ChE 353

Chemical & Biochemical Processes

Plant Trip Report
Course Instructor

: Asst. Prof. Nazar leri Ercan

Date of Plant Trip: 09.12.2016

Date of Submission

: 23.12.2016

zm ZL

Fall 2016
Boazii University

Table of Contents
Company Profile..............................................................................................................................2
Corporate History............................................................................................................................2
Divisions..........................................................................................................................................2
Plant Location..................................................................................................................................3
Raw Materials, By-products and Products......................................................................................3
Processes Used in Plant...................................................................................................................3
Waste Management.........................................................................................................................4
Connections (Export & Import).......................................................................................................4
Export:..........................................................................................................................................4
Import:..........................................................................................................................................5
Product Storage and Packaging..........................................................................................................5
Innovations Made in the Company..................................................................................................5
References........................................................................................................................................6

Company Profile
AkzoNobel is a leading global paints and coatings company and a major producer of
specialty chemicals. They supply innovative and sustainable paints, coatings and specialty
chemicals to customers around the world. Paints (decorative paints) interior and exterior
decoration and protection products. Coatings (performance coatings) includes marine coatings,
metal coatings, powder coatings, protective coatings, vehicle refinishes, wood coatings, and
specialty coatings, such as aerospace coatings, specialty finishes, yacht coatings. Specialty
chemical products used mostly in agriculture and everyday products, like disinfectants, plastics,
soaps, detergents, cosmetics, paper and asphalt. Turkey's number one and industry's favorite
paint brand Marshall operates under the largest paint and coating company in the world
AkzoNobels roof. Marshall produces, markets and distributes a full range of interior and exterior
decoration and protection products and products for surface preparation including paints,
lacquers and varnishes. They also supply a wide range of services, mixing machines, color
concepts and training courses for the consumer, as well as the building and renovation industry.

Corporate History
In 1954, Marshall was founded in Topkap/stanbul in a small factory with 20 people. In
1967 a new factory was established in Gebze. In 1994, it started to produce general industrial
paint. In 1996, Flora, the first water-based paint, was produced. In 1997, for the first time in
Turkey, a paint company had a l sorumluluk belgesi.On the other hand, AkzoNobel was
founded in Sweden in 1646 and it was a large worldwide company headquartered in
Amsterdam/Holland when Marshall started work under the roof of AkzoNobel in 1998.

Divisions
The divisions of Marshall: Engineering Maintenance, Quality Insurance, Research and
Development, Work Safety, Production, Production Planning, Storage and Delivery, Sales,
Finance, Human Resources, Marketing.
2

Plant Location
Marshall Painting and Varnish Industry is located in Dilovasi Organize Sanayi Blgesi 1.
Kisim, Tuna Caddesi No:1 41 455 Dilovasi/Turkey

Raw Materials, By-products and Products

Main products of paint are pigments, solvents, resins, and additives. The pigments which
give the color of the paint are TiO2, carbon black, iron oxide, cadmium sulfide etc. CaCO3 and
aluminum silicate are fillers that give the paint body. Latex and alkyd is used as binder. Besides
these materials dispersants, antifoams emulsions and preservatives are used.
By-products are low quality paint, latex sludge and water. Latex sludge can be used in
other industrial products and water can be used as cooling/heating water.
Main products are interior and exterior decoration and protection paints (water based and
solvent base), surface preparation products and varnish.
Products are also be separated as brands Marshall, Cuprinol, Hammerite, Herbol,
Thermos and Fit are produced in Turkey.

Processes Used in Plant

Paint production is a batch process not a continuous process. Marshall uses the advantage
of gravitational force because the paint unit has 3 floors and the second floor is Paste Unit first
floor is Color Set Unit and ground floor is Filling Unit. First in paste unit raw materials are
added according to recipes and they are mixed to get intermediate bulk solution. At this stage the
materials are grains and water. After a certain time, laboratory controls are done and if there are
no problem some additives are mixed. Than in color set unit binders and color pigments are
added to the paint. After the quality tests the paint sent to filling unit. In this unit no manpower is
needed most of the work is done by machines. The paint is filled in buckets at different volumes
and goes to packaging unit. After packaging unit, the paint is ready to deliver the customers.

Waste Management
Efficient waste management is needed to increase the raw materials efficiency in
manufacturing operations and reduce the environmental footprint. The waste can be reprocessed,
sell to other companies to using or recycling or thrown. For solid waste Marshall complies with
the Solid Waste Control Regulations. Water wastes are used as cooling or heating water.
Hazardous waste is stored in closed vessels. Marshall is reducing their environmental footprint
across the value chain and increasing the use of renewable sources 25-30% more efficient
resource and energy use across entire value chain by 2020.

Utilities Used
The main utility used in paint industry is mixers. Mixers are used to obtain homogeneity
between different components. In Marshall water and steam is also used. Water is used as
process water, as cleaning water, as boiler feed water, as cooling water. Steam is used to
accommodate required heat and power if needed. Water may be supplied from public water lines,
wells or canals or it may be supplied as a byproduct. Also during the manufacturing steps or oil
heating process the liquids are contaminated by foreign matters. The paint may contain unwanted
particles. To obtain salable product, paints and varnished liquids must be purified using filters. In
Marshall, weight measuring system (liter based filling, kilogram based control), pressure
transmitter, flow switch, temperature transmitter and flexible pipe are also used as standby
machines and equipment.

Connections (Export & Import)

Export:
According to 2012 data, annual paint production is nearly 140 thousand ton. Paint is
export the countries that improves the built industry. These countries are from Balkan, Central
Asia, Middle East and Eastern Europe.

Import:
Unlike the other factories, Marshall takes calcite in solution form, this allow them to use
it directly. (other factories, the producer turn calcite into solid form, and the factory should
disperse them before they use it) The titanium oxide and some of the additives are also bought in
solid form. Paint is imported generally from the European countries. The main countries are
German, Italy, France, England and Belgium.

Product Storage and Packaging

Raw materials warehouse is for 2250 palettes. Approximately 350 of the palettes are for
flammable liquids with reliable fire system. The tank farm has 2000m3 total storage. Latex and
Alkyd tank farm has 14 tanks which has total 1000 m3 storage. Since there are packaging factory
near the Marshall, the do not have to store extra package. Buckets are filled and a machine places
lids onto the filled buckets, and a second machine presses on the lids to seal them. Buckets are
numbered than boxed and stacked before being sent to the warehouse.

Innovations Made in the Company

Visualizer app (Marshalls app named Gr ve Boya)

Bermocoll for Stone Paint is a new application for an old product
UV-curable clearcoat is an innovative option for body shops
Interpon ReFlex is an ultra-reflective powder coating that can increase the effective

output of commercial lighting fixtures by up to 30 percent

Nouryact Curing systems are water-insenstive curing systems for bio-fiber reinforced

composites
Nordsj Diamond Floor is reasserting market leadership with a new floor paint

formulation
Dulux Charm Waterborne Woodcare is leading the way on waterborne interior wood

coatings
Automatchic Vision is revolutionizing color matching in the vehicle refinishes market

References

Corporate History http://a98e486c46a8ad459c2847ec727f7593b2a401d5f0f702c923ff.r83.cf3.rackcdn.com/faliyet_raporu_2015.pdf

Company Profile, Location https://www.marshallboya.com/tr/hakkimizda

Waste Management and Innovations, https://www.akzonobel.com

Production of Paint, http://www.madehow.com/Volume-1/Paint.html