MANUFACTURING PROCESS

The different processes involved in the manufacture of paint are mainly unit operation or
physical processes such as grinding, mixing and filtering. The whole process is characterized by
batch processing since this will be helpful in adjusting the colors and properties of the paint. The
chemical conversions are only involved in the manufacture of the different paint constituents as
well as in the drying of the film on the substance.

A. Weighing

Binders (oils and resins), additives, pigments and fillers are placed in a feed hopper/tank.
The raw materials are then automatically fed in weighing tank. The types of binders, pigments,
additives and fillers and their corresponding amounts depend on the type of the paint being
manufactured.

B. Mixing

The weighed materials are fed in mixers. Mixing is done to achieve the homogeneity
between the different components especially in the production of water-based paints. The main
objectives of the mixing process are the following:

a. Mixing of oils or resins

b. Mixing of pigments and fillers with coating materials
c. Decrease the viscosity of resins
d. Mixing of additives with paints

The commonly used mixers usually consist of a mixing tank, usually vertical, and one or
more impeller driven by electrical motor. The impeller consists of a shaft assembled with one or
more mixing blades or propellers. The type of mixer used by different paint industries vary in
terms of their suitability in different applications. The choice of mixer depends on the following:

a. Viscosity. Mixers types used in preparing pastes differ from those used in the production
of low viscosity paints.
b. 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.
c. Solid particle size. Some components, such as pigments agglomerates, have relatively
large particle size compared to other components.
d. Volatility of solvents.

C. Grinding

After mixing, the mixture or the batch is transferred to the mills for grinding, and further
mixing and homogenizing. The type of used mill is related to the type of pigments, vehicles, and
fillers.
 Paints industry uses different types of mills such as roller mills or ball mills.

a. Roller Mills
This type of mill 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.

b. 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. The grinding efficiency and
fineness of particle depend on the dimensions of the cylinder, speed of rotation, ball
size and ball density. 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.

D. Intermediate Storage

After mixing and grinding, the batch is transferred to an intermediate storage tank. This is
done because the batch may need further mixing or grinding to obtain the required degree of
homogeneity.

E. Thinning

The batch is then transferred from the intermediate storage tank to a thinning tank. A
thinning tank is usually a mixer. In this process, solvents and other additives such as driers and
plasticizers are added to the batch. Thinning, from the word itself, is done to decrease the
viscosity of the batch. Thus this process is also known as dilution.

F. Filtration

During the previous processes, the batch may have been contaminated by foreign matters.
Moreover, the batch may contain particles which were not ground to the required size or some
polymers that did not dissolve and some surface hardness may exist.

The filtering step provides a way to remove any undispersed particles or other extraneous
materials that might have been introduced to the batch during mixing, grinding, storing and
thinning. One often-used method employs vibrating screens with 40–300 mesh per square inch as
strainers to separate the unwanted materials from the paint. Another filtering method allows the
paint to drain through felt bags. Sometimes the paint is passed through cylindrical cartridges of
porous material where the paint filters through the walls of the cartridge, leaving the separated
material in the container.
G. Packaging

After filtration, the batch is sent into the filling machine. The paint is poured into cans or
drums, moving through a conveyor belt where they are labeled by a labeling machine. The filled
cans will then be placed in boxes which are ready to be stored or shipped.