Module: 11

Dr. N. K. Patel
Lecture: 45 Paint industries

Module: 11
Lecture: 45

PAINT INDUSTRIES (continued)

MANUFACTURE

Raw material

Paint Formulations

White Gloss Enamels (Solvent Based)

Sr. % by
Ingredients
No. Weight
1 Titanium Dioxide (Rutile) 29.3
2 Calcium Carbonate 1.4
3 Long Oil alkyd (70% NV) 52.2
4 Mineral Turpentine Oil (MTO) 13.3
5 Dipentene 2.1
6 Methyethylketoxime 0.1
7 Cobalt octoate (6%) 0.1
8 Zirconium octoate (18%) 0.3
9 Calcium octoate (3%) 1.2

Red oxide Primer (Solvent Based)

Sr. % by
Ingredients
No. Weight
1 Red Iron Oxide 35.9
2 Zinc Chrome 10
3 Talc 3
4 Whiting 1.5
5 Lecithin 0.4
6 Medium Oil Alkyd (70% NV) 36.4
7 Mineral Turpentine Oil (MTO) 11.4
8 Cobalt Octoate (6%) 0.4
9 Lead Octoate (18%) 1

NPTEL 279
 Module: 11
Dr. N. K. Patel
Lecture: 45 Paint industries

Exterior Emulsion Paint (Water Based)

% by
Sr. No. Ingredients
Weight
1 Water 5.2
2 Non Ionic surfactant 1.1
3 Anti-foam 0.2
4 Ammonium polyacrylate solution (2%) 9.6
5 Titanium dioxide (Rutile) 20.5
6 Talc 8.4
7 Whiting 9.2
8 Propylene glycol 2.1
9 Pine oil 0.3
10 Preservative 0.2
11 Acrylic emulsion (46%) 43
12 Ammonia 0.2

Manufacture

Pigment Other raw material

Vehicle
Mixer

tinting
Mixer

Batch

Ball mill
Packaging & storage

Figure: Manufacturing of Paint

Block diagram of manufacturing process

Diagram with process equipment

Animation

NPTEL 280
 Module: 11
Dr. N. K. Patel
Lecture: 45 Paint industries

Required amount of ingredient along with pigments and vehicles are mixed in
mixer which is usually high speed disperser. The basic operation in the manufacture
of paint is the dispersion of pigment particles (often mixed with extenders) in a paint
vehicle or medium to produce uniform, stable system. The process of pigment
dispersion essentially consists of wetting, dispersion and stabilization of pigments and
extenders in vehicle. The dispersion involves breaking down bigger aggregates and
agglomerates to smaller units, wetting of these units and particles by the paint
medium and stabilization of the resulting dispersion.

After grinding, the mill base is mixed with other paint ingredients, i.e. vehicle
and other additives and if necessary with tinting agents in mixer. Tests such as
degree of dispersion (fineness of grind), viscosity etc. are carried out for finished
liquid paint. The straining of paint is done to remove contaminants and it generally
utilize metal or synthetic fiber gauge (screen). The paint passes through the hopper
of the filling machine where it is filled into cans or drums, labeled and packed.

Grinding mill
All the grinding mills generally utilize application of shear, attrition and impact
to effectively break down pigment agglomerates and aggregates and provide
subsequent dispersion of smaller units.

The grinding mills widely used in paint industry are

 Ball mill
 Pebble mill
 Attritor
 Sand mill
 Bead mill
 Basket mill
 High speed disc disperser etc.

Ball mill
Ball mills are primarily used for fine grinding is consists of a cylinder mounted
on a horizontal axis and rotated at specific speed. Steel balls are used as grinding
media which is placed inside the cylinder. The grinding action of ball mill embodies
combination of impact, shear and attrition.

Pebble mill
Ceramic lining is provided inside the cylinder where ball mills are steel lined.
Pebble mill are charged with balls of steatite, alumina or porcelain. Pebble mills are
slower than the all steel mills in reaching degree of dispersion.

NPTEL 281
 Module: 11
Dr. N. K. Patel
Lecture: 45 Paint industries

Attritor
Attritor is faster than ball mill and utilizes less space and is high efficient. Attritor
consist internally agitated media in which the grinding chamber is static and the
grinding media is stirred or agitated by help of rotating shaft to achieve dispersion
where grinding media are steatite balls, steel balls and natural pebbles.

Sand Mill
Conventional vertical sand mills were invented to get around the batch size
limitations of ball mills. The sand mill consists of a high speed rotor (impeller) with disks
mounted on it at regular intervals in a cylinder. The space between the rotor and
cylinder is filled with grinding media. The pre mixed pigment slurry is pumped in at
the bottom of the cylinder and rises through the grinding media which is vigorously
agitated due high speed rotation of the impeller. Dispersion of pigment takes place
as a result of shear as it rises through the cylinder.

Bead Mill
It operates on the same principle as the sand mill using beads. (generally
glass beads).

Basket mill
The Basket mill is comprised of two shafts. The main shaft is the basket or
media agitator shaft and the second is the batch agitator shaft. The basket mill is a
submersible milling unit where it will achieve particle size reduction without the use of
hard to clean pumps, hoses, and tanks. The basket mill allows a greater amount of
material to pass through the milling chamber.

High speed disperser

High speed disperser consists of a vertical shaft having high shear disc
mounted at the end of the shaft. The disc rotates at very high speed (up to 5000
rpm) and creates a radial flow pattern within a stationary mix vessel. The disc
creates a vortex that pulls in the contents of the vessel to the blades sharp edges.
The disc surfaces then mechanically tear apart pigment particles thereby reducing
their size, and at the same time dispersing them. High speed dispersers are normally
used for pre mixing process, as dispersers for soft pigments and as thinning mixers.

SETTING OF PAINT
When the paint is applied on the surface of the metal or wood, the oil present
in it forms a protective film of dried oil. The film is formed through oxidation in
presence of air and polymerization of the unsaturated constituents of drying oil. The
drier present in the paint accelerates the drying of the protective film through
oxidation and polymerization and thus acts as a catalyst for these reactions.
Pigments strengthen the film and protect it by reflecting the destructive ultraviolet
light, while extenders increase the covering power and weathering of pigments and

NPTEL 282
 Module: 11
Dr. N. K. Patel
Lecture: 45 Paint industries

thus improve the consistency, levelling and setting. The cracking aspects are
reduced by adding some oils as plasticizers.

REQUIREMENT OF A GOOD PAINT

 Pigment should be opaque to ensure good covering power.

 Should be chemically inert to secure stability and hence long life.
 Should have a good colour and high hiding power.
 Should be weather resistant.
 Should have good washability and metal anti corrosive property.
 Its consistency should be suitable to appreciation by the types of application
such as brushing or roller coating.

The individual requirements are met by proper choice of pigments,

extetenders and drying oils.

Pigment volume concentration

Various requirements, such as gloss, washability, durability and reflectance,
rheological properties are largely controlled by pigment volume concentration
(PVC), which is defined as,

PVC =

The PVC range for various paints as follows

Sr.
Paint PVC range
No.
1 Flate paint 50 – 70%
2 Semigloss paints 35 – 45%
3 Gloss paints 25 – 35%
4 Exterior house paints 28 – 36%
5 Metal primers 25 – 40%
6 Wood primers 35 – 40%

 The gloss decreases as the PVC increases. This is due to the fact that when
volume of pigment increases relative to the nonvolatile vehicle, gloss
decreases until the finish or gloss of the paint becomes flat.
 With increase in PVC, adhesion as well as durability both decreases. If volume
of pigment increases as compared to the volume of binder, the film will lose
cohesion. The paint will be in powdered form and obviously will have little
durability.
 When extenders are added, the PVC increases and gloss decreases.

NPTEL 283
 Module: 11
Dr. N. K. Patel
Lecture: 45 Paint industries

PAINT FALIURE
The failure of paints may be due to various causes. Various terms used to explain
the paint failure are as follows.
Chalking
It is progressive chalking or powdering of the paint film and is used by
destructive oxidation of the oil after drying of the paint on the surface.
Erosion
Very rapid chalking is called as erosion.
Flaking or peeling
Poor attachment of the paint on the surface to be coated is called flaking or
peeling and caused by the presence of dirt of grease on the surface or water
entering from below the paint.
Alligatoring
If the center portion remains attached to the surface and the portion around
the center peels off, a term alligatoring is employed.
Checking
Fine surface cracking is called as checking and is due to the absence of
plasticizers in the paint.
Blistering
Appearance of blisters on the coat applied to wood is generally known as
blistering.
Blooming
Appearance of dull patches on the surfaces called blooming.
Blinding
Discoloration of the film is known as blinding.
Cissing
Refusal of some portions of the surface to be painted is called cissing.

Paint failures can be avoided by

 Careful mixing of the constituents or ingredients in specified proportions.

 Proper processing of the surface to be coated before the paint is applied.
 Using a primer coat before the application of the paint.

NPTEL 284
 Module: 11
Dr. N. K. Patel
Lecture: 45 Paint industries

PROPERTIES
Sr. Property
No.
1 Appearance
2 Application Method
3 Drying Time
4 Adhesion
5 Mechanical
Characteristics
6 Resistance
7 Outdoor Durability
8 Storage Stability
Example
Gloss/ Matt/ Semi-gloss
By Brush, Roller or Sprayer
Fast dry/ Slow dry
Adhesion to substrates/ Existing coating/
Intercoating
Hardness/ Flexibility
Ultra-violet/ Chemical/ Abrasion/ Fungus/ Algae
Gloss retention/ Color / Ultra-violet
Settling tendency/ Viscosity stability

Special applications of the paints

 Paints are extensively used as acid resisting coats.

 Oil bound paints or distempers are widely used for interior decoration of walls.
 Coal tar products dissolved in mineral spirits have been used as protective
coatings of pipes under the name bituminous paints.
 Ship bottoms are protected by antifouling paints which are prepared by
mixing iron oxide, mercuric oxide and copper resinate dispersed in tung oil
(vehicle).
Paint with damp resisting properties can be prepared by mixing paraffin wax, rosin.
Bitumen and gutta parcha dispersed in tung oil (vehicle).

NPTEL 285