2019

ASSIGNMENT 1

SUBMITTED TO: DR. ASIF ALI QAISER

SUBMITTED BY: ZAIN JAVED (2016-PE-43)

MIRZA AQEEL AHMED (2016-PE-44)
VISITED INDUSTRY:
ORVA PLUS COATING INDUSTRY(GUJRANWALA).
INTRODUCTION:
We visited the Orva Plus coating industry (Gujranwala) this industry manufactures paint,
varnishes and similar coatings by using powder coating machines. They use different kind of
pigments and raw materials to make their end product better. Different unit installed to solve
the trouble shooting regarding product. Proper testing is being done by different testing
machines like adhesion, impact and flexibility testing. Their business stability depends on
quantity, weight, price and number of transactions.

Industry location:
 Ali Asghar Colony, Street No. 1 Opposite to Lohianwala, Police station, Gujranwala

Raw Materials:
1. Epoxy polyester
2. Calcium carbonate pigments
3. Barium sulphate pigments

Pigments they used for coloring:

1. High black 890
2. Blue 15:1
3. Yellow 131
4. Yellow 121
5. L 88 flowing agent
The grades are being used as FL 1050 and 1052 both.

Products:
Paints, varnishes and similar coatings
 Figure 1: Industrial product

Material data sheet:

Physical and Chemical Properties of polyester epoxy
Appearance Viscous liquid
Colour Amber
Odour Strong
Flash point 31°C
Vapour pressure 6.7 hPa @ 20°C
Relative density. 1.1g/cm³ @ 20°C
Solubility(ies) Insoluble in water
Viscosity 400 cP @ 20°C
Auto-ignition temperature 490°C

Calcium carbonate data sheet

Physical and chemical properties of calcium carbonate
Physical state solid
Appearance White powder or lumps
Color white
Odor None
Melting point 825 °C
Freezing point Freezing point
Flammability Non-flammable
Solubility Water: 0.00153 g/100ml
Molecular mass 100.09 g/mol
RHEOLOGICAL BEHAVIOUR OF MATERIALS:
The impact of epoxy sap on mechanical and Rheological properties, and dampness ingestion of water
substance. The rigidity of material diminished, and versatile modulus and dampness ingestion expanded
with expanding epoxy sap content. The intricate consistency η* expanded with expanding epoxy tar
substance of composites, and a synergistic impact in expanding the η* was seen at 3 wt. % gum. The
epoxy tar changed Polyester material that artificially coupled by MPP indicated least water ingestion
with most elevated versatile modulus. Responsive blending of epoxy‐polyester tar utilizing a corotating
twin screw extruder, and the rheology, morphology, crystallization conduct, and mechanical properties
of covering material were assessed. The melts of covered material blended in with tar showed yield
pressure and the variety of thickness against recurrence can be approximated in two lines with different
inclines. The investigation indicated that the greatest volume division increments by utilizing limited
quantity of epoxy pitch in the definitions. The differential filtering calorimetry indicated that the epoxy
tar smothered the nucleation impact of Polyester while the degree and pace of crystallization expanded.
The compatibilization by maleic anhydride‐grafted polyester indicated an observable increment in
rigidity of covered material responsively blended in with epoxy sap.

Essentially, the rheological conduct of calcium carbonate. The rheological properties of polyester
liquefies loaded up with 30 vol % of CaCO3 particles of fluctuating molecule size are portrayed. The
impact of surface covering the particles with stearic corrosive is considered. By and large, the mixes with
the uncoated particles show viscosities which increment at ever more prominent rates as the shear
rates decline. Elongational stream information likewise propose the presence of yield esteems.
Challenges exist in estimation of typical worries in mixes with sizeable yield esteems. The vital typical
pressure contrast at fixed shear worry of the PS/CaCO3 mixes is lower than that of the PS soften. The
extent of consistency increments and yield esteems increment with diminishing molecule size. Covering
of particles with stearic corrosive outcomes in significant thickness decreases and diminishes in clear
yield esteems. The surface covering is best with the littlest particles. It probably diminishes association
among particles and the degree of total.

High strong sparkle finish paints or coatings requires the utilization of a molecule size about 0.7-0.8μm
accelerated barium sulfate, if with bigger particles it will influence the surface gleam level, if littler
particles because of the impact of higher surface region the use measure of cover.

Accelerated barium sulfate under 0.7μm molecule size can be utilized to isolate color and has
deflocculating capacity, in this way empowering to decrease to an extremely low estimation of the
measure of shade; encouraged barium sulfate of 0.7μm in a wide range has no impact on the
consistency, so it is conceivable to utilize hastened barium sulfate as indicated by the most noteworthy
rate in the formula given, it has no impact on the gleam. Accordingly, hastened barium sulfate help, to
decrease VOC and replaces the more costly shades, to diminish plan costs and give a decent chance.
Other than utilizing in white or splendid shading paint, the white fine accelerated barium sulfate can
likewise be utilized for covering of unadulterated dark and won't influence dark shading. This identified
with the refractive record of the precipitation of barium sulfate, its refractive list like the normal pitch,
so blend of encouraged barium sulfate isn't white yet straightforward. Hence, won't happen light dim in
carbon dark, accelerated barium sulfate additionally can lessen VOC of dark paint. Oil assimilation and
explicit surface territory of carbon dark and accelerated barium sulfate have a major contrast, by
flocculation opposition, compelling job of dark carbon must be expanded insignificantly, if use hastened
barium sulfate rather than bunches of carbon dark it will decrease the amount of base interest and
thickness, and further will diminish the VOC.

PRODUCT TESTING:
Following tests employed in the industry to characterize the final product

ADHESION TESTING:
The adhesion test is performed to determine the paint or coating will stick to the material on which it is
going to be applied. On the industrial scale there are further more methods to calculate the resistance
of coatings and paints. These methods include peel off test, cross cut test and scrape adhesion test.

Figure 2: Product adhesion tester

ASTM used for the adhesion testing:

ASTM D4541 – 17 (Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion
Testers)

ASTM D3359 – 17 (Standard Test Methods for Rating Adhesion by Tape Test)
IMPACT TESTING:
The quality and the strength of the paints and coatings are determined by the impact testing. There are
various standards for the measurement of strength and quality there are various standards that are
introduced by the American standardization testing mechanism. The ASTM used for the impact testing
are such as ASTM D2794, ASTM D609.

Figure 3: Product impact tester

ASTM used for impact testing:

ASTM D2794 - 93(2019) Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid
Deformation (Impact)

ASTM D609 - 17 Standard Practice for Preparation of Cold-Rolled Steel Panels for Testing Paint, Varnish,
Conversion Coatings, and Related Coating Products

Flexibility test:
The flexibility test is performed on the paint to ensure that it does not crack when the material is bent to
a certain level. the manufacturers need to test the flexibility of the paints and coatings they
manufacture. There are different types of substrates on which the paints and coatings are applied for
different pursues.

When a metal sheet is painted, the paint is meant to protect the sheet from external effects such as
weathering, corrosion, effects of oil and grease, etc. The quality of paints used on the metals must be of
the best quality so that there are no chances left for the external environmental factors to affect the
quality and safety of the sheet metal surface. One of the most prominent problems related to painted
surface is that when they experience a certain degree of bending, it causes the surface of the paints to
develop cracks which compromise the safety of the surface. Additionally, cracked paint surface also
results in the bad appearance of the surface.
 Figure 4: Product adhesion tester

ASTM used for flexibility testing:

ASTM D4145 - 10(2018) Standard Test Method for Coating Flexibility of Prepainted Sheet

The degree of reaction not only varies with paint type (resin system) but also gloss level and
color. The higher the gloss level the more resistant the paint may be to the solvents being used.
With strong colors (high levels of colorant) there may be a degree of pigment transfer which
may make interpretation of softening/dissolution reaction more difficult.

SUGESSTIONS:
Pigments are finely ground solids of different shades to give color, durability, consistency and
other properties to paint. It is also one of the major raw materials, accounting for one-third of
the total raw materials cost. We can use RED 122 organic pigment, dark RED 945097, iron oxide
blue 886 and similarly iron oxide black Fe403 instead of High black 890, Blue 15:1, Yellow 131,
Yellow 121 and L 88 flowing agent.so these suggested pigments have low cost and better
performance as compared to the industry using right now. Amongst the vital pigments used in
the process of paint manufacture is Titanium dioxide (TIO 2) and the industry consumes around
60% of TIO2. This pigment is available in two grades: anatase and rutile, of which anatase is
exclusively used in interiors while rutile is preferred in exteriors. India has abundant raw
materials for the manufacture of TIO2, especially ilmenite of which it has 12% of the world’s
deposits. It is ironical that the paint industry presently imports TIO 2 in excess of Rs.1 bn - a
figure that may touch Rs 2 bn by the turn of the century. TIO 2 is responsible for the demand-
supply gap. If the strong demand growth boosts domestic production of TIO 2, there will be an
increased usage in various sectors. If the raw materials are properly utilized, India has the
potential to emerge as a net exporter of TIO 2 in the next five years.
Solvents are volatile organic compounds (VOC) used to dissolve, suspend or change the
physical properties of other materials. They are generally used to bring down the viscosity
of paints to the desired level, which also reduces the cost of paint formation. They
constitute 70%-75% of the paint liquid and ultimate escapes into the atmosphere when the
fluid dries. Solvents such as ethylene glycols and alcohols are finding wider use as co-
 solvents in paint industry.so these are solvents that can be used in this industry to improve
their performance.
Binders are generally oils, resins and plasticisers that give paints its protective property.
Most resin manufacturers make alkyds, polyesters, emulsion polymers, epoxy resins, amino
resins, powder coating resins etc.
Additives are added in small proportion to the paint to improve its performance
characteristics in various ways. Skinning inhibitors, fungicides, wetting agents, driers are
included in this category. We can use Andisil 1100 Silan, AL 121, AC-626 and Silanil 250.
 The automotive paint is costly. As we want high quality finish, we could retain finish quality,
reduce cure time and improve the protective qualities of the coating with a less expensive,
more durable material .