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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.
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.
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...
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:
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
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:
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.
Structure:
Raw Material:
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:
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
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
Formulations
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
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
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
7. PU wood finish
TSA-1003
OTHER PRODUCTS
% Solid
MR Gly
MR Penta
25
100
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
C-1030
Notes : Non yellowing white baking enamels and 2k as plasticizer for NC lacquers and for Acid Curing / Wood Coating.
C-1031
70
Xylene
5-15
Notes : White baking enamels and 2k as plasticizer for NC lacquers and for Acid Curing / Wood Coating.
C-1032
Xylene
5-15
Notes : White baking enamels for refrigerators, washing machines, water filter and hospital appliances and as plasticizer for NC lacquers wood coating.
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
% Solvent Colour Viscosity Epoxide Epoxide Solid Gardner poises at Value Equivelant (2) 25*C
Xylene 2 65-100 as 3 is 450-500
Epoxy450
Ketone Resin
Compitibility
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
Type
% Solvent Solid
100 Solvent Less
Colour Gardner
10
Amine Value
Polyamide Resin
Characteristics : Hardner for Epoxy, Good chemical resistance for faster curing.
SP-125
Polyamide Resin
100
Solvent Less
10
SP-140
Polyamide Resin
100
Solvent Less
10
350-400
SP-160
Polyamide Resin
100
Solvent Less
10
Phenolic Resin
% Solid
100
Acid value
25
P-261
100
25
135-145
Notes : Lithographic and Gravure Printing Inks 3 P-262 50% Solution of Resin: 12Max 100 20 (Ball & Ring) 125-135
P-263
100
25
150-160
Poluester Resin
Viscosity
P-11
65
10
P-12
60
10
P-13
65-70
Styrene
22