Report By: Er. Binod Pandey www.binodpandey.wordpress.

com

Table of content:

1. History of paint 2. Introduction to paint 2.1 Solvent based paint 2.2 Water based paint 2.3 Differences between solvent based and water based paint 3. Status of paint industry in Nepal 4. Methodology 5. Objectives 6. History of Berger paints. 6.1 An overview

3 4 6 6 7 8 9 9 10 10

7. Process of paint production 7.1 Production process 7.2 Design 7.3 Quality control 8. Technology used in paint industry 8.1 Ball mill 8.2 Pug mill 8.3 Twin shaft disperser 8.4 High speed disperser 9 Recommendations 10. Conclusion 11. Bibliography

11 11 13 13 14 14 16 16 17 18 18 18 1

Report By: Er. Binod Pandey www.binodpandey.wordpress.com

The History of Paint:

Colour has fascinated culture throughout history, every age and every region has produced dyes and pigment depending on the available resources. Colour has been with us for more than 20,000 years. Evidence survives in early cave paintings and the ancient Chinese are considered to have brought its manufacture and use to a state of perfection tens of thousands of years ago. Colour was widely used by the ancient Egyptians and was considered to have magical and healing properties and around this time, 1500 BC, paint making as an art became quite widely established in Crete and Greece with the Egyptians passing their skills to the Romans. It was between 600 BC-AD 400 that the Greeks and Romans then introduced varnishes. For the Aztec Indians red dye was considered more valuable than gold and both the Indians and Chinese practiced Colour Healing. A 2000 year old, Chinese chronicle, The Nei/ching, records colour diagnoses. Yet for all this it was discovered that none of the worlds civilisations has named many colours. In the 1960s two anthropologists conducted a worldwide study of colour naming. Many languages only contained two colour terms, equivalent to white (light) and black (dark). Of 98 languages studied, the highest number of basic colour terms was to be found in English - where we have eleven: black, white, red, orange, yellow, green, blue, purple, pink, grey and brown. The other millions of colours have 'borrowed' names, based on examples of them, such as avocado, grape, peach, tan, gold, etc. One of the earliest recorded colour discoveries was made by Plato who discovered that by mixing two colours, a third is produced, therefore changing the, 'manufacture', of colour forever. Prior to that the earliest cave paintings were made by using iron oxides, it was the ancient Egyptians who developed other paints from pigments in the soil (yellow, orange, and red). It was the Romans who gave us purple, a pound of royal purple dye, required the crushing of four million mollusks. Cochineal red, discovered by the Aztecs, was made using the female cochineal beetle. A pound of water-soluble extract required about a million insects and it was the Spaniards who introduced the crimson colour to Europe in the 1500's. Later genuine Indian Yellow was produced from concentrated cows urine which was mixed with mud and transported to London for purifying, Sap Green from the Blackthorn berry and Sepia Brown from the dried ink sac of squid. Paint is made up of a pigment, a binder to hold it together and appropriate thinners to make it easy to apply. 5000 years ago Blue Frit was the first synthetic pigment being produced by the Egyptians from ground down blue glass. Before the nineteenth century the word 'paint' was only applied to oil-bound types; those bound with glue were called 'distemper'. By 1000 B.C. development of paints and varnishes based on the gum of the acacia tree (better known today as gum arabic) had been developed. At this time umbers, ocher's and blacks were readily obtainable, new colours were also discovered - the first was 'Egyptian Blue'; 'Naples Yellow' dates from around 500 BC and 'red lead' was discovered by accident in about 2500. White lead occurred naturally but demand encouraged production of manmade versions. Vitruvius describes production of white lead in the 2nd century AD. Before the 16th century, pigment colour was largely dependant on dyestuffs which could be grown in, or were indigenous to Europe and similar temperate regions. Between 1550 and 1850 only the so-called natural dyestuffs were available but the range was greatly extended with tropical dyestuffs from Central America and India and elsewhere. In the 17th century the Dutch greatly increased availability of white lead and lowered cost by invention of the Stack Process. All white lead paints included chalk in their undercoats, reserving purer white lead for finish coats. In1856 the first real synthetic dye, 'Mauveine', was discovered by Henry Perkins. It was then realized that a great many dyes could be made synthetically and cheaply. 2

Report By: Er. Binod Pandey www.binodpandey.wordpress.com It was then that Linseed Oil began being mass produced. They also had pigment grade zinc oxide - we call it white paint. Using cast-iron paint mills and zinc-based pigments, industrialists produced the first washable paint marketed as 'Charlton White' in the 1870's ( the first ready mixed paint was patented by one D.R. Averill of Ohio in 1867, but it never caught on). The Sherwin-Williams company spent ten years trying to perfect the formula where fine paint particles would stay suspended in Linseed oil. In 1880 they succeeded in developing a formula that far exceeded the quality of all paints available at the time. It was then that emulsions based on similar formulae, were produced and marketed as 'oil bound distempers'. By 1880 the new paints were readily available in tins, in a wide range of colours, and came to be exported all over the World.

Introduction to paint:
Paint can be defined as a chemical made from a mixture of other different chemicals used for coating on different surfaces for protective and decorative purposes. With a brush, a roller, or a spray gun, paint is applied in a thin coat to various surfaces Paint can be chiefly classified into the following types: 1. Water base paint 2. Solvent base pain 3. Dry powdered pain. 4. Industrial paint Paints are made up of following of components:

Pigment Extender Binder Solvent/Liquid Carrier Additives etc

Pigments: Pigments are the chemicals that give colour and opacity/covering power and are finely dispersed solid particles. In some cases they can be used to impart certain protective properties e.g. rust prevention and to control gloss levels. Varnishes, which form transparent or semi-transparent films, are made up of the last three components, with coloured varnishes containing small amounts of pigment. Paints and varnishes may contain pigments or additives to lower the gloss levels in satin or matt finishes. Extenders: They are added in the paint to reduce the cost and also to modify some of the properties of the paints. They reduce the weight of the paint and render paint more durable. They should not be used in excess as other wise paint may lose its original character and may become weak. E.g. barium sulphate, silica, lithophone, gypsum silicate etc. 3

Report By: Er. Binod Pandey www.binodpandey.wordpress.com Binder: The binder is the material that forms the film, giving protection to the substrate and keeping the pigment in place and evenly dispersed. It may be made up of a single component, or a combination of several resins or polymers. Solvent/liquid carrier: The binder and pigment remain in the dry paint film. The solvent is used to effect the application of the coating. It thins the paint or varnish, allowing it to be brushed or sprayed. Once on the substrate, the solvent will evaporate, leaving the dry film. The term liquid carrier is considered more appropriate as it may not be a true solvent for the binder, but may act as a carrier. This may be water or an organic solvent (or a mixture of both). Additives: Additives are used, in small amounts, to modify the film or paint. Examples are driers promoting the drying time of some coatings, flow control agents giving a smooth surface, defoamers preventing the formation of bubbles that could dry in the film, anti-skinning agents preventing the paint from skinning in the can. Some of the common types of additives are: Fungistats: prevent the growth of mildew, Coalescents: help produce a uniform (water based paints) Dryers anti skin: assist in oxidation for oil based paints In can preservatives: prevent bacterial attack Thickeners: modify viscosity; enhance application properties of waster based paints Wet edge additives: prevent paint from drying too quickly water based paints Surfactants: unused to maintain dispersion of powders and resins in water based paints.

Solvent based: The major group of binders used in oil based paints are Alkyds. These are modified vegetable oils. The major vegetable oils used to produce alkyd resins are: Wood/Tung oil drying oils Linseed oil Sunflower oil Safflower oil semi-drying oils Soya oil Castor oil non-drying oil 4

Report By: Er. Binod Pandey www.binodpandey.wordpress.com These oils contain compounds which have active double bonds. These double bonds react with oxygen in the air to form bridges between molecules in the resin which results in the drying or curing of the resin. The more active double bonds in oil, the faster it will dry. It is not desirable that a resin dry too quickly as, if the surface dries more rapidly than the resin underneath, the surface will wrinkle. For this reason, Tung oil alone is rarely used in paint manufacture. Linseed oil alkyds yellow very badly in poorly lit conditions and so, Soya oil is the main oil used to make Alkyd resins. It is cooked up with a number of other synthetic ingredients to produce an Alkyd. Many different types of Alkyds can be manufactured. However, they have certain common advantages and disadvantages. Advantages: Forms a tough durable film coat, High gloss levels are achievable, Resistant to moisture, grease and oil, Penetrate well; can be used on chalky surfaces. Disadvantages: Dry film becomes harder and less flexible with age and this can lead to cracking and peeling, Oil provides a food source for mildew, Solvent thinned - more odour, harder to clean up, less environmentally friendly. Subject to chalking when exposed to U.V. light. Water based: Unlike solvent based paint resins, water based resins are not solutions but are dispersions or emulsions of resin in water. This accounts for their white appearance. These resins are synthetic and there are a number of resin types which are used in the formulation of water based paints. The major types are: Poly Vinyl Acetate (PVA)/Acrylics 100% Acrylics. These resins exist as polymers and dry by coalescence rather than oxidisation. When the paint is applied, the water carrier evaporates, forcing the polymer particles together, which fuse to form a film. Water based resins are thermoplastic, which means they harden as the temperature falls below 10C. Water based resins have the following advantages and disadvantages:

Advantages: Easy clean up with water, Flexible film moves with the substrate, Normally dries faster than an oil based paint, Good colour retention. Film breathes, allowing moisture in or on the substrate to pass through. Longer exterior life than oil based paint.

Disadvantages: Not as tough as Alkyds, Cannot get a high gloss, Does not penetrate the surface as well as oil - should not be applied directly over chalky or crumbly surfaces. 5

Report By: Er. Binod Pandey www.binodpandey.wordpress.com In general, PVA/Acrylic resins are used as interior wall paints, and 100% Acrylic resins are used in exterior gloss or timber finishes.

A short list of the main differences between oil and water based paints are: Solvent based paint uses a hydrocarbon based solvent that produces very nasty vapors during application, but dries slower and penetrates better than water based paints. This has always been a major selling point of oil; however, with modern acrylic retardants the penetration of water based paint can be greatly improved. The water based paint, can be applied with a minimum of irritant vapors, but lay mostly on the surface and don't penetrate or adhere as well as the solvent based paints. The painting tool cleanup is also different, water base paint can be cleaned with soap and water, but tools used with water base paints have to be cleaned with mineral spirits. Although the hiding power and coverage of water base paints is one of their better qualities, the considerable drying time VS water base paints is a negative. Money savings: since you won't be spending on mineral spirits for cleanup when using water base paints. Another money saving consideration is that you can re-use roller covers when using water based paints, not always the case with oil based paints. Another consideration is the application of water base paints over oil base paint: don't do it! The water paint will not stick to the water base paint. The reason: water paint doesn't penetrate as well, it's a like a sheet of plastic that you put on a surface. Slick water based paint, being either gloss or semi gloss, doesn't give the acrylic paint anything to adhere to. If you must use acrylic to paint over oil based paint, use a primer coat between them. The color retention properties of water base do appear to be much better than oil base paints. They hold the color longer and are not given to fading and chalking, as the oil based paints are known to. Deep colors, in particular, stay true much longer with acrylics VS oil.

Characteristics of an ideal paint: The paint should be cheap It should have good covering power. In other words it should be able to cover maximum area of the surface with minimum quantities of the paint. It should be easy and harmless to the user. The painted surface should dry neither too slowly nor too rapidly. It should retain its original colour for a long time. When applied the paint should form a thin uniform film on the painted surface. Atmospheric agencies shouldnt be able to affect the painted surface. 6

Report By: Er. Binod Pandey www.binodpandey.wordpress.com The paint should form a hard and durable coat on the painted surface. The painted surface should possess attractive and decorative pleasing appearance. The paint should not peel off from the painted surface. The painted surface should not show any cracks. It should be good fire and moisture resistant.

Status of paint industry in Nepal:

Making a comparison with other industries the status and scope of paint industry in Nepal is better. In spite of this fact, the number of paint industry in Nepal is quite low. According to the data available from census of manufacturing establishment Nepal 2006/2007 national level, the number of paint industry is only fourteen. But the number seems to be increasing every year. Within the last decade eleven paint industries have been established. Some we can picturize that more and more paint industries will be established in the coming future. Paint industry have not only contributed to the countrys economy but also helped in proving employment to the people. A data relating to the paint industry has been tabulated below: No. of No. of No. of Wages/ industr person employees y engage salary d *1000 Chang Gross e in additi stock on to fixed *1000 assets *1000 *100 0 2881 78 2053 03 8287 5 9886 1951 Gross fixed assets at end of year Valu Value e of of outpu input t *1000 *100 0 Total value added *1000

Total industr y Urban Rural Private Partner ship Private

14

725

701

64405

56876

60981

1212 912 8060 31 4068 81 8935 3 9297

62910 3 50985 7 31924 6 24660 4 63518

38380 9 29617 4 87635 17090 2 29460 7

9 5 6 1 7

415 310 314 256

409 292 298 348

50448 13957 14391 45424

45355 11521 17391 33888

51211 970 17490 50013

ltd. Nepali 12 nationa l Nepali 1 nationa l and foreign ers <1 8 crore 1 to 5 3 crore > 5 3 crore

588

564

37930

45579

Report By: Er. Binod Pandey www.binodpandey.wordpress.com 08 96 9 7 24849 1540 6430 48859 15443 25 31 6 5 -

150 186 389

141 181 379

On the basis of fixed assets 11687 7971 2313 14960 37758 20424 28481 14074 44594

2317 9 6872 9 1962 70

8632 6 3460 36 7805 50

61228 26605 5 50182 0

25098 79981 27873 0

Source: Central bureau of statistics census of manufacturing establishment Nepal 2006/2007 national level

METHODOLOGY: 1. Search strategy Names and location of some of the paint industries in the country were collected. We then visited the head office of Berger paints located in Tinkune. From there we were granted the permission to visit the industry of Berger paints in Hetauda. We then visited Berger paint industry which is located in Hetauda industrial district in Hetauda. There we got a lot of information regarding paint. Information sources The basic information sources are; Berger paints, Hetauda Personnel visits and responses Libraries and valuable books Different websites.

Objectives:
The specific objectives of the preparation of his report are: 8

Report By: Er. Binod Pandey www.binodpandey.wordpress.com To know how the paint is being manufactured at present and the technology used in the context of Nepal. To know the status and scope of paint in the country To know the challenges and problem faced by the paint industry in the country To know the aspect of quality control used in the paint industry. To now the environmental and ecological aspects of paint industries in Nepal. Social interaction status of paint industries in Nepal. Health and wellbeing consideration of paint industries in Nepal. After going through this report, one can also know about Berger paints, one of the most reputed paint industries in the world.

History of Berger paints:

Berger Paints have enjoyed a long, proud and distinguished history. Here are some of the significant moments from that history that have helped to shape the brand over the years. It all began over two hundred years ago. In 1760 a young colour chemist living in London, Louis Steigenberger, was manufacturing Prussian Blue using a secret process. He changed his name to Lewis Berger on marriage, and his company began exporting to Australia in 1850 in ships. In 1916, the 150 year old Lewis Berger & Sons company began its Australian operation at Rhodes, NSW, building the largest timber structure in the Southern Hemisphere. After the demise of Lewis Berger his sons took over the business. Sherwin-Williams, an American company bought control of the company in the 1900s. By the 1940s Mr. Hadfield; set up john layfieldfield's (India) Ltd a small paint company in Calcutta on 17 December,. Towards the end of 1947 British Paints acquired Hadfield's (India) Ltd and thus British Paints (India) Ltd was incorporated in the State of West Bengal. In 1969 Berger, Jenson Nicholson Limited, UK bought the British Paints (India) Ltd. This marked the beginning of Lewis Bergers legacy in India - which the company would later take forward to enviable heights. An over view:

Report By: Er. Binod Pandey www.binodpandey.wordpress.com Berger is the second largest player in the domestic decorative paint industry and also a dominant playerin non-automotive industrial segments such as powder coatings and protective coatings. Bergers decorative business has shown strong growth in the last few years due to buoyant economic growth which leads to faster repainting frequency by consumers. Also, new construction and rural markets where Berger is relatively stronger have shown high growth benefiting the company. Currently 80% of Bergers sales are contributed by decorative paints. Of this half is water based paints having better margins and the rest are solvent based paints. Within this, the exterior paints business is growing at twice the rate of overall business. 75% of decorative sales come from the retail business and 25% from projects (new construction). Berger is a major player in the mass market with brands like Rangoli, Bison etc and in exterior paints segment with Weather Coat. However, Berger had lower presence in premium decorative paints, a segment where it has lined up a significant budget on brand building exercise using Lewis Berger brand challenging the dominance of Asian Paints Royale and ICIs Dulux. The entry of foreign majors like Jotun Paints and Nippon Paints is unlikely to have any impact on the four existing players including Berger as the new entrants will require couple of years to build their brands and distribution network. Of the 20% sales from industrial paints, 50% each comes from the automotive paints business and the other industrial paints (powder coatings and protective coatings). Within automotive paints the company is only present in OEM business (not in replacement market) and that too merely in the 2 wheeler and commercial vehicle segments, not in the largest segment passenger car paints. This is because car paints require sophisticated technology and existing relationships with global car manufacturers, neither of which Berger has. Margins in the industrial business are lower than the decorative business. However, the nonautomotive industrial paints market, in which Berger is a key player, is likely to benefit from the strong growth expected in the new industrial installations as well as in the white goods segments which are the main users of protective coatings and powder coatings respectively. Process for paint production:

The basic principle for the production process for water base paint and solvent base paint is the almost the same except for, in water base paint initially water is used as the base chemical where as incase of solvent base paint different types of solvents is used as the base chemical as per required(e.g. kerosene, xylene, turpentine etc.). In addition to this machines used in the above two processes differ. Solvent base: Initially the production department decides on the solvent base paint batch size. Then the raw materials are mixed together at a required ratio depending upon the type of product to be produced. The raw materials that are used are binder, pigment, extender, solvent, additives etc. foer example for the production of aq product called glossy E the following raw materials are used 10% pigment, 60% alkene, and 10

30%MTO Then this mixture of raw materials is charged into the ball mill. In this process, the mixtures of the charged raw materials are thoroughly mixed and grinded as a result of which a viscous, e\slurry like fluid is formed. This process is done by the help of steel or porcelain ball whose diameter ranges from 1 1.5 inches. the ball mill consisting of steel ball is very noisy and is generally done during the night time. Where as the ball mill consisting of porcelain balls is done during the day time. This process of grinding carried out for 12 hours then the slurry is tested for its consistency by using Hegmein gauge. If it fails to meet the required standard, the slurry is further grinded for a calculated time period. Porcelain ball mill is used for the production of eye catching and clean shaded paint. For e.g. it is used to in fire extinguishers cylinders. Where as the steel ball mills are used for the production of dark shaded paints. After the completion of grinding process the slurry is discharged into the vertex. Using a ttrolley the vortex is moved towards the motor where the slurry is pumped into the surge tank whre the process of blending and maximizing takes place. Here the slurry is mixed with the following chemicals: Binders Resin Solvent Colourants Dryers 300 liters of slurry is mixed with 700 liters of maximizers to produce 1000 liters of paint. This resulting paint is taken for various tests such as Consistency/Viscosity Shade matching Covering Viscosity is tested using instruments such as ford cup and weight/litre cup. Shade matching is the lengthier test in which the paint is applied over the shade paper. When the paint is completely dried is coloured is compared to the standard colour. There are two types of covering namely economical covering and premium covering. In the economical covering less amount of paint covers more surface area. In the premium covering more amount of paint covers less surface area but provides better appeal. If the batch fails to meet the given standards from the above tests the corrective batch is planned and produced, then the faulty and corrective batch is mixed to achieve the final product. This is followed by canning and dispatching.

Report By: Er. Binod Pandey www.binodpandey.wordpress.com

Some of the pigments used here are TiO2 (Anatase/Rutile), red oxide (Fe2O3). Some of the generally used extenders are silicates of calcium, aluminum, magnesium, calcite (CaCO3), Banytes (BaSO4). The raw materials used heavily depend upon the type of product to be produced. For example, for the production of a product called Bison the following raw materials are used: Calcite Dolomite Talk powder Acrylic emulsion Water chemicals 11

Report By: Er. Binod Pandey www.binodpandey.wordpress.com

Then the charging of this batch is done. In this process the produced batch is charged into the pug mill in case of water base and ball mill incase of solvent base. After charging has been done in the above mentioned mills, dispersion takes place. In this process, the mixtures of the charged raw materials are thoroughly mixed and grinded as a result of which a viscous, slurry like fluid is formed. Incase of pug mill mixing is done by the help of shaft where as in case of ball mill its done by the help of steel or porcelain ball whose diameter ranges from 1 1.5 inches. This process is very noisy and is generally done during the night time. This dispersion time for the water base is relatively less which is about 1-2 hours compared to that of solvent base which may take upto 18 hours. After the formation of slurry, a sample is taken for its quality check whether it meets the standard quality or not. If it doesnt then the earlier processes are again repeated. Then the process of stabilization is done so as to obtain the required property of the paint in which the addition of required chemical is done. Then this slurry is discharged into the vertex. After which it is pumped to the mixing tank. After the final mixing has been done, the paint sample is again sent for quality check, where the following property is checked: Specific gravity fineness of grind Viscosity dispersion Colour, etc. After all the quality checking has been done final adjustment is done after which it is sent for filling/canning. Canning: Paint canning is a completely automated process. For the standard 8 pint paint can available to consumers, empty cans are first rolled horizontally onto labels, then set upright so that the point can be pumped into them. One machine places lids onto the filled cans while a second machine presses on the lids to seal the cons. From wire that is fed into it from coils, a bailometer cuts and shapes the handles before hooking them into holes precut in the cans. Paint canning is a completely automated process. For the standard 8 12

Report By: Er. Binod Pandey www.binodpandey.wordpress.com pint paint can available to consumers, Fig: canning process empty cans are first rolled horizontally onto labels, then set upright so that the point can be pumped into them. One machine places lids onto the filled cans while a second machine presses on the lids to seal the cons. From wire that is fed into it from coils, a bailometer cuts and shapes the handles before hooking them into holes precut in the cans. in paint, such as the thixotropic agents that give paint its smooth texture, driers, anti-settling agents, antiskinning agents, defoamers, and a host of others that enable paint to cover well and last long.

Charge

Mixing tank Ball mill/ Pug mill

Canning Vertex
Pump

Fig: Flow diagram of production process of paint (on the basis of technology)

Design: Paint is generally custom-made to fit the needs of industrial customers. For example, one might be especially interested in a fast-drying paint, while another might desire a paint that supplies good coverage over a long lifetime. Paint intended for the consumer can also be custom-made. Paint manufacturers provide such a wide range of colors that it is impossible to keep large quantities of each on hand. To meet a request for "aquamarine," "canary yellow," or "maroon," the manufacturer will select a base that is appropriate for the deepness of color required. (Pastel paint bases will have high amounts of titanium dioxide, the white pigment, while darker tones will have less.) Then, according to a predetermined formula, the manufacturer can introduce various pigments from calibrated cylinders to obtain the proper color.

13

Report By: Er. Binod Pandey www.binodpandey.wordpress.com Quality Control: Paint manufacturers utilize an extensive array of quality control measures. The ingredients and the manufacturing process undergo stringent tests, and the finished product is checked to insure that it is of high quality. A finished paint is inspected for its density, fineness of grind, dispersion, and viscosity. Paint is then applied to a surface and studied for bleed resistance, rate of drying, and texture. In terms of the paint's aesthetic components, colour is checked by an experienced observer and by spectral analysis to see if it matches a standard desired color. Resistance of the color to fading caused by the elements is determined by exposing a portion of a painted surface to an arc light and comparing the amount of fading to a painted surface that was not so exposed. The paint's hiding power is measured by painting it over a black surface and a white surface. The ratio of coverage on the black surface to coverage on the white surface is then determined, with .98 being high-quality paint. Gloss is measured by determining the amount of reflected light given off a painted surface. Tests to measure the paint's more functional qualities include one for mar resistance, which entails scratching or abrading a dried coat of paint. Adhesion is tested by making a crosshatch, calibrated to .07 inch (2 millimeters), on a dried paint surface. A piece of tape is applied to the crosshatch, then pulled off; good paint will remain on the surface. Scrubbability is tested by a machine that rubs a soapy brush over the paint's surface. A system also exists to rate settling. An excellent paint can sit for six months with no settling and rate a ten. Poor paint, however, will settle into an immiscible lump of pigment on the bottom of the can and rate a zero. Weathering is tested by exposing the paint to outdoor conditions. Artificial weathering exposes a painted surface to sun, water, extreme temperature, humidity, or sulfuric gases. Fire retardancy is checked by burning the paint and determining its weight loss. If the amount lost is more than 10 percent, the paint is not considered fire-resistant.

Technology used in paint industry:

Ball mill:

14

Report By: Er. Binod Pandey www.binodpandey.wordpress.com

Fig: ball mill Fig: steel balls

A ball mill, a type of grinder, is a cylindrical device used in grinding (or mixing) materials like ores, chemicals, ceramic raw materials and paints [1]. Ball mills rotate around a horizontal axis, partially filled with the material to be ground plus the grinding medium. Different materials are used as media, including ceramic balls, flint pebbles and stainless steel balls. An internal cascading effect reduces the material to a fine powder. Industrial ball mills can operate continuously, fed at one end and discharged at the other end. Large to medium-sized ball mills are mechanically rotated on their axis, but small ones normally consist of a cylindrical capped container that sits on two drive shafts (pulleys and belts are used to transmit rotary motion). A rock tumbler functions on the same principle. Highquality ball mills are potentially expensive and can grind mixture particles to as small as 5 nm, enormously increasing surface area and reaction rates. The grinding works on principle of critical speed.

The critical speed can be understood as that speed after which the steel balls (which are responsible for the grinding of particles) start rotating along the direction of the cylindrical device; thus causing no further grinding.

There are many types of grinding media suitable for use in a ball mill, each material having its own specific properties and advantages. Common in some applications are stainless steel balls. While usually very effective due to their high density and low contamination of the material being processed, stainless steel balls are unsuitable for some applications.

Types of grinding media: There are three types of grinding media that are most commonly used: Flint pebbles Porcelain balls regular and high density Steel balls Flint pebbles These are the oldest type of grinding media in use and they Continue to be extremely popular. They can be used with all types of lining and even in our chrome manganese mills. Among the best known industries in which they are used are paint and enamel products ceramic slip and glaze latex compounds aniline dyes graphite and clay mixtures for lead pencils and hundreds of other products requiring the finest results without contamination. They are exceptionally tough and longwearing and last for many years regardless of the kind of service. The best pebbles are collected along the Normandy Beach in France. They appear to be as plentiful as ever and the quality remains the same as in past years. The pebbles selected for Paul O. Abb mills are predominantly light colored which have been found to give better service.

15

Report By: Er. Binod Pandey www.binodpandey.wordpress.com Porcelain balls This is a pure white ceramic material with a dense, highly vitrified body that will not chip or crack in service. They have been immensely improved in quality in recent years and are used exclusively in many industries. High density media This is the latest grinding media developed for Ball and Pebble Mills. They are made with high alumina oxide content and have a density 40 to 50% greater than the regular porcelain balls. They are also fired at higher temperature making them harder and more abrasion resistant. High density media are available in various shapes including spheres, cylinders and ovals resembling the natural flint pebbles. Most benefit can be derived from the use of high density grinding media when the product is hard to grind and requires all the energy available to break it down, or where higher viscosities can be developed to advantage as in the paint industry through high pigment concentrations which can later be thinned out to make the finished product. Steel balls Steel balls are unquestionably doing a faster grinding job than any of the other commercially available media. They have proven especially valuable in the paint industry. This has not always been the case, however. In the early days Mill operators were insistent upon large steel balls, comparable in size to the flint pebbles or porcelain balls in use at the time. Contamination was excessive and they did not appear to grind much faster than the other grinding media. It was not until much smaller sizes were put into use and correct operating techniques were developed that such outstanding results were obtained, in some cases reducing grinding time to one-third that required for other grinding media.

Fig: pug mill

Fig: pug mill

pugmill or pug mill is a machine in which materials are simultaneously ground and mixed with a liquid. Industrial applications are found in pottery, bricks, cement and some parts of the concrete and asphalt mixing processes. 16

Report By: Er. Binod Pandey www.binodpandey.wordpress.com

Twin shaft disperser:

Used basically for mixing of highly viscous material, our twin shaft dispersor machine consists of two agitator shaft hence it is called as twin shaft disperser, one operates at high speed and another slow speed. Dual shaft disperser are mainly used in paint industries for mixing plant

High speed disperser:

17

Report By: Er. Binod Pandey www.binodpandey.wordpress.com

18

Report By: Er. Binod Pandey www.binodpandey.wordpress.com

Maintenance

19

Report By: Er. Binod Pandey www.binodpandey.wordpress.com

Recommendations:
It is highly recommended that the government should make policies to protect and promote the paint industries and make them capable in competing in the international market and also the outdated, tedious, and complexes policies should be amended. The government should increase their expenditure in the research and development of the paint product, the raw materials of which are already explored and other are in the way to be explored. The government should give-up the TRADERS DOMINATED ECONOMY and must encourage the small traders and industries that are providing equal support towards the economic development of the country. Even if industries need to discourage the foreign products then they must apply GOOD MARKETING STRATEGY.

Conclusion:
After the completion of our report we have come to a conclusion that the paint industry is truly a location to view technology meet the human welfare. Though, in general people are not much aware about the importance and necessity of paint in our lives. In todays world paint plays a very vital and sensitive role to a human life. In fact it adds colour in our lives Like many other manufacturing industries, paint industries also possess a large number of complex and sophisticated machineries. In fact they even have automated machine to assist them with accuracy. But surprisingly, the paint production process is much easier, quicker and requires less human resources as compared to the other manufacturing industries. Though one wouldnt suppose how paint produced in Nepal could compete with those produced in a much developed country but to our surprise we found that they could do it easily. With the continuous effort of the industry and advancement of technology, they are always striving for the betterment of the quality of the paint and give the costumers better service. Working conditions in paint industries are better than those in most other manufacturing plants. Much emphasis is placed on keeping equipment and work areas clean because of the danger of contamination. Plants usually are air-conditioned, well lighted, and quiet. Ventilation systems protect workers from dust, fumes, and disagreeable odors. Special precautions are taken to protect the relatively small number of employees who work with infectious cultures and poisonous chemicals. With the exception of work performed by material handlers and maintenance workers, most jobs require little physical effort.

Bibliography:

20

Report By: Er. Binod Pandey www.binodpandey.wordpress.com

21