Ireport PDF

BAHIR DAR UNIVERSITY
COLLEGE OF SCIENCE
DEPARTMENT OF INDUSTRIAL CHEMISTRY
INTERNSHIP REPORT ON RAW MATERIALS,UNIT OPERATIONS,
PROCESS AND TESTING
“A STUDY AT KOKEB PAINT FACTORY”
PREPARED BY:
1. Temesgen Abebe(BDU 1103990)
2. Getaneh Minichil (BDU1104144)
3. Dejen Tsegaye(BDU1103673)
Company Advisor: Mr. Worku.
SUBMITTED TO:
Industrial Chemistry Department
Aprill-2022, Bahir Dar Ethiopia

i
LETTER OF TRANSMITTAL
To
Dr.Maru D.
Head of Department of
Industrial Chemistry
BDU, College of Science
SUBJECT: Submission of Internship Report on Kokeb Paint Factory
Dear Sir,
This is our great pleasure to submit the Internship report of our two months long Internship program at
kokeb paints factory. This report has been prepared to fulfill the requirement of our internship program at
our assigned organization. We have put our utmost effort to make this report a successful one. It has been
a joyful & enlightening experience for us to work in the organization. However, it has been obviously a
great source of learning for us to conduct similar types of studies in the future.
It would be our immense pleasure if you find this report worthwhile & informative to have an apparent
perspective on the issue. We shall be happy to provide any further explanation and query regarding this
report or any other relevant matters, if required.
Thanks and Best Regards!!
------------------------------
1. Temesgen Abebe
2. Dejen Tsegaye
3. Getaneh Muche
Industrial Chemistry Department
Bahir Dar University
i
University of Bahir Dar Industrial Chemistry Department
DECLARATION OF ORIGINALITY
We declare hereby this monthly internship report on Kokeb paint factory is our original work and
performed by the effort with the willing of God. We assure that the report contains actual events, and
facts that was observed, and performed during the internship program. All the contents are our own, and
haven’t been submitted to any other institute.
Students Signature Date
1) Temesgen Abebe ________________ ________________

2) Getaneh Mimichil ________________ ________________
3) Dejen Tsegaye ________________ ________________
This is to declare that the above statement made by the candidate is correct and true to the best of our
knowledge.
ii Internship Report On Kokeb Paint Factory April-2022

ABSTRACT
Increasing our skills in the fieldwork, and linking theory with application, becomes the motivation for us
to join factories and companies for achieving this target. One of chemical process industries is the paints
industry. Paints are a main part of coatings, which are composed of five components namely; resin
(binder), solvents, fillers or extenders, pigments, and additives. From the point of view of Industrial
Chemistry and Chemical Engineering; paints manufacturing, requires number of unit operations which
are mixing, milling, and filtration. These operations are done using several industrial units such as;
mixers, mills, and screen filter. Paint manufacturing is done by adding binders, solvents, and thickeners to
provide a gel phase in which its existence is a mark for starting of adding fillers, and pigment. Through,
and after manufacturing processes, a sample is sent to laboratory for some tests, by which the
manufacturer be sure from his or her products quality. The main tests are density, viscosity, and hiding
power test; there several tests can be done also such as wash-ability, and impact test.
iii Internship Report On Kokeb Paint Factory April-2022

ACKNOWLEDGMENT
First, and foremost, we give a special thanks to our God for giving the strength to accomplish this two
months report. None of the activity is done without the will of God! Second; we would like to express our
heartfelt thanks to Bahirdar University College of Science Department of Industrial Chemistry for giving
us such golden chance. The internship enabled us to relate the theoretical knowledge with the actual work
experience. This internship report has been the outcome of two months working experience at kokeb
Paints factory to do our internship. Therefore, we consider ourselves as very lucky individuals as we were
provided with an opportunity to be a part of the organization for the last two months. We are also grateful
for having a chance to meet so many knowledgeable people and professionals who led us though this
internship period. Bearing this in mind, we would like to take this opportunity to express our deepest
gratitude and special thanks to Mr. Worku, the Chief Production Officer of kokeb Paints factory, who in
spite of being extra ordinarily busy with his duties, took time out to hear, guide and keep us on the correct
path and allowing us to carry out our study at their esteemed organization and extended their support to
provide us the needed information. We express our deepest thanks to Mr.Jibril, the chief operation officer
of kokeb Paints factory, for taking part in providing useful information and giving necessary advises and
guidance as well as arranging everything to pursue the program successfully. We choose this moment to
acknowledge his contribution gratefully. We would like to convey our best regards to the laboratory
section heads and all the workers, and operators for their careful supporting and precious guidance.
Working with them is a great success for us!
iv Internship Report On Kokeb Paint Factory April-2022

LIST OF ABBREVIATIONS
BDU: Bahir Dar University

PLC: Private limited company
ETB: Ethiopian birr
E.C: Ethiopian calendar
MEKO: Methyl-ethyl-ketone
MIBK: Methyl-iso-butyl-ketone
SP. g: Specific gravity
PH: Potential of hydrogen (power of hydrogen)
COVID: Corona virus international diseases
UV: Ultra violet
Mm: Millimeter
STD QTY: Standard quantity
QTY: Quantity
ODA: Organic dispersion agent
Pas.s: Pascal second
Vos: volatile organic solvent
v Internship Report On Kokeb Paint Factory April-2022

Contents
LETTER OF TRANSMITTAL ..................................................................................................................... i
DECLARATION OF ORIGINALITY ......................................................................................................... ii
ABSTRACT................................................................................................................................................. iii
ACKNOWLEDGMENT.............................................................................................................................. iv
LIST OF ABBREVIATIONS ....................................................................................................................... v
LIST OF FIGURE........................................................................................................................................ ix
LIST OF TABLES ....................................................................................................................................... ix
CHAPTER-ONE ........................................................................................................................................... 1
GENERAL BACKGROUND OF KOKEB PAINT FACTORY.................................................................. 1
1. INTRODUCTION ................................................................................................................................ 1
1.1. GENERAL HISTORY OF THE FACTORY ............................................................................... 1
1.2. VISION, MISSION AND OBJECTIVES OF THE COMPANY ................................................. 2
1.2.1. Vision .................................................................................................................................... 2
1.2.2. Mission .................................................................................................................................. 2
1.2.3. Objectives ............................................................................................................................. 2
1.3. MAIN PRODUCTS OF THE COMPANY .................................................................................. 2
1.3.1. Water based paints ................................................................................................................ 2
1.3.2. Solvent based paints .............................................................................................................. 3
1.4. ORGANIZATIONAL STRUCTURE OF COMPANY................................................................ 3
1.4.1. Management office ............................................................................................................... 4
1.4.2. Human Resource Development section (HRD) .................................................................... 4
1.4.3. RMS and raw material purchaser .......................................................................................... 4
1.4.4. Production Section ................................................................................................................ 4
1.4.5. Tinting section ...................................................................................................................... 4
1.4.6. Laboratory Section or QCL................................................................................................... 4
1.4.7. Labeling section .................................................................................................................... 5
1.4.8. Leveling and filling Section .................................................................................................. 5
1.4.9. Product store and seller ......................................................................................................... 5
1.4.10. Maintenance Section ............................................................................................................. 5
1.4.11. Waste treatment section ........................................................................................................ 5
CHAPTER-TWO .......................................................................................................................................... 7
RAW MATERIALS OF PAINTS ................................................................................................................ 7
2. INTRODUCTION ................................................................................................................................ 7
vi Internship Report On Kokeb Paint Factory April-2022
2.1. PIGMENTS................................................................................................................................... 7
2.1.1. Prime pigments ..................................................................................................................... 8
2.1.2. Extender pigments................................................................................................................. 9
2.2. BINDERS ................................................................................................................................... 10
2.3. SOLVENTS ................................................................................................................................ 10
2.4. ADDITIVES ............................................................................................................................... 11
CHAPTER-THREE .................................................................................................................................... 12
UNIT OPERATIONS IN PAINT FACTORY............................................................................................ 12
3. INTRODUCTION .............................................................................................................................. 12
3.1.1. Mixing operation and Mixing Equipment ........................................................................... 12
3.1.2. Milling operation and Milling equipment ........................................................................... 13
3.1.3. Filtration operation and Filtration equipment ..................................................................... 14
CHAPTER-FOUR ...................................................................................................................................... 15
PAINT PRODUCTS AND MANUFACTURING PROCESS ................................................................... 15
4. INTRODUCTIONS ............................................................................................................................ 15
4.1. PAINT MANUFACTURING PROCEDURES .......................................................................... 15
4.2. PAINT MANUFACTURING PROCESS DESCRIPTIONS ..................................................... 15
4.2.1. Measurement of raw materials accurately........................................................................... 15
4.2.2. Preparation Mill base and pigment dispersion .................................................................... 15
4.2.3. Let-Down process ............................................................................................................... 16
4.2.4. Finished product and in process laboratory testing ............................................................. 16
4.3. PROCESS DESCRIPTION FOR EACH SECTIONS ................................................................ 17
4.3.1. Raw material weighing ....................................................................................................... 17
4.3.2. Mixing Section .................................................................................................................... 18
4.3.3. Milling section .................................................................................................................... 18
4.3.4. Tinting section .................................................................................................................... 18
4.3.5. Laboratories or Quality Assurance Section......................................................................... 19
4.3.6. Filling and labeling ............................................................................................................. 20
4.4. MAJOR PRODUCTS AND INPUTS OF KPF .......................................................................... 21
4.4.1. Ingredients in Water Based Paints Products and Their Functions ...................................... 21
4.4.2. Ingredients in solvent based paint Products& their functions ............................................. 23
4.4.3. Specific Products of Enamels ............................................................................................. 25
CHAPTER-FIVE ........................................................................................................................................ 27
TESTING OF PAINTS ............................................................................................................................... 27
5. INTRODUCTIONS ............................................................................................................................ 27
5.1. RAW MATERIAL CHECKING ................................................................................................ 27
vii Internship Report On Kokeb Paint Factory April-2022
5.1.1. Solvent Tests ....................................................................................................................... 27

5.1.2. Pigment Test ....................................................................................................................... 27
5.2. FINAL PRODUCTS TESTS ...................................................................................................... 28
5.2.1. Viscosity Test...................................................................................................................... 28
5.2.2. Gloss Test............................................................................................................................ 28
5.2.3. Acid Value .......................................................................................................................... 28
5.2.4. Adhesion Force ................................................................................................................... 29
5.2.5. Drying Rate ......................................................................................................................... 29
5.2.6. Wash-Ability Test ............................................................................................................... 29
5.3. OHERS PARAMETERS ............................................................................................................ 29
5.3.1. Fineness test ........................................................................................................................ 29
5.3.2. Hiding power ...................................................................................................................... 30
5.3.3. Storing effect ....................................................................................................................... 30
5.3.4. Impact Resistance test ......................................................................................................... 30
CHAPTER-SIX........................................................................................................................................... 31
EXPERIENCES ACQUIRED FROM Internship ....................................................................................... 31
6. INTRODUCTION .............................................................................................................................. 31
6.1. Techniques We Used During the Internship ............................................................................... 31
6.2. BENEFIT ACQUIRED FROM INTERNSHIP PROGRAM ..................................................... 31
6.2.1. Practical skills ..................................................................................................................... 31
6.2.2. Upgrading theoretical knowledge ....................................................................................... 32
6.2.3. Improving interpersonal communication skills ................................................................... 32
6.2.4. Industrial problem-solving capacity.................................................................................... 32
6.2.5. Improving team playing skill .............................................................................................. 33
6.2.6. Improving leadership skills ................................................................................................. 33
6.2.7. Understanding about work ethics and related issues........................................................... 33
6.2.8. Entrepreneurship skills........................................................................................................ 33
6.3. CHALLENGES DURING OUR INTERNSHIP PROGRAM ................................................... 34
6.4. Measures taken to overcome the challenges ............................................................................... 34
CHAPTER-SEVEN .................................................................................................................................... 35
7. CONCLUSIONS AND RECOMMENDATION ................................................................................ 35
7.1. CONCLUSIONS......................................................................................................................... 35
7.2. RECOMMENDATION .............................................................................................................. 36
REFERENCES ........................................................................................................................................... 37
viii Internship Report On Kokeb Paint Factory April-2022

LIST OF FIGURE
Figure1.1 General Organizational Structure of the Company ...................................................................... 6

Figure 2.1.1 Different Types of Pigment ...................................................................................................... 8
Figure 3.1 A Mixing Unit ........................................................................................................................... 13
Figure 3.2 (A) Horizontal Ball Mills (B) Basket-Ball Mills (C) Screen Filter ....................................... 14
Figure 4.1flow Chart of Paint Manufacturing............................................................................................. 17
Figure 4.2 Raw Material Weighing............................................................................................................. 17
Figure 4.3mixer Machine ............................................................................................................................ 18
Figure 4.4Milling ........................................................................................................................................ 18
Figure 4.5 5tinting....................................................................................................................................... 19
Figure 4.6 Laboratory Section ................................................................................................................... 20
Figure 4.7 (a)Labeling (b) Filling Section (c)Cartooning Section ............................................................ 20
Figure 4.8 General Flow Chart for Water Based Paints.............................................................................. 23
Figure 4.9 General Flow Chart for Solvent Based Paint ............................................................................. 26
Figure 5.1(a)Measuring Viscosities by Using Cup 4 Device (b)Measuring Viscosities with Viscos-Meter
(c)Measuring Of Gloss Degree Using Gloss Meter .................................................................................... 28
Figure 5.2Wash-Ability Testing Device ..................................................................................................... 29
Figure 5.3 Measuring Fineness with Hegman Device ................................................................................ 29
Figure 5.4(a)Measuring Of Hiding Power by Opacity Meter (b) impact resistance test ............................ 30
LIST OF TABLES
Table 2.1 colors and their respective pigments ............................................................................................. 9

Table 2.2 Additives& their application ....................................................................................................... 11
Table 4.1Benton Solution and Caustic Solution’s Preparations ................................................................. 16
Table 4.2Preparation of Mill Base and Let-Down ...................................................................................... 16
Table 4.3Water Based and Solvent Based Paints........................................................................................ 21
Table 4.4Different Forms of Enamels and Their Ingredients ..................................................................... 25
ix Internship Report On Kokeb Paint Factory April-2022

CHAPTER-ONE
GENERAL BACKGROUND OF KOKEB PAINT FACTORY
1. INTRODUCTION
Internship is a program that gives the job training and taking what’s learned in the classroom and applying it to
the real world or the interns which are looking to explore or gain the relevant knowledge and skills required to
enter into a particular career field. So the main objectives of an internship are to develop a particular job
Experience and professionalism, experience of teamwork and to develop interpersonal skills.
Kokeb paints production is one of the industrial processes among the different paint industries found in Ethiopia.
Paint is a liquid that is used to add color to the surface of an object by covering it with a pigmented (coloured)
coating. Paints are produces from water, chemicals, titanium dioxide, aluminum silicate, calcium carbonate,
tiylos, complainer, caustic soda and color.
1.1. GENERAL HISTORY OF THE FACTORY
Kokeb paint factory is one of the currently launched paint factory in Bahir Dar town. It was established on
November 19, 2017 in Amhara regional State, under the control of BEAEKA General Business PLC. The
company was located in the sub urban of Bahir Dar town about 7.9Km from the center of the town covering an
area of around 15000 square meter in the western part of city commonly called industrial villages. The
construction was completed within 16 months with the capital of 360 million ETB. The president of Amhara
Regional State, Mr. Gedu Andargachew, were invited and attended to the ceremony.
Kokeb paint factory has an annual production capacity of processing about 25 million liters of paint. It has
around 153 employees; of which 140’s is permanent and 13 of the temporary contract. Paint as a new economic
sector was feasible and the company particularly emerged as a reliable sector of economy. The occupation of this
company is not only production but, also creating different colors by using the art technology and skilled
profession within the industry.
The company aims to be one of the well-known and Ethiopian market leader companies in the coming 2025 by
providing customers with high quality products and services. Ensuring long-term relationship with customer and
maintaining high profitability of the company with providing the best product and service that can satisfy
customers need and expectation is one of the target full objectives of the company.
1
1.2. VISION, MISSION AND OBJECTIVES OF THE COMPANY
1.2.1. Vision
 To be one of the well-known and Ethiopian market leader companies by the year 2025 providing
customers with high quality products and services with added value at competitive prices
simultaneously ensuring long term relationship with customers and maintaining high profitability of
the company.
1.2.2. Mission
 To provide the best product and service that can satisfy customers need and there by conform to ever
changing competition to sufficiently excel and satisfy customer expectation.
 To expand the business to different foreign countries with proper diversification mechanisms.
 To ensure being a company of choice to its state holders and an investment choices for owners.
 To contribute positively to socioeconomic development of Ethiopia in particular and to the other

countries in general.
1.2.3. Objectives
 Producing high quality paint with affordable price.
 Establish new plants like glass and edible oil plant.
 To involve foreign market (export).
 Economic use of resources.
 Reduce power consumption.
 To ensure product consistency at required level.
 Promoting the product in fair and ethical way.
1.3. MAIN PRODUCTS OF THE COMPANY
Kokeb Paint Factory (KPF) has two main types of paint products that are water-based paint and oil based OR
solvent based paint, based on the type of solvent used. The water based paints are supper, wubet, mica and
quartz; whereas the oil based paints are enamel, alkyd varnish, traffic paint, anti-rust, poly varnish etc. Generally,
Kokeb paint factory produces many different types of paint depending on the customers need.
1.3.1. Water based paints
Water based paint includes:

 Supper
2 Internship Report On Kokeb Paint Factory April-2022
 Wubet
 Quartz and
 Mica in different colors.
NB. Those paints are called wall and ceiling paints.
1.3.2. Solvent based paints
Solvent based includes
 Metal and wood paint
 Enamel
 Anti-rust
 Traffic paint
 Blackboard paint
 Alkyd varnish, poly varnish.
 Cola or wood & carton glue etc.
1.4. ORGANIZATIONAL STRUCTURE OF COMPANY
Kokeb Paint Factory has different sections that are involved with different jobs interacted with one another.
These sections are:
 Management office
 Human resource development section
 Raw material store and purchasing section
 Production section
 Tinting section
 Laboratory and quality control section
 Labeling section
 Leveling and filling section
 Product store and sellers section
 Maintenance section

1.4.1. Management office
This division is concerned with all activities that take place in the factory. It makes sure the rule and regulation
are well applicable. It provides some raw material, safety equipment and general services regarding transport and
others.
1.4.2. Human Resource Development section (HRD)
These sections are primarily governed by the rules and regulation on that were formed in the co-ordination of
both workers and administration. It makes sure that weather the rules obeyed or not; and hence it reports on the
number of working hours that a single employee has spent, so that the employee earns as they deserve. It also
holds the structure hierarchy of the occupation of the type of employee, so when there is a gap formed it
announces a vacancy based on the job criteria that already exist. It also gives some training assignment for the
employers.
1.4.3. RMS and raw material purchaser
The main purpose of this store is to hold some raw material that are used for the production of paint like
kerosene, calcium carbonate, Titanium dioxide, pests, dries, binder, pigment, packing materials such as cartons,
different size plastics and gallons, marble(fine,0.5,1.2,2.5),cellulose, tetron, additives, Benton powder,
Aluminum silicate etc.
Basically the raw materials are provided by purchasers. Purchasers are purchasing raw materials and services
from the supplier. Its main aim is to support and facilitate the company operations by supplying the right material
and services at the right time, the right prices, the right place, and from the right source.
1.4.4. Production Section
These divisions are concerned with the formulation of raw material for the production of the paint. They prepare
different formulations that are important for the production of the paint.
1.4.5. Tinting section
This is the most important section for the production of paints after letdown process is takes place. The tinter
starts to work or tests the color of the paint product with the standard paints by adding different pastes until
meets the standard specification.
1.4.6. Laboratory Section or QCL
Before the produced paints are filled, it must be checked in laboratory. In the laboratory there are different
quality parameters of paint that has to be checked before the paint was sent to filling. Those parameters are: PH,

Temperature, Sp.gr, Solid content, Wash ability (for water based paints), Viscosity, Drying time, Gloss, and
Fineness of grinding.
1.4.7. Labeling section
In this section bucket that are important to hold the new paint product are labeled after labeling the plastics and
gallons are prepared for filling. This shows general paint information’s and guidelines to use.
1.4.8. Leveling and filling Section
The filling machine fills the gallons by standard volume or required liters.
1.4.9. Product store and seller
This division is used to store the final product and control the product that are ready for marketing, control the
outgoing for reprocess to the production section. It records how many products are enter to the store and how
many of them are prepared to sales. The main functions of sellers are selling the produced paints and receiving
order from the customer and inform the production section to produce the ordered paint.
1.4.10. Maintenance Section
This section stands for the maintenance of electrical and mechanical parts of the company. For example;
controlling the power supply and maintaining electrical and mechanical systems which are mostly on the
machine in order to minimize maintenance cost.
1.4.11. Waste treatment section
The treatment plant covers small area and divided in to three phases as physical, biological, and chemical. In
this section ,wastes released from the company are entered to the storage burrow and after it has been pumped to
the treatment tank, some necessary coagulant such as Ca(OH)2 and Al2(SO)3 are added and by using sand filter
the waste was filtered and released to the environment.

General
Manager
Paint manager
Human Sale and Finance Procurements

Paint
resource marketing managemen and supply
operation
management t
Production
Laboratory
manager
management
Operators
and labour
workers
Figure1.1 General Organizational Structure of the Company

CHAPTER-TWO
RAW MATERIALS OF PAINTS
2. INTRODUCTION
Paints are stable mixtures of one or more pigments which impart desired color and protecting the film from
penetrating radiation such as ultra violet rays. Primitive men are credited with making the first paints about
25000 years ago. Amazingly, they were hunters and cave dwellers, and were probably inspired by the rock
formations of their cave walls to outline and color the shapes of the animals they hunted. It is possible that by
creating these images they thought their power over their prey would be increased.
Today, paints are used for coloring and protecting many surfaces, including houses, cars, road markings and
underground storage vessels. Each of these different applications requires a different sort of paint, and it is quite
different in composition which is focus of this report.
Once looking at a painted wall or paint package, the first conception is it is a colored liquid but it is wrong.
Several ingredients are used to manufacture this colored liquid. Some of these components are solids such as
resin, pigment, additives and the one liquid component that dissolves all of these mentioned solids is the solvent
that obtain the paint in a liquid state.
A paint formulator must choose from hundreds of different materials selecting cost effective; combination which
will have the desired film forming, and service properties. Therefore; a paint formulator chooses raw materials
from the following four basic categories/components. These are:
 Pigments
 Binders OR resins
 Solvents
 Additives
In the following sections each components will be described in some details.
2.1. PIGMENTS
Pigments may be defined as a solid, insoluble, material that is added to a binder to produce color, reduce gloss,
provide physical properties to reduce permeability to moisture, produce texture or even act to prevent corrosion.
Pigments usually have a particle size of about 0.5 to 5µms in standard paints but can be as small as 0.1µms in the
case of some bright organic pigments. They are also defined as finely grounded solids of different shade to give
color, durability, consistency, and other properties to the paint. It is also one of the major raw materials,
accounting for one-third of the raw materials cost.

Pigments may be classified into two main groups:
1) Prime pigments provide color: either inorganic or organic.
2) Extender pigments controls gloss level, texture, etc.
Figure 2.1.1 Different Types of Pigment
2.1.1. Prime pigments
a) Inorganic Prime pigments

The term prime means, color giving when used with the word pigment. The term inorganic means the pigment is
mineral origin and inorganic prime pigments are usually metal oxides. They are called prime because the first
use of paints was for decoration and color therefore of first (prime) importance. Many metal oxides were found
naturally, such as red and yellow iron oxides. Today most are made synthetically to get the cleanest colors
possible. Titanium dioxide is white pigment that colors just about everything we see are white.
Main properties of inorganic pigments
 Excellent opacity or hiding power
 Excellent resistance to fading
 They are bright clean inorganic red, orange and yellow pigments
 Quite dense pigments
 Relatively heat stable and chemical resistant.
b) Organic Prime pigments

The term organic means that pigment is based on the chemical element carbon. It was once thought that all
organic chemicals could only be obtained from living things and hence the name. Today there are millions of
different organic chemicals most of which may be produced synthetically without the need to source raw
materials from living things. Most organic pigments are not naturally occurring and are made from petroleum by-

products in very complicated chemical processes by clever chemists. Organic pigments are the brightly cooler
ones used for the clean colors red, yellow, bright green and blue, purple and magenta.
Characteristics of organic pigments
 Available in bright vivid colors to match all shades of the rainbow.
 Very difficult to get clean reds and yellows with good opacity and good exterior.
 Often these pigments are very difficult to grind into paint mill bases.
 Pigments are generally low in density and not prone to settling out.
 Low density and may tend to float to top of paint.
 Excellent to very poor hiding power.
 Excellent to very poor light fastness.
 Colors are usually very bright and clean toned (apart from black).
Table 2.1 colors and their respective pigments

Color Inorganic Pigment Organic Pigment
White Titanium Dioxide, Zinc Oxide, Zinc Sulphide, Antimony -

Oxide
Black Carbon Black ,Black Iron Oxide Aniline Black
Brown Iron Oxides Brown Benzimidazolone
Yellow Lead Chromate ,Yellow Iron Oxide Aryl amide ,Diarylide
Red Cadmium Red ,Red Iron Oxide Metallized ,Azo Reds

Perylene
Blue Ferric Potassium Ferro cyanide, Cobalt Blue Copper Phthalocyanine Blue
Green Chrome Green ,Chromium Oxide, Hydrated Chromium Copper Phthalocyanine Green
Oxide
2.1.2. Extender pigments
Extender pigments are usually naturally occurring minerals, such as clay, mica, talc, and limestone (or marble or
whiting or calcite (all forms of calcium carbonate), and were often used as a cheap way of reducing the cost of a
can of paint. Adding extra volume or weight of a cheap extender pigment (extender pigments usually cost under

$1/kg) allowed savings to be made on expensive binders and prime pigments (inorganic pigments cost 5-10
times this and organic pigments 50-100 times this). This tool was particularly useful when paint was sold by the
pound or kilogram rather than by a volume basis. The term extender does not really convey a true meaning of the
purpose of the non-coloring pigments used in modern paints but is still used to describe them.
Characteristics of some extender pigments
 Talc: This is a very slippery mineral and is used to give paint good sanding properties.
 Talc and mica: These extenders are plate like in shape and are used to give barrier properties to the
paint. They spread out and prevent moisture travel through the Paint.
 Calcium carbonate: Also known as whiting, limestone, chalk or even as marble dust.
Silica: Silica comes in a number of different forms but is generally best known as a flatting pigment.
 Clay: Clays are used to give paint some extra body and can help to prevent settling
Generally, Pigments are responsible for color, covering power and anti-corrosive properties. Pigments are finely
ground crystalline solids that are dispersed/ suspended in the paint. They may be organic, in-organic and
metallic. The most widely used pigment is TiO2, due to its excellent hiding property. Others examples are carbon
black, FeO2, for red, metallic salts for yellow and orange.
2.2. BINDERS
Binders are the polymeric components in a coating formulation that form the protective film. The binder literally
bonds the pigment particles together in the film. If the coating contains no pigments or extenders, then the binder
will usually form a glossy and possibly transparent coating. Binders are usually resin or oils but can be inorganic
compounds and also, they are actual film forming component and absolutely required ingredient of any paint
which consists of a resin and solvent thinner. Binders improve the paints resistance to moisture permeability,
sunlight exposure, staining, cracking, damage from abrasion & adhesion to the surface. Binder OR Resin may be
natural or synthetic.
Examples of natural resins are: linseed oil, soya beans oil, coconut oil. Examples of popular synthetic resins are:
Alkyds, Acrylics, Epoxies, and Polyurethane etc. Alkyd resins: most commonly used in solvent-based paints,
e.g. enamel paint. Generally, binders are used to bind pigment and additive together, imparts adhesion and
strongly influences: Gloss, Durability, Toughness, and Flexibility
2.3. SOLVENTS
In coating technology, a solvent is generally considered a volatile organic compound used to dissolve the binder
resin so that it can be applied in a uniform thin film. Solvents are also known as carriers or diluent or thinners.
Solvents are low viscosity, volatile liquids that dissolve the binder & hold it in suspension with the paints’
pigment. It ensures even-mixing of the paint components& makes the paint easy to apply and used to reduce the
viscosity of paint for better flow & application. Examples of solvents are Water, MEKO- methyl-ethyl-ketoxime,
MIBK- methyl-iso-butyl-ketone, Xylene, Toluene, Butyl-acetate, kerosene, etc.
2.4. ADDITIVES
Additives are low levels of ingredients that provide specific paint properties such as mildew resistance, anti-
foaming, anti-skinning, improve flow property, improve finished appearance, modify surface tension and
improve pigment stability. They are small amounts of different chemical substances improving or modifying the
paint properties. It gives the paint body and substances without changing its properties. There are many types of
additives.
Table 2.2 Additives& their application

Additives Application
 Anti-skinning agent  Prevent the formation of skin in the can.
 Plasticizer  Increases the paint flexibility
 Driers  Accelerate the paint drying by catalyzing the oxidation of the binder.
 Anti-foam  Prevent formation of air bubbles entrapped in the coating.
 Thickener  To thick the paint.
 Wetting and dispersion  Are surfactants that assist in moistening (wetting) the pigment easier to grind
agent and disperse, and prevent flocculation of the pigment particles
 Preservative  Prevent smelling of paint while in the container and growth of algae /fungi, on
the paint after it has been applied.
 Anti-settling agent  To prevent pigment settling.
NB: Thickeners and thinners have plus or minus applications.

CHAPTER-THREE
UNIT OPERATIONS IN PAINT FACTORY
3. INTRODUCTION
Manufacturing of paints depend mainly on three physical processes which are mixing, milling, and filtration,
which will be described in some details, and according that three industrial units are used which are mixers,
mills, filters.
3.1.1. Mixing operation and Mixing Equipment
In paints manufacturing several ingredients are used to formulate paint system. Each of them has properties
differ from others which mean that there is no homogeneity between all these several components, mixing
process has a vital role in achieving homogeneity to the mentioned components to get the final paint system. The
mixing techniques will be depends on; solid - liquid mixing, and liquid – liquid mixing, all paints components
are in solid or liquid state.
1) Liquid - liquid mixing

Most of paints components are liquids for providing a final liquid state for paint applying, three processes occur
simultaneously to achieve homogeneity which are; coalescence, dispersion, and suspension.
 Coalescence and Dispersion; occur dependence on shear or velocity gradient which resulted from
mixing speed of liquids drops, which force drops to deform, to increase daughter drops due to high
energies that produced by dispersion.
 Suspension; occur depending on flow movement inside mixing vessel, which come from speed of
mixing, so high-speed mixers are used to achieve coalesce drops suspension.
2) Solid- liquid mixing

Solid content of paint system varies, and may reaching to 50% or more from contents of paint formula, and
usually added in the middle stages of mixing after adding some liquids components. This mentioned solid
content is a finite powder, dissolved in other liquids components by three processes which are; suspension,
distribution, and drawing down of solids by agitation.
 Suspension; is the condition where no particle remains on the bottom of the vessel, this position achieved
by existence of anti-settling agents and high rotating speed.
 Distribution; it means that there’s no particles in flocculated state usually in bottom of mixing vessel, this
achieves by using dispersing agents which led for particles distribution in all directions inside vessel.

 Drawing down of solids; it achieved by agitation, and represented in mixing by a cone shape around
agitator.
Mixing operation in paints industry requires a jacketed vessel for water cooling or for steam heating, which is
usually vertical and high-speed mixer consists of one or more impellers, which consisted of a shaft, contain one
or more disk mixing blade, it driven by electrical motor and its rotational speed organized using inverter.
Figure 3.1 A Mixing Unit
3.1.2. Milling operation and Milling equipment
If the mixer power does not achieve the required fineness for the mixture, the needing for milling appear to
achieve the required fineness, the problem which leads for using mills is that there’s a still colloid particle not
dispersed in the mixture although existence enough amount of dispersing agent. The point of view in this process
is damaging these agglomerations of particles and dispersing it in the mixture, and this can be done by several
processes, most common one in paint industry is collision the agglomerated particles with small balls, these
small balls manufactured from several materials such as glass, steel, and ceramics.
There are two types of mills used in paints industry; rotary mills, and ball mills. Ball mills is more suitable and
provide more safety than rotary mills because milling processes done in open-air state which is non-suitable with
paints that contain volatile solvents, these emissions are harm for working team, but in case of ball mills it is
done under circular cover which prevent solvent emissions.
Mill Design
The mills used in paints industry are rotary mills and ball mills, and as mentioned previously using ball mills is
better than rotary mill.
1) Rotary mill
It consists of number of rollers each of them rotates in opposite direction from the other one, and with different
speed, between each two rollers there is a clearance controlled to get the required fineness.
2) Ball Mill
This type of mills use small balls that crashed with colloid particles, it is classified in two types according to its
position the, the first one is horizontal type and the other one is vertical type.
a) Horizontal ball mill; as obtained in figure (3.5), it consists of cylindrical tube and inside its horizontal
axis and disks fixed on it rotate around its center each impeller contains holes for moving of paint, this
machine can use both of steel or glass or ceramics balls.
b) Vertical ball mill; it is also called basket-ball mill which has more efficiency than the horizontal type;
also it only uses ceramic balls.
3.1.3. Filtration operation and Filtration equipment
A rest colloid particles and ability of glass balls to be broken in case of using it, so the filtration operation is
needed, several techniques can be used in paints filtration but, screening filtration is more common in paints
industry.
As mentioned, the screen filter which obtained in figure (3.4) is the most widely used filter; simply it consists of
sheet of cross-linked steel with holes for purification of paint.
Figure 3.2 (A) Horizontal Ball Mills (B) Basket-Ball Mills (C) Screen Filter

CHAPTER-FOUR
PAINT PRODUCTS AND MANUFACTURING PROCESS
4. INTRODUCTIONS
From the ancient time of discovering paints, its making depend on blending, the first paint not have the required
durability, the modern technology and discovering new resins, make humans be able to manufacture new paints
have high adhesion force, durability, and other specific properties as they need, in this chapter the stages of
manufacturing of paints be discussed, beside manufacturing of some products.
4.1. PAINT MANUFACTURING PROCEDURES
Firstly, surface active agents, usually thickeners are added to give a gel stage. After that binders or oils are
added, in addition to pigments and fillers. This procedure is called premixing, after that a sample sent to
laboratory to get a report about its fineness, viscosity, and density. If the fineness not meet the required
specifications, the mixture charged to the milling unit, after that the other additives and the rest amount of
solvent added and mixed in a procedure called thinning, after this procedure another sample sent to the
laboratory to done some tests such as, viscosity, density, and hiding power. If test results meet the required
specification, the quality lab give a permission to start packaging, and before that the final mixture purified using
a bar screen.
After that it is packaged manually, semi-automatic, or automatic according to production volume.
4.2. PAINT MANUFACTURING PROCESS DESCRIPTIONS
Generally, paint is manufactured in a batch operation from its raw material scaling to finished product within the
specific formulation. There are five critical manufacturing steps involved.
4.2.1. Measurement of raw materials accurately
Ingredients are typically measured by weight scale and sometimes by volume in a

calibrated vats and graduated measuring containers.
4.2.2. Preparation Mill base and pigment dispersion
Pigments are powders of typically small in size that tend to stick together to form clumps or agglomerates. These
must be broken down into separate particles that must be then wetted by resins and solvents to stop them sticking
together again. This is the process of dispersion. High speed mixers are used for combining materials and
dispersing most of pigments. This machine rotates stainless steel serrated discs of up to 60mm diameter, at about
1000rpm.
Pigments are added slowly to the portion of the liquid paint component, with the mixer running, to form the mill
base. Some pigments are more difficult to disperse and require ball milling, which are used for small batches of
difficult disperse mill base. Ball mills are large porcelain lined rotating drums containing golf ball sized
porcelain balls. Rolling and tumpline of the ball provides sufficient force to break up agglomerates.
Table 4.1Benton Solution and Caustic Solution’s Preparations

Benton solution preparation Caustic solution preparation
97% kerosene 25% caustic powder
25% Benton powder 67% water
12.5% iso butanol
4.2.3. Let-Down process
After the mill base has completed; the rest of ingredients (solvent and additives) is
added and mixed. This is called let down process. After let down and mill base are
completed and mixed; if required, by the formulation any final additions are made
and added in.
Table 4.2Preparation of Mill Base and Let-Down

Mill base preparation Let-Down process
 70% long oil(not permanent)  Long oil(above 250Kg)
 Benton solution  Zirconium drier
 Emulsifier  Ca drier
 ½ CA drier  Co drier
 Kerosene  Kerosene(maybe)
 Matting agent  Water
 Titanium dioxide  Pastes(differ depending on paint)
 MEKO
4.2.4. Finished product and in process laboratory testing
Product quality is monitored throughout the manufacturing process by the product verification laboratory.
Critical ingredients are tested before manufacturing starts. The mill base may be tested for dispersion and if

further processing may be required the let-down is tested to ensure it sufficiently mixed. The complete batch
(mill base plus let down and any final additives) is thoroughly tested by the product canning. During canning two
samples are taken, a retain sample, which is stored in case it is needed for future reference and a final inspection
sample which is tested by the final inspection laboratory to guarantee conformance with relevant standard and
specification. After this final stage of testing is completed the batch is passed for filling and labeling section. The
final product is prepared for sales as required or stored in the product storage room.
Raw Mixing Milling

material
weighing
Mill base preparation&

dispersion
Canning Finished
Let
product and
down
laboratory
process
testing
Figure 4.1flow Chart of Paint Manufacturing
4.3. PROCESS DESCRIPTION FOR EACH SECTIONS
4.3.1. Raw material weighing
In this step, the raw materials are weighed according to the formulation. The weighed raw materials are allowed
to mix with the respective order.
Figure 4.2 Raw Material Weighing

4.3.2. Mixing Section
We have working by adding raw materials and adjusting the rpm of the mixer manually. In this section, the
components of the paint are well mixed so that the dispersion process checked effectively.
Figure 4.3mixer Machine
4.3.3. Milling section
In this section, because of some pigments are difficult to mix with the resin and solvent in the mixing process
,milling of such pigments are necessary for reducing the size of the pigment for the letdown process, and to avoid
sharp texture formation during painting. In this section milling process is performed, which is the solvent based
paint mill base size reduced/ensuring uniformity. On this process there is coolant that used to regulate the
temperature of the milling machine by recycling the hot water and resend
Figure 4.4Milling
4.3.4. Tinting section
This is the major and important section for the production of paints after letdown process is takes place the tinter
starts to work or tests the color of produce paint with the standard paints by adding different pastes until the paint
in the process is meet with the standard paints.
Figure 4.5 5tinting
4.3.5. Laboratories or Quality Assurance Section
In this section we have been working by measuring different quality parameters such as PH, specific gravity,
wash ability and drying, opacity or hiding. It mostly determined how much qualified the raw materials is and
checked whether the incoming goods are the same as the standard or not. The parameters of sample raw
materials checked in the laboratory before purchased. There are different quality parameters of paint that has to
be checked before the paint was sent to filling. Those parameters are:
 Temperature: temperature measurements of paint are performed in order to check whether the product
resist the environmental effect or not and to measure other parameters at room temperature.
 PH: in order to check whether the product has an environmental effect or not. This is measured using PH
meter.
 Sp.gr: it is the measure of the weight of the paint to know its density.
 Solid content: This characterizes the amount of non-volatile compound which remain parts of paint film.
 Viscosity: used to check whether the product is thick or thin.
 Drying time: This shows the time at which the paint is dry after application.
 Fineness of grinding: it is a measure of the degree of break-down of agglomerates and aggregates of

particles.
 Wash ability (for water based paints): which characterize the strength or capacity of paint during
washing after the paint was applied.
 Viscosity: used to check whether the product is thick or thin.
 Drying time: This shows the time at which the paint is dry after application.

 Fineness of grinding: it is a measure of the degree of break-down of agglomerates and aggregates of

particles.
 Gloss: is used to determine how much the product is attractive after application.
 Opacity: is used to determine how much the product hides.
Figure 4.6 Laboratory Section
4.3.6. Filling and labeling
Filling refers to adjusting the gallons and opening and closing of valves in order to prevent over flow. Labeling is
done by putting the gallon, plastics and tin cans in the horizontal table manually. But, the filling process is semi-
automatic enabling manual operation of canning.In this section some plastics, gallons that are important to hold
the new paint product are labeled after labeling the plastics and gallons for filling; the filling machine fills the
gallons by standard volume or required liters
Figure 4.7 (a)Labeling (b) Filling Section (c)Cartooning Section

4.4. MAJOR PRODUCTS AND INPUTS OF KPF
Table 4.3Water Based and Solvent Based Paints

Water Based Paints Solvent Based Paints
o Quartz o Enamel
o Supper o Traffic paint
o Mica o Metal and wood paint
o Wubet o Anti-rust
o Blackboard paint
o Alkyd varnish, poly varnish.
o Cola/wood & carton glue etc.
4.4.1. Ingredients in Water Based Paints Products and Their Functions
A. Quartz
 Water: As a solvent.
 Homo polymer: For increasing binding efficiency.
 Co polymer: For increasing binding efficiency.
 Anti-foam: For preventing foam formation.
 Sodium hex Meta phosphate/Tetron: for dispersion.
 Thickener powder: for thickening
 Titanium dioxides: as pigment.
 Marbles in different sizes (1.8mm, 1.2mm, 0.5mm, normal, coarse and fine): As fillers to give texture for
the manufacturing quartz.
 Organic dispersion agent: For dispersion.
 Thickener solution: As thickening agent.
 Preservative: To control growth of bacteria, fungi, and algae and for anti-smelling.
 Di butyl: For flexibility/elasticity during painting process.

 Caustic solution: for PH media control, and if necessary add paste.
B. Super wall paint

 Water: As a solvent.
 Anti-foam: For preventing foam formation.
 Thickener powder: - As thickening agent.
 Tetron: for dispersion.
 Co polymer: binder.
 Di butyl: For flexibility.
 Thickener solution: for thickening
 Titanium dioxide: Pigment
 Calcium carbonate, Aluminum silicate, - As fillers.
 .Preservative: - For control growth of bacteria, fungi, algae and as anti-smelling.
 Organic dispersion agent (ODA): For dispersion agent.
 Caustic solution: for PH adjustment.
C. Wubet wall paint

 Water
 Anti-foam
 Sodium meta hex phosphate Tetron and Thickener powder
 Organic dispersion agent
 Calcium carbonate
 Co polymer
 Di-butyl
 Preservative and Thickener solution
 Pastes and Caustic solution
D. Mica paint.
 Water፦ As solvent.
 Titanium dioxide፦As pigment.

 Tetron፦ As dispersion agent.
 Thickener powder፦ As additive

 Copolymer: - As binder.
 Mica powder፦As filler.
 Preservative:-As additive
Raw
material Mixing Tinting Laborat
scaling ory
testing
Labeling
Product Product Canning

distribution storage &carton Filling
packing
Figure 4.8 General Flow Chart for Water Based Paints
4.4.2. Ingredients in solvent based paint Products& their functions
A. Enamel
 Alkyd resin or long oil: As a binder
 Kerosene: solvent
 Texaphore: Non-aqueous organic dispersion: For dispersion of pigment
 Calcium half: Dryer
 Emulsifier: For bond breaking or to mix polar with non-polar.
 Titanium oxide, satellite blue and yellow, chromes trial green: pigment.
 Benton solution: for anti-settling.
 Calcium octets, Cobalt octets, zirconium octets: dryers.
 Water: to increase volume of product.

 Methyl ethyl ketoxime or MEKO: anti skinning.
B. Traffic paint
 Xylene: solvent.
 Thermoplastic: as a binder
 Di-butyl: for elasticity.
 Oregano clay or Benton powder: anti settling.
 Texaphore: non-aqouse organic dispersion.
 Cato lite powder, talc powder, iron oxide: pigment.
 Calcium carbonate: used as filler.
 Butyl acetate: solvent.
C. Anti-rest paint
 Kerosene፦As solvent.
 Titanium oxide፦As pigment.
 Long oil፦ As binder
 Iron oxide፦As pigment.

 Benton solution:-Ant settling
 Emulsifiers: - As additive
 Calcium carbonate:-As filler
 Zirconium: -As drier
 Cobalt octate: -As drier
 Calcium octate: -As drier
D. Poly varnish
 Polyurethane resin: binder.
 Urethane resin: binder.
 Manganese octets, calcium octets, zirconium octets: dryers.
 Kerosene: solvent.
 MEKO: anti skinning.
E. Carton glue or cola

 Homo polymer: binder

 Anti-foam: control formation of foaming.
 Calcium carbonate: filler
 Preservative
 Water
4.4.3. Specific Products of Enamels
Table 4.4Different Forms of Enamels and Their Ingredients

Enamel Black Enamel White Enamel(Sp-417)
Texaphore Long Oil 70% Long Oil
Emulsifier Texaphore Texaphore
Calcium Drier Titanium Dioxide 1023 Benton Solution
Co Drier Emulsifier 4045 Emulsifier 4045
MEKO Zr,Ca,Co Driers Matting Agent
C Black Flashed Water Titanium Dioxide 1023
Matting Agent MEKO Ca,Co,Zr,Driers
Zirconium Drier Kerosene Kerosene
Iron Oxide Black Water
Long Oil MEKO
Pastes
A. Components of aluminum paint

 (Resin plus Solvent)
 Silicone resin
 Xylene
 Propylene glycol mono-ether
 Pigment
 Aluminum
 Additives

 Aqualon
 Butyl Titanate
Milling
Raw Pre- Mixing
material mixing
weighing
Tinting
Labeling
Product
storage&produ
ct distribution Canning Laboratory
&carton Filling
testing
packing
Figure 4.9 General Flow Chart for Solvent Based Paint

CHAPTER-FIVE
TESTING OF PAINTS
5. INTRODUCTIONS
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.
Laboratories, in paint industry are responsible for; testing raw materials for compliance with required
standards, quality control of products to check agreement with standard specifications, check the
physical, chemical, and mechanical properties of final products. Chemicals, including hazardous
materials, are used in laboratories. Storage and handling should be checked by the inspectors, in addition to
the disposal of chemicals empty containers, which is considered as hazardous waste.
5.1. 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.
5.1.1. Solvent Tests
Solvent is the material that dissolve all components of paint following the role; (Like dissolves like), the
manufacturer must be sure that the solvent has agreement to his standards by applying tests such as density,
vaporization time, and flash point each of this tests will be described in some details in the following sections.
Density Test
By using density cup, 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 not.
5.1.2. 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 amounts of mixture from resin and solvent will be added until all tested amount of
pigment powder will mixed.

5.2. 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.
5.2.1. 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 can also be measured by a
viscos-meter to obtain paint viscosity.
1) Manual measuring of viscosity: It is simple method in which a cup with hole has diameter 4mm is
used .The sample put into the cup and a stop watch is used to measure the time that sample take to get out from
the cup through the hole.
2) Automatic measuring of viscosity: This method is easy also as it doesn’t take the time that the first one
takes, by using a viscos-meter device which gives direct value of viscosity dependent on a spindle rotate in the
sample.
5.2.2. Gloss Test
Gloss meaning is the degree by which film reflect the beams that fall on it, or in another meaning the degree of
paint of film shining.
Figure 5.1(a)Measuring Viscosities by Using Cup 4 Device (b)Measuring Viscosities with Viscos-Meter
(c)Measuring Of Gloss Degree Using Gloss Meter
5.2.3. Acid Value
It is the value that indicate the amount of free fatty acids in an oil, this test is important because the more this
mentioned amount increase this led to decreasing the drying rate. It can apply by titration experiment a suitable
alkaline material usually KOH, be put into burette and the oil put into the flask under burette solubilized
in ethanol, phenol phthalein will be used as indicator .

5.2.4. Adhesion Force
It describes how the film adhered to the surface that it painted using this film, which considered one of
important paint properties to consumer expectations. Several methods used for testing the film adhesion
force such as using crystal brand transparent tape or using aluminum substrates, also this test can be done using
a simple method that is scratching the pulled film .
5.2.5. Drying Rate
It is one of important paint properties to consumer, which determine the time that solvent need to volatile and in
same time the dryer solidify the film on painted surface, it simply can done by observation a pulled film and
accounting the time that it takes to be dry, it must compared with company standards.
5.2.6. Wash-Ability Test
It’s the resistance of paint film for washing, which done by a device that drop water with a regular rate and by
using number of brushes that rub the film and the time counted until film is removed.
Figure 5.2Wash-Ability Testing Device
5.3. OHERS PARAMETERS
5.3.1. Fineness test
It is a test applied to test how surface will be smooth after it painted with a definite type of paints
Figure 5.3 Measuring Fineness with Hegman Device

5.3.2. Hiding power
This test used to indicate how the film of paint will cover the coated surface by it, and don’t appear anything
from the surface that coated by this paint. Poor hiding power means that many organic pigments have
transparency properties. This makes them ideal for automotive type metallic finishes when they are used to tint
aluminum flake containing bases. Generally; the pigment particle size is very small 0.01 to 0.1μms. This makes
handling in the factory difficult as spilling just a few grams may contaminate a large area. Some of these
pigments are more like gases to handle than powders.
5.3.3. Storing effect
A test using to ensure that the paint will stand against storing conditions by putting a sample of paint into drying
furnace with temperature 60 degree for two weeks. If one of these conditions appears after the mentioned two
weeks, it will refer to non-standing against string effects, these conditions such as settling of solid content, non-
homogeneity of film, formulated skin over paint.
5.3.4. Impact Resistance test
Impact Resistance Tester for Paints - Indirect is a consistent tool useful for testing on coatings for crack
formation; breaking off; adhesion and elasticity. A bulge is formed in the sheet metal by a falling weight with a
hemispherical end. Also, PH and Specific gravity are kept in account.
Figure 5.4(a)Measuring Of Hiding Power by Opacity Meter (b) impact resistance test

CHAPTER-SIX
EXPERIENCES ACQUIRED FROM Internship
6. INTRODUCTION
University Of Bahir Dar Department Of Industrial Chemistry prepared this program, gives orientation to search
our hosting company for the two months internship program. Based the orientation we search for different
factories and Kokeb paint factory was the one that accept our request.
Therefore; we choose this factory for the following cases:
 The company was new and we would expect problems that can be solved
 It is near to the University
6.1. Techniques We Used During the Internship
The first thing we have been performing was observing and asking of workers in order to get enough
information about what they are doing in each section of the company. After we have grasped this information;
we have started doing with them by taking note on each part of operation and asking the supervisor and
laboratory head about the function of each raw material when the operator add to the mixer tank.
In the first weeks, we were not that much good in performing the work tasks since we were new for the company
and working environment was not suitable; but through time and practice we became good in performing
different tasks in each section of the company.
6.2. BENEFIT ACQUIRED FROM INTERNSHIP PROGRAM
The two months internship program was very important in terms of improving our:
 Practical skills
 Theoretical knowledge
 Interpersonal communication skills
 Team playing skills
 Leadership skills and also
 In terms of understanding about work ethics related issues and entrepreneurship skills.
 Improving practical skills
6.2.1. Practical skills
From our internship program we have developed the following practical skills:
 How to measure the physical parameter

 How to control speed of mixer and milling machine
 How to prepare sample in the lab section
 How to take sample from mixing tank to lab section
6.2.2. Upgrading theoretical knowledge
The same with practical skill the internship program plays an important role in improving my theoretical
knowledge. As it is known; the real world comes from theories, knowing the basic points behind something are
the first step. This program paved the way to relate the real world with theories in actual. There were lots of ideas
raised to solve practical problem. This creates good visualization on application of theories on practice which
never gain from attending regular class.
6.2.3. Improving interpersonal communication skills
Asking clearly and shortly we have understood that inter personal communication skill is very important. The
other and main thing is inter personal communication skill and have greatly improved my interpersonal
communication skills because we have to communicate with others healthily to get same supports that we need
from someone who is around (helps like explanations, suggestion, and resources). The following are some of the
values we have gained from the internship in terms of improving my interpersonal communication skills. This
includes;
 Pay more attention to people sayings.
 Increase understanding skill by different methods.
 Staying focused.
 Problem solving.
 Honesty and punctuality.
 Motivation
6.2.4. Industrial problem-solving capacity
We learned how to solve any industrial problems starting from identifying the problem up to how to solve them
using the following problem-solving questions:
 How to identify the problem
 How to analysis it
 What kind of problem-solving way we can use
 How to implement the solution

6.2.5. Improving team playing skill
At the beginning of the internship, we feel lack of confidence and also, we have fear to interchange the ideas
with manufacturing company workers. Through progress, we solve this problem and learn:
 How to communicate with teammates
 How to tolerate and respect with each other
 How can be punctual
 Giving respect for other
6.2.6. Improving leadership skills
Internship made us smart in managing our expenses regarding the project, how to
become better sales person or how to manage a team. Learning these skills can really
help in creating better individuals & better team. These items will help everyone developing their skills as a
leader;
 Understanding group needs and characteristics
 Representing the group
6.2.7. Understanding about work ethics and related issues
We have learned much enough work ethics related issues from the hosting company. The following are some of
the values we have gained from the internship in terms of improving our
understanding of work ethics:
 Responsibility
 Self-confidence
 Hard working
 Morality
 Professionalism
 Punctuality
6.2.8. Entrepreneurship skills
As entrepreneurship is the process of acquiring something new with value by devoting the necessary time and
effort, assuming the necessary risks, and expecting rewards for the undertaking from this internship program we
gained different ideas to:

 High need for achievement
 Willingness to take risks
 A need to exercise leadership
 Creativity
 Communication skills
 The ability work independently
 Able to plan coordinate and organize effectively
 The ability to work under pressure
 We gained the knowledge how to create different business related jobs in the future
 Able to take responsibility and make decision
 Ability to network and make contacts.
6.3. CHALLENGES DURING OUR INTERNSHIP PROGRAM
In our internship program we have faced many challenges. Some of them are:
Peace and stability: the current Ethiopian political disturbance
 Working environment: there is an adverse environmental condition such as dust and irritated odor
 Lack of different books and manuals about paint in the company.
 Facility problems such as safety clothes.
 Odor of some volatile organic solvents
6.4. Measures taken to overcome the challenges
 Adapting the working environment
 Make close relation with each section workers
 Asking them repeatedly with respect

CHAPTER-SEVEN
7. CONCLUSIONS AND RECOMMENDATION
7.1. CONCLUSIONS
Paints are a main type of coatings, used in purposes of protection, and decoration. An example is epoxy and poly
urethane system. Paints have several methods for applying such as spray gun.
Kokeb paint factory is one of the paint manufacturing factories in Ethiopia, particularly in Bahir Dar producing
different types of paints based on customer’s need and contains the requirement paints. It produces two types of
paints depending on the solvent used, which are water based, and oil or solvent based paints. Paints are
composed mainly of five components: resin (binder), which collects all the rest of paint components, classified to
convertible binders such as epoxy, and polyurethane. The other classification is non-convertible binders such as
cellulose, and nitro-cellulose.
The second component is the solvent, which is used to dissolve all components of paint. Other components are
pigments which give the paint its color, the filler which perform usually half of formula amount, and finally
some additives such as thickeners, dryers, anti-foaming agents, and other additives which obtained in table (2.2).
Paints manufacturing depend on three-unit operations which are; mixing, milling, and filtration. Mixing
operation is used for mixing all components and homogenizing it, by using two mechanisms which are; liquid-
liquid mixing and solid-liquid mixing. Milling operation is used to damaging all agglomerated particles to
prevent its settling. Filtration is used to remove any agglomerated particles or anything before filtration.
Paints manufacturing pass through several procedures, be in cleaning of industrial units, and start adding the
resin, solvent, thickener, and anti-settling agent to provide pre gel phase to contain powders, that will be added
and mixed. After that, a sample sent to QCL to test its fineness and after that the rest
Components added, mixed well and milled, filtrated, and packaged. During and after manufacturing processes
several test done such as density, and viscosity test

7.2. RECOMMENDATION
Since the company is new, we have recommended the following major problems that can be solved for the
future.
The first thing we have recommended is safety problem. They have to prepare safety close for all workers;
The general manager is not that much polite & voluntary to respond the questions we have asked, for the future
he try to solve it;
To satisfy customer need, they have to write the exact expiration date of their product.
Filling section is preformed manually, for this reason, over filling and under filling of plastics container occurs;
this must be modified in to automatic means of filling.
In labeling section: all kind of label is done manually; it need more labor, time consuming, labeling problem also
occur since it was done by human. It must be replaced by print machine or labeling machine.
In tinting section: additives were added manually this leads health problem for workers and quality problem for
the production; it must be resolved.
They have to employee skilled man power within the respective sections
There is poor interaction between workers and the plant manager. So the manager shows good face for workers
in order to create smooth relation with works and workers should be open minded to create good relation with
the manager.
In waste water storage tank there is unpleasant odor, which cause health problem for humans and environmental
pollution.
There is no checking of inlet and outlet samples which is difficult to know whether it meet the standard
specifications or not!
To overcome such problem, the company should use waste water treatment such as primary, secondary, and
tertiary treatment.

REFERENCES
1. Fitzner B, Heimlich’s K (1998): Damage diagnosis at natural stone monuments - mapping and
measurements. In: Proceedings of the IV International Congress on Restoration of Buildings and
Architectural Heritage, 17 July 1998, La Habana-Cuba
2. Power WR (1975): Construction Materials: Dimension and Cut Stone Dimension and Cut Stone. In:Lefond
SHJ (end) Industrial Minerals and Rock, 4th edition, American Institute of Mining Engineers, New York,
157-174
3. Saris A, Sariisik G, Senturk A (2010): Characterization of Physical and Mechanical Properties of Natural
Stones Affected by Ground Water under Different Ambient Conditions .Ekoloji 19 (77): 88-96. Sharma
PK, Khandelwal M, Singh, TN (2007): Variation on physico-mechanical properties of Kota stone under
different watery environments. Building and Environment 42: 4117-4123.
4. S. Cevhero˘gluÇıra, The Investigation of the eﬀects of Operational Variables of Polishing Machine and
Material Properties of Marble on Surface Quality and Optimization, Ph.D. thesis, Çukurova University,
Adana, Turkey, 2014.
5. Ahmed, E.A.; El-Kourd, A.A. Properties of concrete incorporating natural and crushed stone very ﬁne
sand. ACI Mater. J. 1989, 86, 417–424.
6. Heavy Metal Removal from Paint Industries Wastewater Using Wood Ash as an Adsorbent (A Case of
Zemilli Paint Factory) By BirukTsegaye
7. R. Norris Shreve, 1956, the chemical process industries, second edition, McGraw-Hill book company,
Tokyo.
8. [2] Rodger Talbert, 2008, Paints Technology Handbook, Taylor & Francis group, Boca Raton & New
York & London.
9. R. LAMBOURNE and T.A. STRIVENS, 1999, Paint and surface Coatings theory and practice, second
edition, Wood head Publishing Ltd, Cambridge.
10. Charles A. Harper and Edward M. Petrie, 2003, Plastics Materials and Processes A Concise Encyclopedia,
John Wiley & Sons, New Jersey.
11. Charles E. Carraher, Jr., 2003, Polymer Chemistry, MARCEL DEKKER, NEW YORK and BASEL.
12. Lyle F. Albright, 2009, Albright’s Chemical Engineering Handbook, Taylor & Francis Group, Boca Raton
& New York & London.

13. James R. Couper, W. Roy Penney, James R. Fair, and Stanley M. Walas, 2012, Chemical Process
Equipment Selection and Design, Third edition, Elsevier, United States of America.

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BAHIR DAR UNIVERSITY

DEPARTMENT OF INDUSTRIAL CHEMISTRY

INTERNSHIP REPORT ON RAW MATERIALS,UNIT OPERATIONS,

PROCESS AND TESTING

“A STUDY AT KOKEB PAINT FACTORY”

1. Temesgen Abebe(BDU 1103990)

2. Getaneh Minichil (BDU1104144)

Company Advisor: Mr. Worku.

Industrial Chemistry Department

Aprill-2022, Bahir Dar Ethiopia

SUBJECT: Submission of Internship Report on Kokeb Paint Factory

Thanks and Best Regards!!

Industrial Chemistry Department

Bahir Dar University

Students Signature Date

1) Temesgen Abebe ________________ ________________

3) Dejen Tsegaye ________________ ________________

ii Internship Report On Kokeb Paint Factory April-2022

iii Internship Report On Kokeb Paint Factory April-2022

iv Internship Report On Kokeb Paint Factory April-2022

BDU: Bahir Dar University

ETB: Ethiopian birr

E.C: Ethiopian calendar

SP. g: Specific gravity

PH: Potential of hydrogen (power of hydrogen)

COVID: Corona virus international diseases

UV: Ultra violet

STD QTY: Standard quantity

ODA: Organic dispersion agent

Pas.s: Pascal second

Vos: volatile organic solvent

v Internship Report On Kokeb Paint Factory April-2022

5.1.1. Solvent Tests ....................................................................................................................... 27

viii Internship Report On Kokeb Paint Factory April-2022

Figure1.1 General Organizational Structure of the Company ...................................................................... 6

Table 2.1 colors and their respective pigments ............................................................................................. 9

ix Internship Report On Kokeb Paint Factory April-2022

GENERAL BACKGROUND OF KOKEB PAINT FACTORY

1.1. GENERAL HISTORY OF THE FACTORY

1.2. VISION, MISSION AND OBJECTIVES OF THE COMPANY

 To contribute positively to socioeconomic development of Ethiopia in particular and to the other

 Producing high quality paint with affordable price.

 Establish new plants like glass and edible oil plant.

 To involve foreign market (export).

 Economic use of resources.

 Reduce power consumption.

 To ensure product consistency at required level.

 Promoting the product in fair and ethical way.

1.3. MAIN PRODUCTS OF THE COMPANY

1.3.1. Water based paints

Water based paint includes:

1.3.2. Solvent based paints

Solvent based includes

 Metal and wood paint

 Alkyd varnish, poly varnish.

 Cola or wood & carton glue etc.

1.4. ORGANIZATIONAL STRUCTURE OF COMPANY

 Human resource development section

 Raw material store and purchasing section

 Laboratory and quality control section

 Leveling and filling section

 Product store and sellers section

3 Internship Report On Kokeb Paint Factory April-2022

1.4.1. Management office

1) Temesgen Abebe

3) Dejen Tsegaye