DATE: OCTOBER 26, 2016

RE: PROGRESS REPORT 02

TO: MYKA ANGELA M. RUFO
FROM: SHEILA A. ABACAN

QUALITY CONTROL
TOP AND BOTTOM TESTING
Every batch of finished paint is tested before it is filled and packed to ensure HOMOGENEITY from
top to bottom and COMPLIANCE to the set of specifications and nominal values set by ACI. Testing also
serves to check if the raw materials were properly incorporated with each other to guarantee that a good
quality is to be released to the market.

A | SAMPLING
The Process Engineer informs the QC department when a batch is ready for testing. The batch to be
tested must be properly mixed as samples are taken from the letdown tanks. Representative bottom
samples are obtained by drawing off a drained sample prior to the bottom sample itself. Drained samples
are returned to the letdown tank.

B | TESTS
The tests to be conducted depend on the product line and are presented at Table 1. Prior to testing,
the sample is brought to a temperature of 29ºC, except for B7760 which is tested at 25ºC.

B701 B710 B715 B7151 N1540 N1541 B7760 B700

Viscosity ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
Density ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
pH ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
Grind ✔ ✔ ✔ ✔ ✔ ✔
Hiding Power ✔ ✔ ✔ ✔ ✔ ✔
Foam Count ✔ ✔ ✔
Tint Strength ✔
%NV ✔
 QUALITY CONTROL
ABACAN, Sheila A.

TABLE 1. Top and Bottom Tests

VISCOSITY
Expressed in Krebs Unit, KU for paints

SIGNIFICANCE: Determines the consistency of paint

EQUIPMENT: KU Viscometer, Thermometer

DENSITY
Expressed in lbs/gal

SIGNIFICANCE: Determines if all raw materials are properly incorporated during in

the batch and detect the overcharging and undercharging of solids

EQUIPMENT: Pycnometer (Ford’s Cup); Analytical Balance

pH
A measure of acidity or alkalinity

SIGNIFICANCE: Determines whether paint/raw materials are held on their basic

state of 8.5 – 9 to ensure that bacterial growth and contamination are avoided

EQUIPMENT: pH meter

GRIND
The degree of dispersion which commonly referred to as FINENESS OF GRIND of
the pigment in a pigment-vehicle system expressed in mills, microns or North standard,
Ns

SIGNIFICANCE: Determines if the pigment agglomerates have been sufficiently

broken into primary particles so as not to interfere with the smoothness of the finished
coating film

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ABACAN, Sheila A.

EQUIPMENT: Hegman’s Grind Gauge

HIDING POWER / OPACITY

Determines the ability of the paint to hide a surface

SIGNIFICANCE: Determine the evenness of the paint when applied; Can also be
used to identify the presence of grits on wet paint

INSTRUCTION: The sample is drawn on the paper beside a control. The control is
kept on the left side of the draw down paper while the sample is on the right. It is dried
and evaluated by visual assessment with the naked eye.

EQUIPMENT: Drawdown Paper; Bird Applicator

FOAM COUNT
Test done to determine the number of foam present for water-based (gloss and semi-
gloss) paints since they contain relatively more binder which are foamy in nature

SIGNIFICANCE: Determines the effectiveness of the defoamer used

INSTRUCTION: 15g of sample is applied and dried on the foam count paper. Three
1-inch squares are drawn over the areas with densest foam formation. The average
number of foams is taken as the foam count reading.

EQUIPMENT: Foam Count Paper; Roller; Magnifying Glass; Square Guide

TINT STRENGTH
The ability of a colorant to alter another colorant

SIGNIFICANCE: Determines whether pigment particles were sufficiently dispersed

INSTRUCTION: Phtalo blue is mixed thoroughly with the sample. The mixture is
drawn on the paper, dried, and evaluated using the spectrophotometer and with the naked
eye and aid of light booth. This is done only on B7151 Pastel White Base.

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EQUIPMENT: Fast and Fluid Shaker; Bird Applicator; Drawdown Bar;

Spectrophotometer; Light Booth

PERCENT NON-VOLATILE
The amount of total solids left in the paint after the solvent has evaporated

INSTRUCTION: Approximately 0.40 g of sample is placed on a pre-weighed and

pre-heated foil and heated in the oven for 30 minutes at 150°C. It is then desiccated for at
least 5 minutes to remove the moisture. The dried sample is weighed and %NV is
calculated as follows:

wt of dried sample with foil−wt of foil

%NV =
initial wt of sample

EQUIPMENT: Memmert Oven; Analytical Balance

C | RESULTS
Results are recorded in the Top and Bottom Results Form, checked by the Quality Control Engineer,
and forwarded to the Process Engineer. The results must be within the specifications so the batch could
proceed to filling and packing. If not, POST ADDITIONS are made and the batch is to be tested again for
top and bottom properties. CONTROL SAMPLES are replaced daily.

FINISHED GOODS AUDIT

This test is conducted to determine finished goods properties after 5 DAYS of storage. This is done to
monitor the behavior of the raw materials used in the paint. The properties of finished goods using NEW
RAW MATERIALS are also monitored with tests done after 1 MONTH and after 2 YEARS of storage.

A | TESTS
As on finished products, tests on finished goods are conducted at 29°C except for B7760 which is
tested at 25°C. Finished goods are tested for their VISCOSITY, DENSITY, pH, GRIND and FOAM COUNT.
Additional properties tested are CONTRAST RATIO and GLOSS.

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ABACAN, Sheila A.

CONTRAST RATIO
Determines the hiding property of paint

INSTRUCTION: The sample is drawn down on the paper, dried, and measured using
the spectrophotometer. With the software installed in the computer unit, values on
contrast ratio including L-value, and a, b, c (CHROMATICITY – the saturation of color/tinge of
color) and h (HUE – the lightness and darkness of a color) values are obtained.

EQUIPMENT: Bird Applicator; Drawdown Paper; Spectrophotometer

GLOSS
Associated with the capacity of the material to reflect more light with other

INSTRUCTION: The sample is casted in a glass panel. For FLAT PAINT, reading is
done after 1 DAY while for GLOSS PAINT, it is done after 3DAYS. For FLAT PAINT,
GLOSS 85°is read while for GLOSS PAINT, GLOSS 60° is read. If gloss 60° is greater than
70, gloss 20° is used. If gloss 60° is less than 10, gloss 85° is used.

EQUIPMENT: Drawdown Bar; Glass Panel; Gloss Meter

B | RESULTS
Result variations do not suggest non-conformity of product. It suggests the behavior of raw materials
and will be a basis for corrective actions for succeeding batches.

NOTE: Finished paints are stored for 2 YEARS.

RAW MATERIALS TESTING

The quality of the raw materials must be ensured before it is used by the production to produce
quality finished paint.

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A | SAMPLING
Raw materials are usually delivered in BULK, TOTE or DRUM with a CERTIFICATE OF ANALYSIS
which indicates the properties to be tested and the equipment and setting used. RMs in bulk are received
and sampled at the tank farm, while those in totes and drums are at the warehouse.

NO-TEST RAW MATERIALS

These are raw materials which are no longer tested for their properties given that a
COA is provided. Suppliers of these RMs have been proven to deliver consistent and
good quality materials for at least one year as reflected by their CpK. All PIGMENTS,
EXTENDERS and THICKENERS are no-test raw materials.

B | TESTS
The samples are tested at 25°C except for DEG which is tested at 16.5°C. Tests are generally
conducted as presented in Table 2.

Emulsion Opaque Wetting Dispers pH Preserv Defoamer Coalescent Co-

Polymer Agent ant Corrector atives solvent

Viscosity ✔ ✔ ✔ ✔ ✔
Density ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
pH ✔ ✔ ✔ ✔ ✔
Appearance ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
%NV ✔ ✔

TABLE 2. Raw Material Tests

NOTE: VISCOSITY of raw materials is expressed as CENTIPOISE, cps and tested using the Brookfield
(LV and RV) viscometers. DENSITY of emulsions are taken as that of a 50WT% SOLUTION.
APPEARANCE is checked in terms of COLOR, presence of GRITS upon draw down, and quality of DRIED
FILM formed.

C | RESULTS
Results are coordinated with the QCE and RMWHE. If raw materials did not comply with the set
specifications, it is BACK LOADED to the supplier after verification of the result.

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OTHER ACTIVITIES
A | BACTERIA TESTING
Bacteria test is done on request for wash waters and drained paints. If wash waters and drained
paints are not used during their 3-DAY LIFE PERIOD, they must undergo bacteria testing to ensure that
they are still safe to use. Wash water and paints which are found positive with bacterial contamination is
treated with double dosage of DB20 solution. Wash water and paints which are free from bacteria can be
used up until the fifth day after the result had been interpreted.

DIP SLIDES with two types of agar are used and reading is done after an incubation period of 48
HOURS. It is noted that the DENSITY of microbial growth, not their size, that is considered.

B | LABORATORY BATCHING
New raw materials or formulation are subjected to laboratory batching. It is a small-scale
preparation of the new formulation whose properties are evaluated against a control before proceeding to
production scale.

Evaluation batches undergo additional tests for properties like SCRUB RESISTANCE, ALKALI
RESISTANCE, DRY AND WET FILM RESISTANCE, WEATHERING RESISTANCE, ADHESION,
and AFTER-HEAT STABILITY.

C | AFTER-HEAT STABILITY
This is done on evaluation batches of paints wherein a new raw material is used. For one week, a
sample is placed in the oven at 60°. The paint behavior is observed. It is equivalent to 2 years’ worth of
exposure.

D | STERILIZATION
The Quality Control Engineer monitors the schedule for sterilization. All LD1 valves should be
tested by the first week of the month; LD2 valves on the second; LD3 valves on the third; and, LD4
valves on the fourth. Sterilization is done by washing with 2% sodium hypochlorite solution, rinsing with
water, and then soaking in 0.2% Acticide MBS solution for at least 3 minutes. This involves prompt
coordination between Quality Control, Maintenance, and Process Engineers.

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Sterilization is also done on flexible hose, containers, filters, strainers and metal binds used in
production.

E | CALIBRATION
Laboratory equipment is subjected to internal and external calibration which should be monitored
by the Quality Control Engineer. Internal calibration of the viscometers and balances is done quarterly.
That of the gloss meter and spectrophotometer is done weekly. For the pH meter, internal calibration is
done daily. External calibration is done every after two or three years depending on the equipment.

F | CANS AND CARTONS

The QCE also verifies the appearance and dimensions of cans and cartons delivered against LSD
and specifications sheets.

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