downtime due to maintenance
- Percent of planned maintenance hours as compared with emergency maintenance
• Determination of corrective actions.
It is clear from the above paragraph that maintenance is a pollution prevention measure as it
increases the efficiency of the unit, minimizes water consumption by preventing leaks, helps
conserve energy through proper maintenance of electric and mechanical equipment as well as
insulation of steam pipes. The following are examples of typical maintenance procedures for
some service units operated in chemical plants:
Compressors Routine checking should include:

- Testing for leaks
- Checking refrigerant charge
- Checking oil level and lubrication
Boilers and There are many items to be checked to prevent explosion, such as
steam lines checking operating procedures, detection of flame failure, detection of
unburned combustibles. With respect to energy conservation, the
maintenance of steam traps, steam valves and insulation of steam
lines is important. The following parameters should be monitored:
- Water level in the boiler
- Water quality to prevent the build up of scales that reduce heat
transfer rates
- Temperature of metal, gas and water
- Pressure
- Fuel to air ratio
Dow-therm oil The primary consideration in the maintenance of heaters is to avoid

heaters conditions that might result in an explosive fuel/air mixture.
- Check the fuel supply for leaks
- Check air supply for leaks
- Check the flue gas temperature.
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Table (23) Monitoring and Preventive Maintenance

Parameters Monitoring method Indication
Total number of shut downs and Recording number and reason Overall assessment of the
production interruptions. for shut down. process reliability and avoided
environmental loads.
Number of equipment failures Recording number and reason Critical equipment.
resulting in production shut down per for failure.
type of process and type of
equipment.
Process performance monitoring. Methods depending on the Process performance/ efficiency

performance criteria. of equipment.
Process equipment condition Numerous methods, Prevention of failures.

monitoring. inspection, testing.
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10. Environmental Monitoring
Environmental Monitoring covers emissions to air, effluent and solid and

hazardous wastes. Section 4 presents the various laws and regulations that
apply to emissions, effluents and wastes from the paints industry. Expected
pollutants and hazardous releases from the industry are specified in section
2.4. For each production line related pollution aspects are identified in section
2.2., Figures 22-27 The pollution aspects of service units are presented in
section 2.3 and Figure 28 The output from the measurements and analysis of
the parameters are recorded in the environmental register of the facility.
Tables 24, 25, 26 present the compliance monitoring activities for the different
aspects of pollution as per environmental laws.
Monitoring of pollutants and releases requires careful consideration of the

techniques being used because of the expected effect on the interpretation and
hence, the reliability of the collected data. The common techniques used in
monitoring will be explained in next section.
10.1 Emission to Air

Air emissions can be measured either on periodical or continuous basis, the
monitored parameters for point source combustion emissions are : NOx, SO2,
CO, CO2, ashes, and particulates. Parameter monitored fugitive emissions
depend on the specific production process.
Periodical measurements
Periodical measurements give the state of emissions over the chosen sampling time. Quantities
needed in every emission calculation, such as volumetric flow rate, oxygen content, and
humidity of the flue gases, are determined by periodical measurements. Periodical
measurement results are also used as a support for converting the continuous concentration
measurement results into annual emissions.
Periodical measurements are carried out as manual single measurements or as
short period continuous measurements by the plant itself or by an exterior
measurer. Periodical emission measurements are carried out annually for the
following emission components NO x, SO2, CO, CO2 and particulates.
Continuous measurements
The continuous measurements describe the temporal variation of the
concentrations and volume of the emission components during the operation.
General requirements for continuous monitoring systems are that the sampling
locations should be representative and that the monitoring equipment should
be suitable for the concentrations to be monitored in the prevailing
circumstances. The emission control data system should preferably be part of
the process control system. SO2, particulates and CO are generally measured
continuously.
Emission calculation
Differences between the different calculation methods can cause mistakes
when comparing the environmental loads of different plants. Material balance
calculations are used to complete emission measurements in order to get an
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impression of the reliability of the measurement results as well as to create a

general view of the total emission level of each component. The amount of
diffuse emissions that can not be recorded by emission measurements can be
substantial.
10.2 Effluents (wastewater)

The regulations set the limits for the concentrations of specific pollutants in
wastewater when discharged to a recipient body. For monitoring purposes, the
discharge values for specific substances or parameters are mostly expressed as
total amounts per unit time. In some cases these values are given as specific
amounts per ton of product or as purification efficiencies. Limit values are set
for a large number of parameters such as COD, BOD5, O&G, TDS, TSS, pH,
color, heavy metals (iron, copper, chromium, cadmium, lead, zinc, nickel, …).
Monitored parameters
Typical wastewater parameters include the following:
• Wastewater flow (Q), m3/d
• Total suspended solids (TSS), mg/l
• Total dissolved solids (TDS), mg/l
• Oil and grease (O&G), mg/l
• Heavy metals (iron, copper, chromium, cadmium, lead, zinc, nickel, …), mg/l
• Chemical oxygen demand (COD)
• Biological oxygen demand (BOD5)
• pH
• Color
Flow measurement
Measuring of the total wastewater flow is required for the operation of the wastewater
treatment plant. There have been no provisions on the procedures or the accuracy of a flow
measurement, but installation of automatic composite samplers (preferable flow dependent)
can be used. Wastewater flow is usually measured with a venturi measurement equipment, but
also magnetic and ultrasonic methods are used. Measurement equipment is maintained several
times a year and the measurement system is calibrated regularly.
Regular maintenance, control and calibration are needed to obtain an acceptable measurement
accuracy level. The structure of the measurement system, a possible mounting fault or a false
choice for measurement area can cause errors. Other sources of error or factors disturbing the
measurement are dirt deposition and temperature variations. Evaluation of the total error is
extremely difficult, as it must include all these factors.
Sampling
Well realized sampling is essential for determining of wastewater discharges. There are
general instructions for wastewater sampling. However, industry-specific problems such as
variation of the wastewater quality or flow rate have to be solved case-by-case.
Samples are either single grap samples, composite samples, or composite samples in
proportion to the flow. A single grap sample reveals the composition of the wastewater at the
sampling time. With several grab samples it is possible to follow the wastewater load peaks,
quality variation and the variation range of the significant parameters. A composite sample
reveals the average composition over a chosen period. A 24 hour composite sample is
normally taken in proportion to the flow so that the sampler is controlled by flow meter.
Sampling period and sample size are considered case-by-case depending on the analyses used
and on the issues affecting the reliability of sampling and analyses. Samples for wastewater
analysis are mostly taken over 24 hours, 5-7 days a week. In some cases samples are frozen
and combined to cover a longer period. Samples for COD and suspended solid determination
96 Environics
September 2002
are taken daily or continuously and analyzed daily. Samples for BOD and nutrient
determination are usually taken weekly. PH, temperature, and conductivity are usually
measured continuously.
Analyses
A specific analysis program is needed for each plant. The program usually covers a wide
range of measurements and analyses, as predetermined in the self-monitoring plan. The
measurements and analyses should be carried out according to the standards recommended by
EEAA “Methods for sampling and Analysis of Water and Waste Water” October 1999”
Calculations
Wastewater discharges are calculated and reported according to the specifications determined
in the monitoring plan. Discharges are often calculated as below:
Discharge per batch The equipment cleaning wastewater or solvents can be

calculated as follows; amount/ equipment * number of
equipment * average number of batches / day.
Discharge per day The arithmetic mean value of the daily samples taken during
one month divided by the number of sampling days.
Discharge per month Daily discharge multiplied by calendar days.
Discharge per year Sum of the values of monthly discharges
The efficiency of biological wastewater treatment is also controlled by

calculating the reduction of organic matter (BOD,COD) between untreated
wastewater before primary sedimentation and treated wastewater after
secondary clarification.
A typical wastewater discharge monitoring report includes e.g. monthly mean

values and variations for discharges at the monitoring points before and after
the treatment, applicable limits values and also some production information.
10.3 Monitoring of Solid Wastes

The properties of solid wastes that are generated, especially when they are
utilized or taken to a landfill, have to be investigated. The general principles in
landfill operation are that the composition, leachability, long term behavior
and the properties of the waste have to be known. The approval for using a
landfill for a specific waste is based on the origin and the properties of the
waste. The evaluation of the properties of the waste is based on:
• The composition of the waste.
• The organic content and degradation properties of the waste,
• The content and leachability of harmful compounds, and
• The ecotoxicological effects of the waste and the landfill waters
Table (25) presents a compliance monitoring plan for the solid wastes.
10.4 Monitoring of Hazardous Wastes Management
In order to comply with the law regulations, the industrial establishments are required
to take all necessary measures to properly manage their hazardous waste on site. Law
4/1994 and its Executive Regulations address the measures to be implemented at the
97 Environics
September 2002
different stages of the management process starting from the reduction of waste at
source through to identification, collection, on-site storage, on-site treatment,
transport for off-site disposal, as well as keeping records (Environmental Register).
Following are the main requirements to be implemented by an industrial
establishment generating hazardous waste. These requirements are summarized in
table (26). Details for these requirements are presented in sections 4.2.2 through to
4.2.10 of the EPAP Hazardous Waste Management Manual for Industries, 2002.
Figure (32) shows the hazardous waste management options for paints industry.
98 Environics
September 2002
Table 24 (Attached Below)

Table 24(Attached Below)
Table 25(Attached Below)
Table 26 (Attached Below)
Spent cleaning solvent
Filters sludge containing paints

and solvents
Sludge containing
paints& solvents
Solvent recovery unit
Sludge generated from the
wastewater treatment unit
containing paints and solvents
Incinerator
Ashes
Chemicals empty
containers
Landfill
Spent filter cloths containing

paints and solvents
Spent cleaning
solvents
Cleaning with solvents
Alternative 1
Alternative 2
Figure (32) Hazardous Waste Management Options
99 Environics
September 2002
11. Data Collection, Processing and Usage

The general objective for the self-monitoring system is to produce data that is representative,
repeatable, reliable, compatible and comparable. These characteristics are dependent on the
applied measures for quality control and quality assurance throughout the data production
chain i.e. volume determination, sampling, sample pretreatment, treatment and analysis, data
processing and reporting.
11.1 Data Collection and Processing

The different parts of the monitoring system of a plant include diverse factors affecting the
reliability and comparability of the emission data. These factors have to be taken into
consideration in sampling, sample treatment and analysis as well as in processing and
reporting of the data. Requirements for the whole data production chain should be set in the
monitoring program. In addition, implementation of the relevant measures for quality control
and quality assurance is extremely important in obtaining maximum reliability, repeatability
and comparability.
The aspects and parameters that are involved in data collection and processing are explained
in the Appendix A. Figure (33) shows the main aspects and parameters that affect the
effectiveness of SM in terms of reliability, repeatability and comparability.
11.2 Using SM Outputs

The implementation of the self-monitoring plan will basically result in three outputs:
• Data and information about the facility

• Preparing the environmental register as required by law.
• Reports describing results of the self-monitoring and problems
faced during implementation
• Feed back and decision making
100 Environics
September 2002
Quality Control + Quality Assurance
Calibration
Data Production
• Maintenance
Sampling Measurements & Records • Reference measurements
• Documentation
• Determination of volume/ • Data collection • Knowledge of the process
amount - Data handling
• Sampling - Data processing
- Sample pretreatment • Reporting
- Sample treatment
- Sample analysis
Total Uncertainty
• Data processing
- Reporting
Reliability- Repeatability- Comparability
Figure (33) Parameters Affecting SM Reliability
101 September Environics

2002
11.2.1 Techniques for Summarizing and Illustrating Data

It is best practice to record process and environmental information in a detailed archive or database. It can then be
related easily to the monitoring results and used to evaluate, compare and manage aspects of process performance
such as:
• the rate of release of pollutants compared to production

• the rate of generation of waste compared to production
• the rate of consumption of energy and/or materials compared to production
• the impacts on environmental receptors compared to production or to their
sensitivity
• the overall resource efficiency of the process, i.e. production compared to
inputs or raw materials and energy, and outputs of pollutants and waste
There are many techniques used in the interpretation of results (e.g. statistical analysis of
the measurement results, reduction of operating conditions to normal conditions when
monitoring gaseous emissions).
11.2.2 Environmental Register

Only monitoring data related to compliance will be included in the environmental register. Description of the
measuring and/or analytical techniques used should be reported as well as the location of sampling and
measuring. EEAA/EPAP prepared a detailed description of the environmental register, based on the
requirements of law 4/1994, see Annex B. The competent authorities could request the inspection of the
measuring devices to check their operability and the maintenance record for these devices. The procedures for
taking samples could also be checked by the inspector. The inspectors check whether the facility has provided
information that is relevant and of sufficient quality. To assess compliance, a simple numerical or statistical
comparison between the measurements, their uncertainty and the limit value is performed.
According to Law 4/1994, compliance self-monitoring data should be recorded and kept for a minimum of 10
years.
11.2.3 Reporting
Description of the reporting scheme, its content, recipient and purpose should be included in
the self-monitoring plan. A monitoring report is a uniform presentation of data over a fixed
period. An annual monitoring report that provides information of the past calendar year is
always required. Shorter period reports are required for significant polluters. The conditions
of the process and equipment as well as location of monitoring points should be specified.
Reporting can be:
• Internal to inform management and raise the environmental awareness of the facility personnel. It should
include problems met during the implementation of the SM plan to be used in decision making.
• External for the competent authority. based on the environmental register, establishments are required to
report on environmental violations.
11.2.4 Internal Auditing and Conclusions on Results

The data obtained must be compared regularly with the objectives written down in the monitoring program to
check that they are being met.
11.2.5 Feedback and Decision Making

Feedback on the assessment of compliance based on the monitoring results should include all parties involved
with the monitoring activities. The participants should make the necessary improvements and corrections to the
next monitoring program.
In those parts of the monitoring program where compliance is met, possible reduction in frequency of
monitoring can be considered and instead move resources to parts that need more accurate monitoring, e.g.
borderline or non-compliance situations.
Feedback should include all parts of the monitoring program, process, product control, maintenance,
environmental management and occupational safety. Detailed requirements should be set for the improvements
102
needed and a date fixed for their implementation.
11.2.6 Using Outputs in Public Relations

The monitoring data is refined and distributed to the end users such as national and international reporting,
research and statistical purposes, citizens, and the media.
The citizens have the right to present complaints about the health or environmental impacts caused by the
operation these complaints are directed to the permitting and supervising authority.
Monitoring data is needed e.g. in national research and statistics, for planning and evaluation purposes, by
national group organizations and the media.
103
Page no Report Name (Times New Roman font 10 bold italics)
Table (10) Egyptian Environmental Legal Requirements for Industrial Wastewater
Law 48/82:
Law 4/94: Law 93/62 Discharge into :

Parameter
Discharge Discharge to Sewer
(mg/1 unless
Coastal System (as modified Underground Reservoir & Nile Drains
otherwise noted) Nile
Environment by Decree 44/2000) Branches/Canals
(Main Stream) Municipal Industrial
BOD (5day,20
deg.) 60 <600 20 30 60 60
COD
100 <1100 30 40 80 100
pH (Grease)
6-9 6-9.5 6-9 6-9 6-9 6-9
Oil & Grease

15 <100 5 5 10 10
Temperature (deg.) 10C>avg. temp of

<43 35 35 35 35
receiving body
104 Month year Consultant Name

Law 48/82:

Parameter
(mg/1 unless
Total Suspended
Solids 60 <800 30 30 50 60
Settable Solids
__ <10 __ 20 ___ ___
Total Dissolved
Solids 2000 __ 800 1200 2000 2000
Chlorine
__ <10 1 1 ___ 10
1
PO4 5 30 1 ___ ___
Total phosphorus
25 ___ ___ ___ ___
105
Law 48/82:

Parameter
(mg/1 unless
0.5
__
Fluoride 1 <1 0.5 0.5
Cadmium 0.05 0.2 0.01 0.01
__ __
Chromium 1 __
Chromium Total concentration for theses
Hexavalent __ 0.5 1 1 metals should not exceed 1 for
all flow streams
106
Law 48/82:

Parameter
(mg/1 unless
1
Copper 1.5 1.5 1
Iron 1.5 __ 1 1
Lead 0.5 1 0.05 0.05 __ __
__ __
Mercury 0.005 0.2 0.001 0.001
__ __
Nickel 0.1 1 0.1 0.1
__ __
Silver 0.1 0.5 0.05 0.05
__ __
Zinc 5 <10 1 1
107
Law 48/82:

Parameter
(mg/1 unless
__ __ __
Cyanide 0.1 <0.1 0.1
__ Total metals should not

Total heavy metals 1 1 1 1
exceed 5 mg/l
108
Table (22)a Operation Control for Production Lines
Major Frequency
Pollution Cause of Affected Parameter Person
Indication /Duration
Process pollution media monitored Method used Responsible
Water- Based paints Production Line
Mixing Particulates and Work - Mixer speed - Speed (rpm) meter - Out-of-spec. product Once/ batch
VOCs emissions - Properties of raw - Quality control analysis for
environment product (table 21)
materials (table 19)
- Pollution in work place
Spills Wastewater Liquid level in the - Level indicator - Spills or leaks

mixer - Flowmeter - Lower productivity
- End-of- pipe effluent
characteristics
Grinding Particulates and Work - Mill speed - Speed (rpm) meter - Product quality (table Once/ batch
(Rollers VOCs emissions environment - Properties of raw - Quality control analysis for
materials (table 19) product 21)
and ball
mills) - Pollution in work place
Spills (ball mill) Wastewater Liquid level in the - level indicator - Spills or leaks
ball mills - Lower productivity
characteristics

Reject paint Hazardous - Spacing between - Vernier Paint quality

solid waste - Speed meter (rpm)
rollers - Flowmeter and
- Mill speed thermocouple
- Temperature and flow
rate of cooling water
Finishing VOCs emissions Work - Mixer speed - Speed (rpm) meter - Product quality (table Once/ batch
(Mixing) environment - Properties of raw - Quality control analysis for

characteristics
Filtration Filter sludge Land Pressure drop Pressure gauge - Product flow rate (lower Once/
productivity)
batch
Packaging Paints losses Wastewater Spills amount Mass balance calculation - Spills Once/
- Lower productivity batch
characteristics
Solvent- Based paints Production Line

VOCs emissions environment - Properties of raw - Quality control analysis for
product (table 21)
110

characteristics
and ball
characteristics
Reject paint Hazardous - Spacing between - Vernier Paint quality

Finishing Spills Wastewater Liquid level in the - Level indicator - Spills or leaks Once/ batch
(Mixing)
characteristics
111
productivity)
batch
Packaging Paints losses Wastewater Spills amount Mass balance calculation - Spills Once/
characteristics
Printing Inks Production Line

product (table 21)

characteristics
and ball
characteristics
112
Reject inks Hazardous - Spacing between - Vernier Inks quality

Finishing Spills Wastewater Liquid level in the - Level indicator - Spills or leaks Once/ batch
(Mixing)
characteristics
productivity)
batch
Packaging Inks losses Wastewater Spills amount Mass balance calculation - Spills Once/
characteristics
Varnishes Production Line

product (table 21)
113

characteristics
Spills Wastewater Liquid level in the - Level indicator - Spills or leaks Once/ batch

characteristics
productivity)
batch
Packaging Varnishes losses Wastewater Spills amount Mass balance calculation - Spills Once/
characteristics
Alkyd Resin Production Line

Reaction Reaction - Temperature - Thermocouple - Lower productivity Once/ batch
completion - Pressure - Manometer - Product quality (table
- Clock
- Time of reaction 21)
- Amount of - Amount of solvent
solvent
114
needed for the

removal of
reaction water
Xylene Efficiency of Wastewater - - Analysis - Xylene concentration Once/ batch

recovery separation
Concentration - Weight/ volume in wastewater from gas/
measurements
liquid separator
of xylene in
- Higher solvent
water/ xylene consumption (lower
amount of solvent
mixture recovered)
- End-of-pipe effluent
- Amount of make-
characteristics
up solvent used
115
For All Units

Equipment - Spent caustic Wastewater Amounts Calculations and book End-of-pipe effluent Once/ day
cleaning characteristics
and floor solutions contain keeping
washing - Spent solvents hazardous
between
batches materials
Desacking Empty Land Efficiency of Mass balance calculations - Particulates or spills Once/ day
and - Empty containers
emptying containers feeding
of contaminated with
contaminated
chemicals significant amounts of
containers with significant
chemicals
amounts of
chemicals
Feeding of Work
solid chemicals envronment
Feeding of Wastewater
liquid
chemicals
116
Table (22)b Operation Control of Utilities

Service units Cause of Affected Parameter Indication Method used Person Frequency
pollution media monitored Responsible /Duration
Boilers
Steam Air - Temperature Steam leaks - Thermocouple On-line
- Pressure level Steam quality - Pressure gauge
- Degree of saturation - Flowmeter
- Flow rate
Boiler flue gas Air - Fuel to air ratio Incomplete combustion - Flowmeters Once a month
- Excess air (CO % in flue gases) - Gas analyzer
- Combustion efficiency - Calculations
Boiler fuel Air - Type SOx % in flue gas - Flowmeter
- Flow rate - Inventory
- Consumption rate - Chemical analysis
- Sulfur content
Water treatment Water - Type Losses Inventory Once a month
chemicals - Consumption rate
Lube oils Water - Type Losses Inventory
- Consumption rate
Boiler Feed Water Water - Flow rate - Blow-down and carry - Flowmeter Once a day
- Chemical quality (TDS, over - Chemical analysis
oxygen content) - Scale formation and conductivity
meter
Softener back wash Water Flow rate Zeolite regeneration Flowmeter on wash
efficiency water
Boiler blow-down Water Flow rate Feed water quality Flowmeter
Dow-therm Oil Heater
Heater flue gas Air Fuel to air ratio Incomplete combustion Gas analyzer Every 6 months
(CO % in flue gases)
heater fuel (mazot/ Air Sulfur content SOx in flue gas Gas analyzer
solar)
Cooling Towers
Input water quality Water Temperature, dissolved - Scale formation - Thermometer Twice a month
and suspended solid - Higher temperature - Analysis
(low efficiency)

Output water Temperature Higher temperature (low Thermometer

efficiency)
Blow-down Flow rate Scale formation (low - Flow rate
efficiency) measurement
(flowmeter)
- Calculation and
mass balance
Wastewater Treatment Plant
- Input flow rate Receiving water - Input flow rate and End-of-pipe effluent Analysis and Once a month
higher than design body characteristics characteristics (low measurements
value - Output flow rate and treatment efficiency)
- Pollutants characteristics
concentration
higher than
design value
Solvent Recovery Unit

Efficiency of Land Sludge composition Sludge characteristics Analysis and Once a week
separation (containing higher measurements
amounts of solvents)
118
Table (24) Compliance Monitoring for Air pollution, Workplace, and Wastewater
Major Impact Parameter Method used Source type Operating Person
pollution monitored responsible
sources Poin Diffu Normal Exceptio
nal
t se
Boilers
Flue gases Air - Sulfur oxides - Gas analyzer
- Nitrogen - Dust meter
oxides
- Carbon oxides
- Particulate
matters (ash)
Fans Work Noise Noise meter

environment
Boiler house Work Heat stress (temp. Thermometer and
environment and humidity) hygrometer
Dow-therm Oil Heater

Flue gases Air - Sulfur oxides Gas analyzer
- Nitrogen - Dust meter
oxides
- Carbon oxides
- Particulate
matters (ash)
Paints, Inks, and Varnishes Production lines

Mixing Work VOCs, Particulates - Ambient air
environment (PM10) analyzer
Grinding VOCs, noise - Noise meter
Filtration VOCs

Filling and VOCs, noise

packaging
Alkyd Resin Production Line
Reaction Work - VOCs - Ambient air
Solvent/ water Environment - Heat stress analyzer
separation - Thermometer and
Cooling and hygrometer
dilution
Filtration
End-of-pipe
Wastewater Receiving BOD, COD, - Chemical analysis
effluent water body O&G, TDS, - Measurements:
TSS, pH, color, BOD tester
heavy metals COD tester
(iron, copper, TSS tester
chromium, (Hoffman funnel)
cadmium, lead, Atomic absorption
zinc, nickel, (spectrophotometer)
…).
120
Table (25) Compliance Monitoring Plan for Solid Wastes
Process Unit Type of waste Tons/year Tons /ton Segregation from Internal Utilization Disposal
production hazardous waste Reused Recovered
Packaging Plastic, paper, metals
Workshops Scrap
Garage Scrap

Table (26) Compliance Monitoring Plan for Hazardous Wastes Management
Process Unit Type of waste Tons/ Tons /ton Waste Waste minimization Handling Storage On-site Disposal
year production segregation Source Reuse/ treatment
reduction Recovery
Empty containers
contaminated with
chemicals
Filters sludge containing

paints and solvents
Spent filter cloths,

All production contaminated with
lines
paints (resins, pigments,
fillers,…) and
containing heavy metals,
solvents
Spent cleaning solvents
Out-dated, rejected, and

off-spec. products
Solvent Sludge containing paints

recovery unit and solvents
Wastewater Sludge containing heavy

treatment unit metals and hydrocarbons
122
List of References
1) Saarinen K., Jouttijarvi T. and Forsius K. (1998) Monitoring and Control Practices of Emissions in Pulp
and Paper Industry in Finland. The Finish Environment 220. 38 p.
2) Saarinen K. (1999) Data Production Chain in Monitoring of Emissions. The Finish Environment 326. 52
p.
3) .

4)
/

5) Shreve’s, Chemical Process Industries by George T. Austin, fifth edition. Published by McGraw- Hill
Book.
6) Guide to Pollution Prevention, The Paints Manufacturing Industry, EPA (June 1990).

Annex J
List of interviewed Organizations
Organization Address Contacted Person

A- Private Sector
Eng. Yasser Bishay – Eng. John Bishay;
EAGLE Chemicals ‫ اور ادس – روآ‬-‫ رع از‬72
Managing Directors
Egyptian American Paint & Mr. Ahmed Abd El-Ghany – General
‫ن‬#$‫ ر‬%$ &'‫( ا‬$ ،(1-‫ا ا )ب‬
Coatings (EAP) Manager & Mr. Hazem Meligy
Eng. Lotfy El-Badrawy, research &
-* -.‫ض ا‬+‫ ا‬0+*&‫ب ا‬+1 2‫ ا‬2‫ ا‬- '*‫ر‬+, Quality Assurance General Manager –
KAPCI Coatings
6 Eng. Waleed Helmy, Business
Development Manager
Modern Chemical Industries 4(‫و( ا‬.‫ات ا‬
Eng. Saleh Ali Saleh, CEO
(MCI) ‫ اه&ة‬- 7* ‫ح‬9: – ‫ر‬+6'‫ رات ا‬12
‫رو=& ا‬ Mr. Mohamed Hassan - Financial
Rover
@‫ ا&و‬A$ – ‫?>ر‬$ ‫ رع‬16 Department*
German Lebanese Co. ‫و(ت ا ا‬.‫(ت و ا‬+6B C6B‫ ا‬CD‫&آ ا‬E‫ا‬ Mr. Abd El-Fatah Ibrahim El-Hoot;
(GLC) ‫ر‬+6'‫ ا‬- 54 ‫ رع‬,‫و‬D‫ا‬ Head of the Company
Eng. Maged Ibrahim Mostafa Ali – Mr.
‫(ت‬+6B ‫ان‬I‫ر‬ ‫ر‬, ($ ‫ ـ ا ا اد* ـ‬52 'J
Saied Abd-El-Latif
SIPES
‫ اه&ة‬- ‫& ا(ة‬$ - ‫رة‬+4‫ رع ا‬104 Mr. Mahmoud Bdier, General Manager
Quality Paints
M+‫ت ا‬C‫ اه‬NC$ ‫&آ‬ $ ‫م‬$‫ أ‬9/8 'J – C4‫ر – ا ا ا‬+6'‫( ا‬$
Ms. Janet
(‫ل‬C+C ‫ت‬C‫)ده‬ U6B, ‫م‬+*&‫ ا‬,‫ا‬+, ‫ار‬+, (‫ ا‬0‫ا‬
4(‫ت ا‬C‫ه‬B ‫ او‬+‫ا‬ Eng. Omar Ghaly – Exports Manager
‫&ج ا'&ب ا(ة‬, ($ – C4‫ ا ا ا‬33 ‫ك‬+B,
(‫و‬$) and Deputy chairman
Eng- Sherif El-Ghaysh - General
(‫و‬.‫اد ا‬+B ‫&ق‬E‫&آ ا‬ ?‫&ا ا‬6 - ‫ ا ا‬- 1 7J‫ ر‬- %(‫ ا‬%(‫ ز‬BZ ‫رع‬
Manager / Mr. Hazem Ramadan -
‫(ت‬+6‫وا‬ (, 7‫&اه‬,‫ ا‬$ - ‫ر‬+[ ‫ آ&*>ل‬135 ‫)رع‬
Adminstrative manager
(B M+J N$ ‫ار‬+, - A3 - 44‫ا ا ا‬
(\[:) ‫ك‬,‫&آ ا(&و‬ Mr. Mohamed Shafik
‫ن‬#$‫ ر‬%$ &'‫ ا‬- ‫ت‬194B .‫] و&آ ا‬B‫وا‬
0b - B _`, ‫& رع‬a‫ ا‬- 4 7J‫ ر‬- ‫^ت‬EC N$1 ‫رع‬
Eng. Badr Sidnawy - Chairman (Tel:
‫و(ت‬.‫ت وا‬C‫ه‬B ].* ‫&آ‬ ‫&ج ا>رة‬, %$ ‫&ب‬, - ‫ اور ادس‬- ‫&ج دء‬, - cC‫ر‬+.‫ا‬
0227355838 - 1)
e$f‫ ا‬- ‫^ت‬EC N$1‫ و‬1‫ا?ر‬
PACHIN Pachin Information is being filled by Eng. Mohey Abdel-Razic and Eng Ahmed Maher,
Experts from Pachin.
Mr. Ramez Mounir – Export Department
A6C – (&‫ت ا‬C+,&.‫&آ ا‬
‫& ا(ة‬$ – B*g‫ان ا‬$ – %M[‫ رع ا‬3 Manager (Tel: 022634995) "Contact
(eBb‫ت و‬C+,&‫ )آ‬U>B=
Person: Ms. Amira"
Ms. Nashwa (Technical Office
(&(+‫&آ ا&( ا‬E‫ا‬
‫ء‬9‫ ا‬h[C - J‫ ا‬- 106 7J‫ ر‬- A‫رع ا‬ secretary) - Eng. Amal Ezzat - Technical
(‫و‬.‫ت ا‬B
office manager) - Tel: 0233363171/2
Mr. Ashraf Amin - Exports and Imports
%b+( ‫ا`س‬ N,‫ن اور ا&ا‬+b‫ &ا‬%‫آ‬$ ‫ل‬+$ ‫ر(ا‬+B=
Manager - Mob: 0122202803
_6(‫ ا‬A== ‫&آ‬ ‫ ا'دى ـ اه&ة‬105 ‫ ش‬50 Mr. Said Ayoub Zaki –
Organization Address Contacted Person
- 0225253724 ‫ت‬B'‫اد وا‬$k‫ن ا‬+l &($
0122145184
‫و(ت‬.‫ وا‬4(‫ت ا‬C‫&آ اه‬ %$‫ار &آ آر‬+, 193 'J ، ‫و‬D‫ا ا ا‬
Dr Abd El-Aty Taha, Tel: 0238341154
(MCC) &,+>‫ أآ‬6 ، ‫ت‬J‫ر‬+B
‫(ت وات‬+6B ‫&آ ال‬ Mr. Adel Badry – Exports Manager
&,+>‫ أآ‬6 ($ ، ‫و‬D‫ ا ا ا‬220 'J
(‫و‬.‫ا‬ 0106040901
B- Public Sector & Government
Egyptian Organization for
‫دة‬+‫[ت وا‬:‫ا‬+B $'‫ ا&( ا‬l`‫ا‬ Eng. Essam Shams El-Din, Head of
Standardization and Quality
Central Department for Standardization,
(E.O.S.), Ministry of Trade ‫ اه&ة‬- (&$D‫ – ا‬%,‫ر(] ار‬b ‫ رع‬16 E.O.S., MTI.
and Industry (MTI)
‫>&وآو(ت‬6B #,‫&آ ا&( ا‬E‫ا‬ Eng. Mohamed Sami Abd El-Hady, Vice
Egyptian Petrochemicals
Holding Co. - &C ($ ،*‫ ا اد‬J: %Z&‫ ا‬6 ‫ رع‬18 Chairman for Technology & business
‫اه&ة‬ Development
Egyptian Environmental ‫ة‬Z‫ و‬- ‫ث ا‬+B>‫ = ا‬7.>‫&وع ا‬E$ – l6‫ن ا‬+l ‫`ز‬1 Eng. Mamdouh Hegazy & Eng.
Affairs Agency, Ministry of ‫ا‬ Mohamed Issa, Environmental
State for Environmental
‫ اه&ة‬- ‫را – ا'دي‬f‫ان ا‬+BZ &$ h(&M 30 Specialists
Affairs
‫ ارك ا&( – وزارة ا‬B$ Mr. Magdy Sief El Nasr, Department
Egyptian Customs, Ministry Director at Commissioner’s Office and
of Finance ‫ اور‬3 7J‫&ج ر‬, ,‫&اج وزارة ا‬,‫ ا‬,U$‫>اد رع ر‬$‫ا‬ Mr. Ali Galal, Egyptian Customs,
o4‫ا‬ Ministry of Finance
General Organization for Mr. Mohamed Shafeek, Head of the
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Export and Import Control Central Directorate of Chairman’s
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Paints Market - Industry Profile

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Industrial Modernization Center

Industrial Modernization Program

Export Support Study for Paints and Coating

Cairo, December 2008

Submission Letter (to be scanned and inserted here)

Annexes No. of Pages

Industrial Modernization Center (IMC)

Export Support Study for paints and Coating Industry

I.1 Industry structure

I. ACRYLIC POLYMER EMULSIONS

Local Demand (only paint industry): 50,000 – 60,000 Tons

Paint and Coatings Inputs:

Paints and Resins Production:

Decorative 271 65% 1.1 51% 52% 48%

Decorative 462 75% 1.8 63% 60% 40%

Decorative 620 75% 2.5 63% 68% 32%

Government Direct Customs, Taxation, environment, EOS, GOEIC

Public Sector Indirect Egyptian General Authority for Petroleum

PARASTATAL Supervision Chemical Chamber and Export Council

Private Sector Indirect Private sector companies (Producer and

Source: Sector interviews

I.4 Market structure

Egyptian Economic Growth

Important Economic Indicators

Source: Industry Insight Petrochemicals – Zawya

Investment and Employment:

Producer Producer & Exporter

I.4.2 Paints Market in Egypt

Synthetic Paints 30% 47%

I.4.3 Industrial Coatings Market in Egypt

challenges by focusing on the development of sustainable and renewable products. The

I.4.4 Global Coatings Market1

I.4.5 Egyptian market share of the industry in the international market

I.4.6 Local market supply and the competition structure

* The competitive position in industrial paints is as follows:-

Table 1: Average Consumption of Paints (Kg), 1990’s

I.4.7 Sales and Marketing strategies

I.4.8 Existing Support to paints, coatings and resins industry

I.5 Manufacturing Process of paints, Coatings and resins

Manufacturing Alkyd Resins include an exothermic, reversible chemical reaction in which

II. Data Collection/ Sources

II.1.1 Main producers of Paints and Coating by country

COUNTRY Main Paints Producers

Chart II.1: Imports of Paints and Resins, 2002-2007

Chart II.2: Imports of Raw Materials, 2002-2007

B. Imported Intermediate products

C. Imported Raw Materials

II.1.3 Egyptian Exports of Paints and Coatings

A. Paints and Coating Exports by Region

Chart II.2: Exports of paints by Region

Source: Table II.3

B. Paints and Coating Exports by HS Code

Table II.6: Resins Exports (USD) by HS 1992 Code

II.2 SWOT Data (Stakeholders)

II.2.2 Paint and Coating Exporters’ Population and Sample Size:

$5,000 or more 147,922,263 99.5% 49,307,421 99.5% 152 39%

Table II.8: Paints and Coating Exports, in Million US$ (2005-2007)*

Source: Table II.8.

Egypt Paints and Resins exports

Egypt Resins Exports:

Table III.3: Exports of resins by HS Code without support (US$ Million)

III.2 EU Demand on Paints and Coating products

III.3 Expected EU and Non-EU Exports of Paints and Coatings

* * ***

* * ***

* * ***