Experiment

Aim:
Study of Paint Manufacturing process using PLC & SCADA software.
Theory:
Paint is one major segment of the surface coatings industry, which also includes
arnishes, enamels, lac!uers printing in"s and polishes.
#he production of paint is a relatiely straightforward $atch process that re!uires
the mi%ing of arious components such as tints, thinners, resins, oils and
pigments.
Physical means are used to completely mi% the ingredients.
#he "ey to producing paint of the correct consistency and color is strict
adherence to recipes that are determined through e%perimentation.
&ig.'( Paint Process )isuali*ation
Proper paint formulation centers on the specific application +recipe,
re!uirements. #hese re!uirements are hiding power, color, weather resistance,
wash a$ility, gloss, metal anticorrosie properties and consistency, as related to
how they are applied +$rushing, dipping, spraying, or roller coating,.
-ne major feature of these facilities is that they can easily hae hundreds
of different raw ingredients depending on the specific paint formulation. #hus, the
tan" farm is a ery critical area of the plant.
Manufacturing Process:
Depending on the recipe, different com$inations of raw materials will $e mi%ed in
a premi% tan". .istorically these tan"s were installed on load cells, $ut most
manufacturers hae switched to flow metering and a /meter dec"0 concept.
1ach main supply line will generally include a flow meter2 from the dec" is
another manifold of pipelines that direct the different ingredients to each pre3mi%
tan".
#he operator uses fle%i$le hosing with !uic" disconnects to direct the tan" farm
ingredient to the proper pre3mi% tan".
Dry pigments are also added to the premi% tan".
4atch masses are coneyed to the floor $elow where grinding and further mi%ing
ta"e place through a dispersion mill, which grinds down the pigments for proper
color characteristics.
Mi%ing is completed $y recirculation.
After dispersion, the paint goes to the final letdown, where it is diluted.
#inting and additional thinning with solents is done in an agitated tan".
#he li!uid paint is strained into a transfer tan" or directly into the hopper of the
filling machine on the floor $elow.
Centrifuges, screens or pressure filters are used to remoe un3dispersed
pigments.
#he paint is then pac"aged into cans, $uc"ets or drums, la$eled, pac"ed, and
moed to storage, each step $eing automated and fairly rapid.
&rom there according to the order of dealer or customer it is $een dispatched to
them.
Process Flow Diagram:

No
Yes
Yes
No
Yes
If weigh
60% then
Feeder
Weigh
Mixing
Storage of mixing
Milling
If fine
material
then
Final Storage Paste
Labeling
Thinning
Pa!ing
Start
Solvent, Driers,
Plasticizers
Additives, Binders,
Pigments & Fillers
If "aste
#0% then
Thinning
Sl$dge Sreening
Filling
Storage %
&is"ahing
'nd
No
&ig.5( Process flow diagram
PLC & CADA imulation:
678 +6raphical 7ser 8nterface, can $e easily design using SCADA software.
Ladder logic of paint manufacturing process has $een created using PLC
software 9S logic3:;;.
<ith the help of PLC & SCADA simulation whole plant can $e irtually isuali*ed.
Process can $e easily controlled and monitored i.e. Monitoring & Controlling of
flow , leel , mi%er & coneyor $elt , and 8ndications of pump & ale etc.
Conclusion:
8t is concluded that with the help of PLC & SCADA and its arious tool options
different unit of Paint Manufacturing Process has $een designed. <ith an additional
controlling of mi%er, ale & pump indications & monitoring and controlling the flow &
leel of process line & arious tan"s respectiely .