NATIONAL COLLEGE OF ENGINEERING

(Affiliated to Tribhuvan University)

Talchhikhel , Lalitpur

[Subject Code: CT…..]

A Minor Project Proposal On

“Case Study On Berger J&N Paints”

Submitted by
Yagyan Munankarmi Roll 047

Yalab Guragain Roll 048

Pratik Biska Shrestha Roll 026

Anusha K.C Roll 002

Submitted to
Department of Computer and Electronics Engineering
31st January 2020
Acknowledgement
We would like to express our special thanks of gratitude for providing us the
fabulous opportunity to have an industrial visit for the case study of the subject
“Instrumentation II”. It is our pleasure to submit this report to the Department of
Computer and Electronics Engineering of National College of Engineering. We also
like to thank our subject teacher Mr. Sanuj Shakya for guiding, encouraging and
inspiring us throughout the study.

We are grateful to the Nepal Berger paint for taking out some time from their busy
schedule to provide us all the necessary information. We are thankful to Er. Manoj
Basnet, the owner, all the staffs, workers, management, associates and the project
manager of the corporation for providing knowledge about machinery details,
productions and financial information without which this case study would not have
been successfully accomplished.

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Abstract
This report spectacle the findings of the case study done as per the curriculum for
Instrumentation II. Our foremost target was to study the microprocessor-based
instrumentation systems being used in industries in Nepal. The process and machines
involved in making of Paint and packaging were observed and necessary guidance
was provided by the technicians. This report is based on study conducted on the
production plant that makes different color. We were made aware about the existing
system being used in the process. This report includes the overview of the existing
system being used and also the proposed system so that the production of the material
can be more efficient and can increase the productivity of the company.

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Content
Acknowledgement..........................................................................................................1
Abstract..........................................................................................................................2
Content...........................................................................................................................3
1.List of Figures.............................................................................................................4
2.Introduction.................................................................................................................5
3.Objective.....................................................................................................................6
4.Manufacture of paints..................................................................................................7
4.1Raw Materials.......................................................................................................7
4.2Machines used in production of paints................................................................10
5.Basic overall process.................................................................................................12
6.Working principle.....................................................................................................14
7.Power Transmission and Distribution.......................................................................18
8.Limitation of the current system...............................................................................19
9.Proposed system........................................................................................................20
10.Advantages of the purposed system........................................................................22
11.Recommendations...................................................................................................23
12.Conclusion...............................................................................................................24
13.Bibliography............................................................................................................25

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1.List of Figures
Fig 1. Pigments.......................................................................................................7
Fig 2. Twin Shaft Disperser (TSD)......................................................................10
Fig 3. High Speed Disperser (HSD).....................................................................10
Fig 4. Automatic filling........................................................................................11
machine................................................................................................................11
Fig 5. General overview of manufacture of paints...............................................12
Fig 6. Block diagram of TSD/HSD......................................................................14
Fig 7. Density test................................................................................................16
Fig 8. Block diagram of Automatic filling system...............................................17
Fig 9. Power Transmission...................................................................................18
Fig 10. Block diagram of proposed TSD.............................................................20
Fig 11. Block diagram of proposed automatic filling system..............................21

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2.Introduction
Berger (Jenson & Nicholson) Nepal Pvt. Ltd. has been engaged in the manufacturing
of decorative paints since 2000 in Nepal. It was established through FDI from Berger
Paints India Limited (BPIL), a MNC based in India with subsidiaries in Bangladesh,
Russia, Poland, and Cyprus. The company has ushered in advanced manufacturing
technology to conform to international benchmarks of quality at its modern
production facility in Hetauda and Bhaktapur. Since its inception, Berger (J&N) has
consistently responded to consumer needs and demonstrated its commitment to
consumers by offering a varied range of high-performance decorative products with
the highest level of customer service.

In its two decades of operation as a manufacturer of high-quality decorative paints,

Berger (J&N) Nepal claims it is now one of the companies with the highest
compounded growth in the Nepali paints industry holding almost 30 to 34 percent
share of the market.

The company’s annual turnover hovers around Rs 5 billion and it has nearly 30
products in its portfolio. It has nine depots and over 1,000 dealers across the country
to distribute premium quality exterior, interior and undercoat paints products.

Similarly, the company has been providing direct employment to approximately 200
people while more than 5,000 paints contractors are engaged with the company.

The two decades long smooth journey has made Berger a household name in Nepal
for decorative, luminous and eco-friendly paints. “It’s been a fantastic journey for us
being among the top-ranked companies engaged in manufacturing and marketing of a
variety of architectural coatings in Nepal.

Over the years, it has received a fabulous response and support from the customers,”
claims Satya Prakash, CEO of Berger (J&N) Nepal.

This is the first service of its kind in Nepal under which trained painters use automatic
machines to paint the houses of Berger customers offering a hassle-free painting
experience. The Express tools help the customers for better painting performance and
give aesthetic value without any hassle and extra cost. In the meantime, Berger (J&N)

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is also the first company to bring designer finished paints in Nepal such as the Berger
Illusion Coating.

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3.Objective
 To learn about electronics design using microcontroller and microprocessor in
commercial field.
 To observe the current system carefully and the problems encountered in the
industry.
 To boost up the technical skill with practical approach.
 Practical implementation of knowledge and to expose ourselves in industrial
environment.
 To purpose solution if any fault is present.
 To study the existing management system and technology of company.
 To be familiar with various engineering aspects provided by the company.

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4.Manufacture of paints
4.1Raw Materials
Pigments

A pigment is a material that changes

color of reflected or transmitted light as the
result of wavelength-selective absorption.
Pigments are granular solids incorporated with
the paint to contribute the base paint. Pigments
can be classified as natural or synthetic types.
Natural pigments include various clays,
calcium carbonate, mica, silica, talc and so on. Fig 1. Pigments
Synthetic pigments are engineered molecules,
calcined clay, blanc fixe, predicated calcium
and so on. Hiding pigments make paint opaque as well as protect the substrate from
the harmful events of ultraviolet light. Hiding pigments include titanium dioxide,
phthalo blue, red iron oxide and so on.

Solvents

For water-based paints, water is the solvent. It helps the powdered raw
materials to mix and form a homogenous mixture, that is, paint.

Binders/ Emulsifiers

Binders are the film forming component of a paint as it dries and affects the
durability, gloss, and flexibility of the coating. Polyurethanes, polyesters, and acrylics
are all examples of common binders. BPBL produces its own emulsion in the
emulsion part and this emulsion is the blinder in this emulsion is used as blinder in
water based plants.

Dispersing Agents

The raw materials are all in the powdered form and after mixing the materials
can solidify and precipitate to bottom. To prevent this and to ensure uniform
dispersion of raw materials, dispersing agents are used.

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Defoaming Agents

Defoaming agents are used to modify the mixing process to ensure that the
foam and bubbles do not form. Foaming impedes the mixing process and negative
impact on mixer performance.

Additives

Paints can have a wide range of miscellaneous additives, which are usually
added in small amounts, yet provide significant effect on the product. Some examples
include additives which modify surface tension, improve flow properties, improve
finished appearance, improve stability and spread and so on. Depending on the
properties required, additives are formulated and added.

Thickeners

Thickeners are used to modify the viscosity of the paint. Nitrocellulose,

Benton Powder are some of the thickeners.

Stabilizers

Stabilizers such as formalin are used with paint to increase the stability of the
emulsion and increase the shelf life of the product.

Resin

It is the component that identify the paint, several resins are used in paints
manufacturing, it works as binder for collecting all paint components, the mixture of
solvent and resin usually called “vehicle”. The binder (Resin) classified into two
classifications; the first classification is convertible binders which non fully
polymerized but it partially polymerized and it complete its polymerization during
film formation when painting.

Filler

Fillers is considered as additives but adding it with high quantities in paint

formula, forcing to consider it as a main component of paint formula, it has several
types can perform a co-work as fillers and others such as; retardants for flame like
alumina tri hydrate (ATH). The most common are calcium carbonate, talc, silica, clay,

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calcium sulfate, mica, glass structures, and ATH. Fillers serve a number of purposes
such as reducing cost.

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4.2Machines used in production of paints

Twin Shaft Disperser (TSD)

The twin shaft disperser has two shafts. One

shaft holds the primary impeller which imparts
rotary mixing motion of the water and powder
mix, while the other shaft holds a grinding disk.
The grinding shaft rotates at high speed whereas
the impeller rotates at lower speed. With the help
of TSD, the raw materials are grounded, mixed
Fig 2. Twin Shaft Disperser
and turned into slurry.
(TSD)

High Speed Disperser (HSD)

High speed disperser is a type of industrial mixer that

utilizes a disc shaped blade that is mounted on the end
of the mixing shaft. To achieve high speed dispersion,
the blades are rotated at an optimal speed. The
amount of disperser is also dependent on the mixing
vessel size. Unlike TSD, HSD doesn’t have any tanks.
Therefore, a mobile pot is used for mixing. The
Fig 3. High Speed Disperser
speed of HSD can be set as required ranging from (HSD)
800 RPM to 1400 RPM.

Mixing Tank

Mixing tanks are high capacity tanks which have only one agitator or impeller to
continually mix the slurry.

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Automatic filling machine

Automatic filling machine uses different kind of sensors which

are monitored by a control system. The control system also
monitors and controls the filling process of paints on the basis
of volume. This system is a closed loop microprocessor-based
instrumentation system (MBI) that utilizes the generated output
signals to automatically bring changes in process variable as
needed.

  Fig 4. Automatic filling

Machine

Lid press machine

Lid press machine use compressed air to actuate pneumatic pistons to press lids on top
of buckets. The lid press can be of different shape depending on the lid to be pressed.

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5.Basic overall process

Fig 5. General overview of manufacture of

paints

 Raw materials formulated by R&D department are first transferred into

TSD/HSD according to the proportion per batch card.
 Water is added to the TSD/HSD and is left to mix at a specified speed for
certain period.
 Fillers materials are added at certain intervals.
 After successful completion of grinding, the mixture is transferred to a mixing
tank (thinning tank) via pumps where emulsion is added and mixed till
specific quality is met.

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 Further additions and fillers are added and mixed to ensure proper shade,
viscosity.
 The sample of the batch is tested in lab and are send to filling system after
approval.
 The automatic filling system transfers the paints into paints bucket and lid
press machine applies lid to the bucket.

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6.Working principle
From the ancient time of discovering paints, its making depend on blending, the first
paint did not have the required durability. The modern technology and discovering
new resins make humans to be able to manufacture new paints which have high
adhesion force, durability, and other specific properties as they need

The modern manufacture of paints, which are generally made in batches, involves
three major steps:

 Mixing and grinding of raw materials;

 Tinting (shading) and thinning;
 Filling operations

The detailed process of the operations with the equipment used are as follows;

Twin Shaft Dispenser (TSD)/High Speed Dispenser (HSD)

The raw materials for water-based paints are all in powder form. The surface-active
agents, usually thickeners added to give a gel stage after that binders or oils added. In
addition to adding pigment and fillers also amount of solvent added, this procedure
called premixing. At first, water is taken in the TSD/HSD and then the raw materials
are added one by one. The proportion and time of mixing is maintained as per batch
card. Dispersion is checked time to time to mark whether the dispersion is satisfactory

Input panel Control system DAC

Raw materials
Twin Shaft
Disperser/ High
speed
disperser

Speed
Display panel Sensor(RPM
sensor)

Fig 6. Block diagram of TSD/HSD

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or not. Filler materials are introducing at certain intervals. The process ends when
satisfactory dispersion is achieved.

The raw materials for water-based paints are all in powder form. At first, water is
taken in TSD. Then the raw materials are added one by one. The speed is set with the
help of input panel. The control panel send signal to the TSD through a DAC and the
TSD starts to mix the paint. Fillers are added in between. TSD is also linked to a
speed sensor that detects if the speed varies from the input speed and displays the
speed at which the TSD is rotating.  

Mixing Tank and Addition of Emulsions.

Addition After successful completion of grinding, the mixture is transferred

via pumps and pipes to the mixing tank and emulsion is added with it. For a
successful completion of the paint making process, TSD is enough; that is emulsion
addition can also be done in TSD. But mixing tank is used because the capacity of the
TSD is too small for batch production with emulsion. A typical TSD in BPBL has 600
gallons capacity whereas a mixing tank has 900 gallons. Also, segregating the process
in two machines improves the productivity of the whole process.
After emulsion addition, further additions are made to ensure proper shade,
specific gravity and viscosity. Stainer are used to match shades whereas thickeners are
used for viscosity. Different types of additives are also added. Stabilization is done
with stabilizers. The Quality Control department checks for the properties
and shade at certain intervals and when proper properties are gained.
Testing Paints
Testing is an important part of the operation of a paint system. Testing is done to
monitor the system and to confirm that the finish meets established quality standards
and the expectations of the customer. The end use of a painted product should
determine what tests are important. The incoming paint material is sometimes tested
to confirm that the color and gloss are correct and the paint is free of defects. In some
cases, the paint supplier will certify that the paint they are providing meets all
required physical properties.

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Raw material checking
Usually in paints industry the raw materials be got from several suppliers, so that it
needs to be tested and compared with the manufacturer standards. Several tests done
to paint components such as; resin, solvent, pigment etc.
Solvent Tests
Solvent is the material that dissolve all components of paint following the role. The
manufacturer must be sure that the solvent has agreement to his standards by applying
tests such as density, vaporization time, and flash point.

Density Test
By using density cup, which showed in
figure with volume about 100 ml, that
first put empty on the balance to make
the balance on zeroes state after that the
cup filled by the solvent and weighted
again. The target from this test is to
know if the solvent mixed with another
component or no.

Fig 7. Density test

Pigment test
It is the test that done to know the amount of binder and resin required to absorb
definite amount of pigment by using a glass board and mixing manually resin and
solvent that already mixed before with pigment powder on this board. An additional
amount of mixture from resin and solvent will be added until all tested amount of
pigment powder will be mixed.

Final Products tests

Several tests done to final product to check the degree that it agrees with required
specification. These tests used to put standards value for the organization or company
to distinguish its products.

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Viscosity test

One of tests that applied to paints is viscosity. It can be determined by measuring the
time required for a given quantity of paint to flow through a hole in the bottom of a
metal cup. It also can be measured by a viscometer to obtain paint viscosity.
Density test
It is the second important test after viscosity. It done by using cup has volume of 100
ml. The sample put into this cup without leaving any spaces in cup. Then the density
measured by a digital balance.

Automatic filling machine 

User panel Panel interface

Paints Paint tank Level Sensor ADC Control system

DAC ADC

ADC Proximity
Compressor
Sensor

Weight Sensor Paint container

Fig 8. Block diagram of Automatic filling system

After the paints are

made the paints are transferred to the paint tanks through valves. The tanks are
connected to a level sensor that keeps the record of the level of the paint being filled
in the tanks. The sensor sends the signal to an ADC and ADC sends it to the control
system. The control system automatically stops the valve when the tank is full. The
control signal receives a signal from a proximity sensor if the paint bucket is placed
via an ADC. Then it sends signals to the compressor through DAC to fill the paint
bucket. The compressor fills the paint buckets with paints by using compressed air.
The paint bucket is placed over a weighing sensor that sends a signal to the control
system to stop the paint when reached a certain weight limit. 

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 7.Power Transmission and Distribution
Power is consumed from
distribution line. Distribution line
voltage is around 11 KV.
Distribution line is connected to
HT (high transmission switch)
gear. HT switch gear separates
transformer side from distribution
line. Transformer lowers the
voltage of distribution line to 415
V. Transformer is connected to
LT switch panel. LT switch panel
separates plant side from
transformer side. Then the line
passes through ATS. A
connection from generator also
comes to ATS. A PFI (power
Fig 9.factor improver) is used to
Power Transmission
improve power factor of the
line. PFI generally balance inductive load of the plant by using reactive load.

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8.Limitation of the current system
The following are the limitation of the current system:

 The process is time consuming because the machine does not have automated
rotation time controller.
 Excessive worker involvement during material handling.
 Restricts free movement of workers as it requires the use of movable ports.
 Makes the whole process less efficient.
 Since many systems are open looped MBI system continuous monitoring is
required.
 Since gravimetric filling system is used, it is time consuming.

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9.Proposed system
What the current system lack behind is in smooth automation of and less
inputs to adapt changes into the system and also the product created. All that the
system allows is the transfer of raw materials and almost no any preventive or
adaptive measure control to any variable fix or change during the system process.
Also, although the system works as per the mentioned diagram, the process is to be
flown manually after every procedure/step. And although the entire system works as a
step wise procedure the system on the inside is a manual process as a whole. Partially
processed material is to be moved through each processing system to finally create a
processed material.

The proposed system tries to amend the problems that the present system fails
to address. The present system acts as an open loop MBI system, so the proposed
system creates a closed loop system where more of the variables are monitored and
their control signals are used to change process variable. This results into

Fig 10. Block diagram of proposed TSD

enhancement of the system that also manages and improve the quality of the product
and the efficiency of the system as a whole. We look to better handle the sub-system
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of Twin Shaft Disperse/High speed dispenser (TSD/HSD). With more control over the
system, and tweaks like a better equipment use like using an HSD with higher RPM
and better grinding performance. On the control level the system is integrated with a
better control environment by adding a control circuit that monitors the system
parameters and suggests changes to the system. The suggestions are then processed by
the control system that then applies changes and the system then functions to handle
parameters like if the speed of the TSD/HSD is not enough or is rather greater than
what is required then the speed is automatically controlled. Also, timer or a clock is
added so that the process can start at a specific schedule and specific amount of time
can be allocated to the mixing process.

The system in case of Automatic Filling System in the present system handles the
paint fill up process on the basis of a purely Gravimetric Filling method. The system

Fig 11. Block diagram of proposed automatic filling system

fills up the paint bucket until a fixed weight of the bucket is attained. To further refine
this

system procedure and overcome the random flaws that maybe generated at intervals
due to the system being entirely dependent on weight-based analysis, the purposed
system looks up to other parameters as well. The system along with the weight of the
bucket also monitors the volume of the liquid in the bucket and the liquid level of the

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bucket at predefined intervals and provides feedback to the control system. The
control system then analyses the parameters continues to fill-up or holds the process
while the proximity sensor senses the presence of the container. Also, the system
displays the parameters being processes further allowing the manufacturer to apply
any manual overwrites within the system. However, the system remains independent
to any fix requirements required without any human support.

10.Advantages of the purposed system

 Produces better refined and polished and quality assured product.
 Handles more parameters and helps in resource management of the
manufacturing process.
 The sensors added assists better decision making for the manufacturer.
 Relatively faster production of product.
 Helps in purchase planning for the manufacturer.
 Less worker and man power implementation.
 Is better for free movement of the workers.
 Production in slightly more controlled environment.

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11.Recommendations
As the system did have flaws in it and many rooms for improvement, we suggest
some of the ideas that may forfeit for the improvement of the system with some minor
changes and tweaks to the parts of the system. 
 The transfer of the process materials between sub-systems can be automated. 
 HSDs with higher rpm can be used for better processing. 
 Frequent monitoring of the machines for their smooth functioning should be
done. 
 Use of better equipment seems to be a need. 
 Overall system monitoring system should be implemented. 

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12.Conclusion
Thus, we visited Berger J&N Paints as the field visit to understand the
instrumentation system used for the paint manufacturing process. The paint
manufacturing procedure of the Berger J&N Paints has a production system that is a
control system based that follows through different stages of production which are
handled automated or manually by the working staff.
 

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13.Bibliography
https://bergernepal.com/
https://en.wikipedia.org/wiki/Paint
https://www.slideshare.net/yagrawal2/paint-manufacturing-process
https://www.slideshare.net/PujanShrestha15/bergerpaintspptmarketing-nepal

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