Punjab Paint Colour & Varnish Works Pvt Ltd,. Kanpur.

- MANUFACTURING
PROCESS.
1.0

Products and Process

Punjab Paint Colour & Varnish Works (P)Ltd. 123/529 FazalGanj, Kanpur, is
currently
manufacturing solvent based Primers and finishes ,water based coatings and
Acrylic Distempers. Apart from manufacture for own market, this unit also
manufactures the paint products on the behalf of Asian paints for more than 15
years & for Kansai Nerolac paints for more than 10 years.
1.1 Production Process
The following products are manufactured with expected quantities (80% of
designed
Capacities) as follows

Product Stream

Capacity per month

(KL)

1. Water Base Primers

600

2. Solvent base White Primers

500

3. Red Oxide Primers

200

4.Enamels Retail pack

700

5. Enamels Small pack

300

6.Distemper

400

Total
7. Resins

2700
700

1.2 Acrylic Distempers and Wall Putty

The manufacturing process
For both the above products manufacturing process is similar. It involves
mixing
Vigorously to a fine paste in a pug mill, various categories of Raw Materials,
Water,
Polymer Emulsion, Dispersing Agents, Additives, Pigments like titanium
dioxide,
Extenders and Aqueous Dispersions of Pigments as coloring matter. Final
adjustments
include additions of thickening agents (for increasing viscosity), Water (for
decreasing

Punjab Paint Colour & Varnish Works Pvt Ltd,. Kanpur. - MANUFACTURING
PROCESS.
viscosity) and colored pigment dispersions for matching of shade. The
resulting
product is a smooth paste which can be thinned with equal parts of water to
give liquid
water based paint suitable for application on walls, ceilings etc.
1.2.1 The Typical Ingredients used
Raw Material
Water
Sodium Carboxy Methyl Cellulose
Additives

Percentage
23.0
2.6
2

Dispersing Agents

0.1

Biocides

0.3

Extenders(Mineral Powders)

59.8

Pigments powders and aqueous Colour

Pastes
Liquor Ammonia

2
0.2

Polymer Emulsion

8.8

Thickening Polymer

1.2

Total

100

1.2.2 The Process Flow Sheet Diagram

Sequential addition of the following ingredients to a Pug Mill is carried out
and after that,
balancing additions of water or stainers is done. After adjusting to the
specification
parameters and QA approval, the product is filled into plastic buckets of 20
kg, 10 kg, 5
kg, 2 kg and 1 kg. The buckets of 5 kg, 2 kg and 1 kg are put into cartons
and transferred
to Finished Goods Warehouse for dispatch to destinations.

Punjab Paint Colour & Varnish Works Pvt Ltd,. Kanpur. - MANUFACTURING
PROCESS.

1.3 Water Base Primers and Finishes

Various types of water base primers and finishes are produced for different
applications. These include water based primers, Wood Primers, Cement
Primers, General Purpose Primers, and finishes .

Punjab Paint Colour & Varnish Works Pvt Ltd,. Kanpur. - MANUFACTURING
PROCESS.
The manufacturing process

The products of this category are free flowing viscous liquids unlike distempers
which are
paste like. They come in different price ranges depending upon the performance
required, which in turn is dependent upon the polymer content and the type of
emulsion
polymer used.
The manufacturing process is almost similar to that of distempers except that
the
machine required for dispersion is Twin Shaft High Speed Disperser (TSHSD) in
place of
pug mill.
The various categories of raw materials are added into the TSHSD in sequence,
with the
high speed cowl disc running. Thus, in presence of water, wetting agents,
dispersing
agents, thickening agents, extender powders and pigment powders are added in
sequence to achieve a fine aqueous dispersion to which emulsion polymer is
added at a
slow speed, followed by addition of balancing quantities of water or any other
ingredient as may be required to meet the specification parameters.
1.3.1 The Ingredients and the quantities used per month

The raw materials used in both water base primers and finishes are the same
though the
proportions vary. Same way the manufacturing process and the manufacturing
equipment is TS HSD for both. As mentioned earlier, finishes contain more of
polymer
and pigments and less of extenders to give them more opacity, more
smoothness and
better durability as compared to primers.

Punjab Paint Colour & Varnish Works Pvt Ltd,. Kanpur. - MANUFACTURING
PROCESS.

1.4 The Solvent Based Primers & Finishes

The products in this group are based on mineral turpentine Oil (MTO) as solvent
and the
other ingredients being alkyd based medium as film former and pigment
powders both
white and all colours for giving colour and opacity, wetting agents, antisettling
agents,
Antiskinning agent, flow promoters, driers etc. The finishes do not incorporate
extenders
and are generally glossy . Primers on the other hand are generally matt to semi
glossy as a
result of incorporating extenders alongside pigments.
1.4.1 The Process Flow Diagram

Punjab Paint Colour & Varnish Works Pvt Ltd,. Kanpur. - MANUFACTURING
PROCESS.

1.5 Alkyd Mediums

These form the binder component in solvent based primers and finishes. They
are
prepared by reacting drying oils like linseed oil, commercial Castor
oil,dehydrated castor oil, soyabean oil etc with polyols like glycerol,
pentaerythritol and sorbitol and with polyacids like phthalic anhydride. In
between a monoglyceride formation step is involved to ensure compatibility of
phthalic anhydride with the reaction mixture.

Punjab Paint Colour & Varnish Works Pvt Ltd,. Kanpur. - MANUFACTURING
PROCESS.