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TRAINING REPORT ON MACRO POLYMER PLANT

AT G.V.M.M, ODHAV, AHMEDABAD BY RONAK A. SHAH B.E CHEMICAL

LUKHDHIRJI ENGINEERING COLLEGE, MORBI, GUJARAT.

Acknowledgement

It gives me great pleasure to submit this in plant training report on completion of my industrial training during 6.06.2011 to 24.06.2011 at the MACRO POLYMER PLANT, ODHAV G.V.M.M, AHEMEDABAD. It was a great experience for me at this esteemed organization, which I will cherish forever. I express my sincere thanks to Mr. Mayank Parikh[DIRECTOR] for giving me the opportunity to pursue my industrial training at the MACRO POLYMER PLANT. I am highly indebted to Mr. Pankaj Parmar[MANAGER] for guiding me throughout my training report. Id also like to express my gratitude to all the staff of MACRO POLYMER PLANT for their support and cooperation.

Thank you all once again.

RONAK A. SHAH B.E. CHEMICAL L.E. COLLEGE, MORBI

INDEX SER NO
1 2 3 4 5 6 7 8

TOPIC NAME
INTRODUCTION OVERVIEW HIGHLIGHTS DETAIL DESCRIPTION APPLICATION FORMULATION TYPES OF PAINTS OTHER PRODUCTS

PAGE NO

INTRODUCTION

We MACRO POLYMERS is a private limited & an ISO 9001:2008 certified company located at ODHAV & MORAIYA at Gujarat in Western India.

The company is built on a foundation of technocrats who have experience of five decades in the manufacture of Synthetic Resin for Paints, Printing Inks and Adhesive Industries.

Our Chairman Mr. Shirish Parikh started factory in 1962. In 1995 we turned into Private Limited Company.

Since the inception of the company in 1995 with an installed capacity of just 500 tones per year, and now we are achieving 15,000 tones per annum.

The credit of the companys rapid progress is largely attributed to the most valued customers for patronizing the products of the company, hard work done by all the employees and an unprecedented support extended by all the stack holders and well wishers.

Currently we are one of the leading manufacturer of resins in India and

exporting to Middle East, Africa, Asian and south east Asian Countries.

We are known for our consistent quality and uninterrupted supply position. We can provide performance guarantee for the material supplied by us.

We have manufacturing capacity so as to give full container load with one single batch.

We are committed to deliver customers consistent quality products and an assurance of the quality for the entire range of the products.

This assurance begins from the purchase of the raw materials, its analytical testing and approval before consumption, stringent control of processing parameters, intermediate quality monitoring and approval of the finished products before dispatch.

The norms of Quality Assurance Department are being strictly followed, without any compromise and deviation from the standards.

We laid down stringent specification and procedures for the purchase of raw materials, processing parameters and specification of the finished goods testing in detail.

OVERVIEW

Manufacturer of Alkyd Resins, Butylated Melamine Formaldehyde Resin, Butylated Urea Formaldehyde Resins, Maleic Modified Rosin Ester, Acrylic Resins, Epoxy Resin, Epoxy Hardner & Ketone Resin.

We Macro Polymers is a private limited & an ISO 9001:2000 certified company located at Odhav &Moraiya at Gujarat in Western India.

The company is built on a foundation of technocrates who have experience of five decades in the manufacturer of Synthetic Resin for Paint, Printing Inks and Adhesive Industries...

Research & Development Centre

We have good facilities to develop and standardize resin and varnishes to suit customers requirements and specifications.

Our R&D Centre is recognized by Department of Scientific & Industrial Technology, Ministry of Science & Technology, Government of India.

Our Chairman Mr. Shirish M. Parikh is a qualified Chemical Engineer from UDCT Bombay University and has master degree in Chemical Engineering from U.S.A.

Our Director Mr. Mayank S. Parikh is also a Chemical Engineer from L.D. Engineering College of Engineering Ahmedabad.

Our Chairman has worked in Production and in research & development facilities abroad and in India in renowned paint and synthetic resins manufacturing companies.

HIGHLIGHTS

Product:
Butylated MF Resin Butylated UF Resin

Production of UF Resin:

Production of MF Resin:

Applications:

PU Automotive Paint and Automotive Refinishing Paint Paint for specific use Wood coating Amino-alkyd baking coating, alkyd air drying paint Alkyd air drying paint Nitrocellulose lacquer, polyurethane paint Alkyd for polyurethane paint Polyester Resin for coil coating

Formulations:

Air Drying Paint NC Paints Stoving Paint Wood Coating

Types of Paints:

Stoving enamel/varnish Air Drying enamel/varnish NC lacquer/Sanding sealer/paint Stoving finishes Air Drying finishes Melamine wood finishes PU wood finishes Polyurathane (PU) finishes

DETAIL DESCRIPTION

PRODUCTION OF UREA FORMALDEHYDE RESIN:

Structure:

Properties:

Urea-formaldehyde resin's attributes include high tensile strength, flexural modulus and heat distortion temperature, low water absorption, mould shrinkage, high surface hardness, elongation at break, and volume resistance.

Chemical structure:

The chemical structure of UF resins can be described as polymethylene. This description leaves the details of the structure undetermined which can vary linearly and branched. These are grouped by their average molar mass and the content of different functional groups. Changing synthesis conditions of the resins give good designing possibilities for the structure and resin properties.

Raw material:

Butanol Formaline Urea Seperat solution [Toluene] Tri Ethanol Amine [T.E.A] Recover Butanol [RCB]

Process description:

In this manufacturing process, add butanol and formaline in the close vessel for agitation. This vessel should be rounded at the bottom. An impeller is mounted on an overhung shaft, which is supported from above. The shaft is driven by motor, is directly to the shaft. After addition of material add 10%of caustic solution and set pH. pH should always be an equal to 6.

If it is greater than, add formic acid and if it is less than, add 10% caustic and set pH. This solution is completely miscible then add urea and start to heat this vessel from the boiler. Heating is started in the vessel, When the temperature of vessel will reach to 70C-80C . We can get this temperature then close heating and under stirring this mixture up to 90 min but do not change of temperature. After completion of this again start to heating and wait for getting reflux. We can get reflux after 30-45min. then add toluene, recover butanol and also catalyst. Here toluene is used as a seperat solution. Catalyst is the mixture of phthalic powder, oxalic acid, butanol. Addition of RCB is connected to the removal of water. We can get this water as a byproduct which as a steam is condenced in the vertical condenser and separate in the separator. Approx. addition of 940 ltr. RCB, add catalyst. At that time temperature will be increase. In all this process, we can get two by product water and RCB. After that, the product goes through the packing by filtration.

Types:

UF-8 UF-8LFF UF-8NFF

Urea Formaldehyde Resin:

Ser Product no Code

Type

Solvent % Non Viscosity Acid Mineral Volatiles in poises Value Spirit (2) at 25* C KOH/gm Tolerance ml/10gm resin
60 10-20 P 3 10-20

UF-8

Butylated Butanol UF

Notes : Very fast, low temperature acid curing screen and wood lacquers. 2 UF-8 LFF Butylated Butanol 60 UF 10-20 P 3 30-50

Notes : Low Free Formaldehyde content (0.5% max.) used for acid curing wood coatings. 3 UF-8 NFF Butylated Butanol 60 UF Brook Field RVT/S-3, RPM-20 3Max

Notes : To be used for wood coating in acid cure application partially no free formaldehyde, low odor.

PRODUCTION OF MELAMINE FORMALDEHYDE RESIN:

Structure:

Raw Material:

Butenol Formeline Methanol Toluene Urea RCB

Process description:

In this manufacturing process, add butenol and catalyst in the close vessel for mixing and also add formeline. Then by stirring process add 10% costic and set pH value 7 and add methanol. Again check the pH value and if it is less than 7 then again add 10% costic and if it is more than 7 then add formic acid. After pH value is set add melamine and urea. Then close the vessel and give heat till 70C. After getting 70C temp. stop heating and keep it under stirring for 90 min. After 90 min. start heating. After 30 min. at about 96C-97C we will get reflux. After getting reflux add RCB. When water came out then add RCB and catalyst. Take reading at 1hr interval and taking reading from reflux for 15hr check tolerance by using o-xylene and MTO. Then set the viscosity at 10 poise. Lastly pack the product by filtration process.

TYPES:

MF-268 MF-970 MF-910

Melamine formaldehyde resin:

Ser Product Type Code no

Solvent % Non Viscosity Acid Mineral Volatiles in poises Value Spirit (2) at 30* C KOH/gm Tolerance resin
60 10-15 2.5 30-50

MF-268

Butylated Butanol MF

Notes : High gloss stoving enamels with alkyds, epoxy and acrylic systems.

MF-970

Butylated Butanol MF

68

8-12

Infinite

Notes : Wide compatibility, low temperature curing flexible lacquers for metalized plastic articles. Useful for MTO based finishes and anti wrinkling agent for Rosinated alkyd based stoving finishes.

MF-910

Butylated Butanol MF

60

10-15

2.5

30-50

Notes : Highly efficient, fast curing colour retentive stoving enamels resistant to overbaking.

Application

1. PU Automotive Paint and Automotoive Refinishing Paint


Polyester Resin Acrylic polyol Thermoplastic Acrylic

2. Paint for specific use


Anticorrosion for container Electroplating article Resin for dipping and air drying for long/large article Glass painting, solid varnishes Aluminium paint for motor of agricultural automobile Heat resistant paint Paint for aluminium single pack system Glazing for paper Special Resin for hammer tone coating Special Resin for traffic paint Special Resin for leather coating F class insulating varnish Fast drying electrical insulation General use electrical insulation Coil coating application Water clear stoving varnish Glass sleeve coating Resin Auto refinishing chain stopped air drying paint Machinery paints for faster and better drying Machinery parts touchup or fast drying paint which dries as fast as stoving paints

3. Wood coating
One component patty/sealer Alkyd Resin for melamine finish UF Resin for melamine wood finishes Resin for clear or matte paints Resin for PU bright finish Resin for nitrocellulose lacquer Polyester Resin for lamination coating

4. Amino-alkyd baking coating, alkyd air drying paint


Automotive finish Miscellaneous car and high grade industrial baking coating Universal type Solid finishing cost Hammer tone paint Low temp. quick drying baking coating Wet on wet coatings application

5. Alkyd air drying paint


Air drying paint Air drying modified paint

6. Nitrocellulose lacquer, polyurethane paint


Resin for grind Nitrocellulose coloured paint Leather varnish

7. Alkyd for polyurethane paint


C - 1032 economy, universally F - 4035 excellent leveling and weathering resistance C - 1030 excellent yellowing resistance

8. Polyester Resin for coil coating


P-11 UF-8

Formulations

1. Air Drying Paint


White decorative enamel for interior & exterior use Tinted decorative enamel Yellow decorative enamel for interior use Knifing paste filler Air drying varnish

2. NC Paints
Nitrocellulose primer Nitrocellulose lacquer General purpose white stoving enamel Polishing lacquer for furniture Polishing lacquer for furniture

3. Stoving Paint
Silver gray automotive baking finish White stoving enamel for hot spraying Blue automotive stoving enamel Stoving primer White stoving primer Gray stoving primer Polyurethane spraying sealer Black spraying enamel for tracks & bases General purpose white stoving enamel Polishing lacquer for furniture White stoving enamel (poor shelf life) White stoving enamel for boilers, electrical heaters. Stoving enamels for steel furniture Varnish resistant to boiling alkalis

4. Wood coating

General purpose white stoving enamel Polishing lacquer for furniture

Types of paints

1. Stoving enamel/varnish
TSA-1001 C-1052 (IPA+TMP) D-2040 HV D-2040L C-1032 C-1030 MF-970 MF-268 UF-8

2. Air drying enamel/varnish


TPA-2001M HV TPA-2001 S-5060 (IPA) STRY-25 Acry-30 ACRY-25 F-4035 L-6060 S-5060 L-6050 R S-5050

D-2060 F-4043 F-4038 D-2050 R D-2050

3. NC lacquer/sanding sealer/paint
TPA-2001 CA-3045 CA-3035 D-2040L D-2040M C-1032 C-1030

4. Stoving finishes
TSA-1001 C-1032 (IPA+TMP) C-1052 (IPA+TMP) C-1030 D-2040L D-2040 HV MF-268 MF-910 C-1032 D-2040M UF-8

5. Air drying finished


TPA-2001
TPA-2001 M HV ACRY-25 Acry-30 STRY-25 S-5060 (IPA) D-2050 D-2050 R D-2060 S-5050 L-6050 R S-5060 L-6060 F-4035 F-4038 F-4043

6. Melamine wood finish


C-1030 C-1032 S-5030 UF-8 UF-8LFF

7. PU wood finish
TSA-1003

8. Polyurethane (PU) finishes


TSA-1003 Polyol-32 Polyol-280

OTHER PRODUCTS

Maleic Modified Rosin Ester

Serno Product Code Type

% Solid

Acid value Capillary Melting KOH/gm point in deg. C


25 100-110

MR Gly

Maleic modified solid rosin glycerine ester

Notes : NC compatible hence used in NC formulation. Not compatible with MTO.

MR Penta

Maleic modified solid rosin Penta ester

25

100

Notes : MTO Compatible used with Long / medium Alkyd

Alkyd Resins
Serno Product Code Oil Type & Length % Solvent Acid Value Viscosity in Solid KOH/gm seconds at (2) 30 C in FC4*
Saturated Fatty Acid type Non oxidising short oil length 70 Xylene 5-15 225-300 seconds in FC4

Colour on Gardner Scale 50% solution of resin(max)


1

C-1030

Notes : Non yellowing white baking enamels and 2k as plasticizer for NC lacquers and for Acid Curing / Wood Coating.

C-1031

Saturated Fatty Acid type Non oxidising short oil length

70

Xylene

5-15

175-225 seconds in FC4

Notes : White baking enamels and 2k as plasticizer for NC lacquers and for Acid Curing / Wood Coating.

C-1032

Coconut oil Acid 70 Non oxidising short oil length

Xylene

5-15

225-300 seconds in FC4

Notes : White baking enamels for refrigerators, washing machines, water filter and hospital appliances and as plasticizer for NC lacquers wood coating.

D-2040M Dehydrated Castor 70 oil, type semi oxidising short oil

Xylene

5-15

80 100 Sec

Notes : Fast drying general purpose baking enamels for industrial equipments, machineries, household appliances and printing inks. Very useful for cold catalysed lacquers with UF Resin used in textile printing screen. Residual hydroxyl of DCO usefull as co-reactant in polyurethane finishes.

Epoxy Resin

Serno Product Type Code

% Solvent Colour Viscosity Epoxide Epoxide Solid Gardner poises at Value Equivelant (2) 25*C
Xylene 2 65-100 as 3 is 450-500

Epoxy450

Bisphenol 75 Epoxy Resin

Characteristics : For Two pack Epoxy Paints.

Ketone Resin

Serno Product % Hydroxyl Code Solid value KOH/gm


1 KF-10 100 250 Min

Melting Point Capillary


85-105

Viscosity Solubility at 30*C

Compitibility

35-50 in 60% Toluene

Alchols ester ketones & glycol ethers cholrinated hydrocarbons

Ester & alchol soluble Nitrocellulose short oil alkyds aminos phenolics polyurethanes PVB resins natural & synthetic rubber & commonly used plasticizer

Notes : For all types of NC lacquers, printing inks for paper, ball pen inks and in casting resins. In surface coatings, it improves gloss & adhesion, plastisols, nail lacquers Etc.

Polyamide Hardner

Serno Product Code


1 SP-115

Type

% Solvent Solid
100 Solvent Less

Colour Gardner
10

Viscosity poises at 25*C

Amine Value

Polyamide Resin

as such in Brook Field LVT/S-4, 210-230 RPM-6 at 40C: 450-650 Poise

Characteristics : Hardner for Epoxy, Good chemical resistance for faster curing.

SP-125

Polyamide Resin

100

Solvent Less

10

as such in Brook Field LVT/S-4, 2290-320 RPM-6 at 25C: 400-550 Poise

Characteristics : Coating for Paint and Adhesive.

SP-140

Polyamide Resin

100

Solvent Less

10

such in Brook Field LVT/S-4, RPM-6 at 25C: 130-170 Poise

350-400

Characteristics : Floor Coating for Construction and Solvent Less Coatings.

SP-160

Polyamide Resin

100

Solvent Less

10

as such in Brook Field LVT/S-4, 350-400 RPM-6 at 25C: 3-6 Poise

Characteristics : Floor Coating for Construction and Solvent Less Coatings.

Phenolic Resin

Serno Product Code


1 P-260

Colour on gardner scale


50% Solution of Resin: 12Max

% Solid
100

Acid value
25

Capillary Melting point in deg. C


100-110

Notes : Paints, Printing Inks, Insulating Varnishes, oil Varnishes etc.

P-261

50% Solution of Resin: 13Max

100

25

135-145

Notes : Lithographic and Gravure Printing Inks 3 P-262 50% Solution of Resin: 12Max 100 20 (Ball & Ring) 125-135

Notes : Paints, Printing Inks, Insulating Varnishes, oil Varnishes etc.

P-263

50% Solution of Resin: 12Max

100

25

150-160

Notes : Paints, Printing Inks, Insulating Varnishes, oil Varnishes etc.

Poluester Resin

Serno Product Code


1 P-10

Solid (+ Solvent 2%)


55 Styrene

Acid value mgKOH/gm


15

Viscosity

Colour on Gardner Scale


1

25-35 Sec in FC4 Cup at 25'C

P-11

65

3.4:1 CIX, 2 Butoxy ethanol Mix Xylene

10

90 110 Sec in FC4 Cup at 30'C

P-12

60

10

75 95 Sec in FC4 Cup at 3 30'C

P-13

65-70

Styrene

22

5 8 Poise as such in BF 7 RVT/S-3, RPM-12 at 25C