Internship Report 2010

INTERNSHIP REPORT 2010

BERGER PAINTS , PAKISTAN

MEER SALMAN MUDDASARCHEMICAL ENGINEERING DEPTT.UNIVERSITY OF ENGINEERING & TECHNOLOGY , LAHORE

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MEER SALMAN (2007-CHEM-53)

UNIVERSITY OF ENGINEERING AND TECHNOLOGY , LAHORE

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INTERNSHIP REPORTFOR

BERGER PAINTS PRIVATE LIMITED28-KM MULTAN ROAD, LAHORE

IN FULFILLMENT OF FOUR WEEK INTERNSHIP, UNDERGRADUATE

SUBMITTED BY

MEER SALMAN MUDDASAR

07-CHEM-53

CHEMICAL ENGINEERING DEPARTMENT

UNIVERSITY OF ENGINEERING & TECHNOLOGY LAHORE


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DEDICATION


THIS EFFORT IS DEDICATED TO THE NATION OF PAKISTAN; COMPRISING FLOOD VICTIMS

ESPECIALLY, PAKISTAN ARMED FORCES, AND WELL WISHERS OF MOTHERLAND.

TO MY PARENTS WHO BROUGHT ME , SO THAT I CAN BE A PART OF PAKISTAN

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CONTENTS

AUTHORIZATION.......................................................................................................................................7

ACKNOWLEDGEMENT.............................................................................................................................8

EXECUTIVE SUMMARY...........................................................................................................................9

HISTORY OF ORGANISATION...............................................................................................................10

MISSION STATEMENT............................................................................................................................14

ORGANIZATIONAL CHART...................................................................................................................15

DEPARTMENTS COVERED IN REPORT...............................................................................................16

PAINT..........................................................................................................................................................18

BERGER PRODUCTS & COSTUMERS...................................................................................................24

ENVIRONMENT AND HEALTH SAFETY.............................................................................................29

TECHNICAL / QUALITY CONTROL.....................................................................................................33

MACHINE ROOM.....................................................................................................................................35

RESINS........................................................................................................................................................38

IS THERE NEED OF IMPROVEMENT???...............................................................................................47

POWDER COATING..................................................................................................................................49

POWDER COATING LABORATORY.....................................................................................................55

PRINTING INK...........................................................................................................................................57

BERDEX AND INDUSTRIAL CHEMICALS.........................................................................................87

A TOTAL SOLUTION COMPANY.......................................................................................................87

MAINTENANCE ENGINEERING DEPARTMENT................................................................................94

PRODUCTION DEPARTMENT................................................................................................................96

AUTOMOBILE PRODUCTION................................................................................................................99

CONCLUSIONS........................................................................................................................................103


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AUTHORIZATION


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ACKNOWLEDGEMENTA summer project is a golden opportunity for learning and self development. I consider myself very lucky and honored to have so many wonderful people lead me through in completion of this internship and report.

My grateful thanks to all of the TECHNICALS, ENGINEERS AND OPERATORS who in spite of being extraordinary busy with their duties, took time out to bear, guide me and keep me on the correct path. I don`t know where would I have been without them. A humble “thank you” to all of them.

MR.WAQAS ASHRAF , HR Department monitored my progress and arranged all facilities to make my life easier. I choose this moment to acknowledge his contribution gratefully.

I would like to thanks MR.SHAHID NAVEED,OUR WORTHY CHAIRMAN (CHEMICAL ENGINEERING DEPARTMENT) for his effort and help provided me to get such an excellent opportunity.

I would like to thanks OFFICERS MESS STAFF for such a delicious meal they provided.

Last but not the least there were so many who shared valuable information that helped me in the successful completion of this internship.


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EXECUTIVE SUMMARY

“INTERNSHIP REPORT / FIELD MANUAL”

This is an internship report but still it is designed so that it can help up coming internees to be very valuable in the days of their field work as trainees. I utilize all of my will power and my mind set to prepare flow sheets and details of all the plants assigned to me. Reader (if any) will INSHALLAH enjoy if takes interest.

While preparing report I was of the mind to prepare such a thorough notes. I utilize BERGER past reports for it, discussions , and details regarding to similar plants assigned to me.

During my days there it was very surprised to me that it was my first experience to a batch process unit, and scenario is little different than to continuous process. Being a chemical engineer , as I have always visited continuous , so this really add to my Spartan of knowledge and experience , how to work with it. People working out their have there mind set to provide maximum with minimum under such worse conditions.

It is found that safety level were not satisfactory in spite of EHS department just established. Operators and workers are working under such a volatile chemicals that catches fire instantaneously, poor ventilation system in plants, as in PVA , levels should be stepped up so that there must some sort of insurity of the lives of people working around.


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HISTORY OF ORGANISATION

In 1760 a young color chemist living in London,

Louis Steigen Berger, was manufacturing Prussian

Blue using a secret process. He changed his name to

Lewis Berger on marriage, and his company began

exporting to Australia in 1850 in ships like the

Catherine Shearer.

In 1916, the 150 year old Lewis Berger & Sons

company began its Australian operation at Rhodes,

NSW, building the largest timber structure in the

Southern Hemisphere.

In 1923 Berger and other famous Australian brands,

such as Berlei Lingerie, Uncle Toby's and Tooheys,

joined together to form the Australian Made

Preference League.

Also in the 20's, Berger paint was selected for aviator

Charles Kingford Smith's famous Southern Cross and

Ford Motor Company started using the company's

automotive finishes in 1925.


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1932. The opening of Sydney Harbour Bridge was a proud moment for Berger.

Berger had supplied 60,000 gallons of paint to protect the bridge steelwork, thus

providing work for many hundreds during the Great Depression.

In the 1940's and 1950's Berger increased employment opportunities by

establishing manufacturing facilities in every state of Australia.

In 1974, 51.4% of Australians chose Advance Australia Fair as the national anthem

to supersede God Save the Queen. In the same year, the company changed its name

from Lewis Berger & Sons to Berger Paints.

In September 1988 Berger Paints was acquired by Dulux Australia. This provided

a sound base for the future by giving Berger access to the very best worldwide

resources for research, technology and marketing.

In the 1990's Berger was relaunched in Australia with the 'Made with People in

Mind' proposition, reflecting Berger's deliberate consideration of the human

sensitivities when painting.

2003 Berger revisits its famous 'Keeps on keeping on' proposition and continues to

deliver honest results.


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For 88 years it's been said that Berger 'Keeps on keeping on', so now, backed by

this history, you can look forward to a future of continued reliability and trust.

ALL ABOUT BERGER – PAKISTAN

The BERGER name has been associated with paint manufacturing for almost two

centuries. The BERGER group has worldwide affiliations, with companies

operating in 46 counties. In Pakistan, the history of BERGER is as old as the

history of organized paint manufacturing. The first company to introduce premium

quality paints in the country. The BERGER started its operations in 1950. Initially

the paints were imported from the United Kingdom. It was in 1955 that a local

manufacturing facility was established at Karachi. Ever since, the Company has

met the growing demand through regular extensions in its products range, which

has continued to attract a healthy market share and has maintained a high

reputation for consistent quality.

BERGER PAINTS PAKISTAN became a public limited company in 1974, when

49.38% of the shares were acquired by Pakistani investors with the remaining

50.2% being held by the U.K. parent company, Jenson & Nicholson Limited. Soon

afterwards, Jenson & Nicholson Limited was taken over by Hoechst, one of the

world's major manufacturers of chemicals and allied products.

Slotrapid Limited, a. U.K. based company with diversified business interests,

acquired the management of BERGER PAINTS PAKISTAN in 1991.


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Also in 1993, BERGER entered into a technical collaboration agreement with

Nippon Paint Company of Japan. Nippon is acknowledged as one of the most

sophisticated paint manufacturers in the world, and ranks among the leaders of the

paint industry. This collaboration has enabled BERGER to develop automotive and

industrial paints conforming to exacting international standards.

BERGER Paints has also built up technical collaboration for decorative paints with

BERGER Crown of Akzo Nobel UK.

With its Head Office at Karachi, BERGER PAINTS PAKISTAN has regional

offices at Lahore and Islamabad as well as a wide network of distributors/

dealers and sales personnel at all major urban centers of the country.

BERGER paints launched its second paint manufacturing facility in 2006 located

in Lahore, this is a state-of-the-art plant geared to incorporate the latest

technologies to produce paints and coatings for a variety of applications.


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MISSION STATEMENT

Company have a slogans:

WE WILL VIGOROUSLY PROMOTE AND SAFEGUARD THE INTERESTS OF OUR EMPLOYEES, OUR SHAREHOLDERS, OUR SUPPLIERS AND ALL OUR OTHERS BUSINESS ASSOCIATES.

WE WILL ACHIEVE CORPORATE SUCCESS THROUGH AN UNWAVERING COMMITMENT TO PROVIDE OUR CUSTOMERS HIGH QUALITY PRODUCTS TO THEIR ULTIMATE SATISFACTION.


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ORGANIZATIONAL CHART


BOARD OF DIRECTORSMDCEODIRECTOR SALESGM TECHNICALGM FINANCE & AUDITCONTROLLER PERSONAL & ADMINLOGISTIC MANAGERPRODUCT MANAGERMANAGMENT TARINEE

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DEPARTMENTS COVERED IN REPORT

EHS

TECHNICAL/QUALITY CONTROL

RESIN/PVA

POWDER COATING

PRINTING INKS/ VEHICLE REFINISHES

DECORATIVE PRODUCTION

AUTOMOTIVE PAINTS PRODUCTION

MAINTENANCE ENGINEERING

BERDEX & CONSTRUCTIONAL CHEMICALS


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PAINTFROM A LAYMAN POINT OF VIEW IT IS SIMPLE A “ COATING MATERIAL”

TECHNICALLY DEFINED AS

“Paint is any liquid, liquefiable, or mastic composition which after application to a substrate in a thin layer is converted to an opaque solid film”

COMPONENTS OF PAINTS:

PIGMENT BINDER SOLVENT ADDITIVE

Pigment

Pigments are granular solids incorporated into the paint to contribute color, toughness, texture or simply to reduce the cost of the paint. Alternatively, some paints contain dyes instead of or in combination with pigments.

Pigments can be classified as either natural or synthetic types. Natural pigments include various clays, calcium carbonate, mica, silicas, andtalcs. Synthetics would include engineered molecules, calcined clays, Blanc fix, precipitated calcium carbonate, and synthetic silicas.

Hiding pigments, in making paint opaque, also protect the substrate from the harmful effects of ultraviolet light. Hiding pigments include titanium dioxide, phthalo blue, red iron oxide, and many others.

Fillers are a special type of pigment that serve to thicken the film, support its structure and simply increase the volume of the paint. Fillers are usually made of cheap and inert materials, such as diatomaceous earth, talc, lime, baryte, clay, etc. Floor paints that will be subjected to abrasion may even contain fine quartz sand as


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a filler. Not all paints include fillers. On the other hand some paints contain very large proportions of pigment/filler and binder.

Binder or vehicle

The binder, commonly referred to as the vehicle, is the actual film forming component of paint. It is the only component that must be present; other components listed below are included optionally, depending on the desired properties of the cured film.

The binder imparts adhesion, binds the pigments together, and strongly influences such properties as gloss potential, exterior durability, flexibility, and toughness.

Note that drying and curing are two different processes. Drying generally refers to evaporation of the solvent or thinner whereas curing refers to polymerization of the binder. The term "vehicle" is industrial jargon which is used inconsistently, sometimes to refer to the solvent and sometimes to refer to the binder. Depending on chemistry and composition, any particular paint may undergo either, or both processes. Thus, there are paints that dry only, those that dry then cure, and those that do not depend on drying for curing.

Paints that cure by oxidative cross linking are generally single package coatings that when applied, the exposure to oxygen in the air starts a process that cross links and polymerizes the binder component. Classic alkyd enamels would fall into this category. Oxidative cure coatings are catalyzed by metal complex driers such as cobalt naphthenate.

Paints that cure by catalyzed polymerization are generally two package coatings that polymerize by way of a chemical reaction initiated by mixing resin and hardener, and which cure by forming a hard plastic structure. Depending on composition they may need to dry first, by evaporation of solvent. Classic two package epoxies or polyurethanes would fall into this category.

Solvent


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The main purposes of the solvent are to adjust the curing properties and viscosity of the paint. It is volatile and does not become part of the paint film. It also controls flow and application properties, and affects the stability of the paint while in liquid state. Its main function is as the carrier for the non volatile components. In order to spread heavier oils (i.e. linseed) as in oil-based interior house paint, a thinner oil is required. These volatile substances impart their properties temporarily—once the solvent has evaporated or disintegrated, the remaining paint is fixed to the surface.

Water is the main diluent for water-borne paints.

Solvent-borne, also called oil-based, paints can have various combinations of solvents as the diluent, including aliphatics , aromatics ,alcohols, ketones and white spirit. These include organic solvents such as petroleum distillate, esters, glycol ethers, and the like. Sometimes volatile low-molecular weight synthetic resins also serve as diluents. Such solvents are used when water resistance, grease resistance, or similar properties are desired.

Additives

Besides the three main categories of ingredients, paint can have a wide variety of miscellaneous additives, which are usually added in very small amounts and yet give a very significant effect on the product. Some examples include additives to modify surface tension, improve flow properties, improve the finished appearance, increase wet edge, improve pigment stability, impart antifreeze properties, control foaming, control skinning, etc. Other types of additives include catalysts, thickeners, stabilizers, emulsifiers, texturisers, adhesion promoters, UV stabilizers, flatteners (de-glossing agents), biocides to fight bacterial growth, and the like.

Additives normally do not significantly alter the percentages of individual components in a formulation.


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ProductionPlanning

Orders

Tin Preparation

Grinding(5-6 hours)

PDP(B.O.M.)

Tanks(Large Batch)

Store(Raw Material)

Ink JetPrinting

Filling(1 day)

Colour Matching + Quality Control(2-3 days)

Store(Finish Goods)

Pots(Small Batch)

QualityControl

Charging(1-2 hours)

Container Div.(Tins)


BRIEF MANUFACTURING PROCESS


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MATERIAL ACQUISITION FROM STORE: Store is controlled by the Procurement Department. Any material required by production Department is ready after max 24 hours. As this store issues raw material from the warehouse which orders raw material of 3 months ahead by the forecast created and approved by the sales department. E.g. if standing in November the forecast will be approved for Febuary and the Material Procurement process will come into action.

NOTE: The daily deviations are also reported to all the departments as any new extra or out of ordinary orders are placed.

CHARGING: it is the phase of production in which the raw materials are inputted into machines as there are many types of raw materials and are in bulk quantities keeping in mind the exact standardized quantity of raw material to achieve consistent quality and performance of the product.

GRINDING: Grinding the raw material of solid form and mixing of liquid raw material with it. After this process the output is in the form of paste and this similar to the base material.

MIXING: after grinding raw materials are mixed.

FINISHING: Raw materials for the durability, bonding and glossiness of the paint are added.

COLOUR MATCHING: Colour is added and checked according to the specified standards and according to the ordered requirement.


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QUALITY CHECK (Q.C): the quality of the product is checked in all terms and respects including colour, shine, bonding, base material, drying procedures, drying time etc.

FILING: The Orders for the filling packs or tins are given at the time when production Schedule is made, so by the time manufacturing is completed the empty packs and tins are ready and available from the supplier.

NOTE: Filing of Industrial Products of 2000 – 5000 litres takes one day. And filling of Decorative products of 2000 – 8000 litres a day.

PRINTING: Ink Jet printing is used to print each tin or packets. A single packet or tin takes 1 min for printing.

STORING: all the finished goods after packing and printing are stored in the warehouse which is situated within the premises of Berger Pakistan S.I.T.E.


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BERGER PRODUCTS & COSTUMERS

BERGER HAS 600 PRODUCTS IN ALL AND 1800 SKU’S DEPENDING ON TYPE OF PAINT, AND SHADES.

1 DECORATIVE: (HOUSEHOLD PAINTS)

WATER BASE

• PLASTIC EMULSION

• ECONOMY EMULSION

OIL BASE

• BERGER ELEGANT

• BERGER ENAMEL

2 AUTOMOTIVE PAINTS

3 POWDER PAINTS

4 TIMBERCOAT RANGE OF PAINTS

5 BERGER ROAD SAFETY

6 DEFENCE MARINE PAINTS

7 PRINTING INKS


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BERGER'S CUSTOMERS FOR AUTOMOTIVE PAINTS

CARS ASSEMBLERS

• HONDA.

• TOYOTA.

• CHEVROLET JOY.

• REVO.

COMMERCIAL VEHICLES

• ZABARDAST, TRUCK.

• MASTER TRUCK.

• STAR TRUCK.

• KALASH PICK-UP.

• HINO BUSES.

MOTORCYCLES:

• HONDA.

• YAMAHA.

• SUZUKI.

• 25 CHINESE BRANDS.

TRACTORS:

FIAT TRACTORS.

SUNIVERSAL TRACTORS.


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GENERAL INDUSTRIAL PAINTS:

SINGER.

PHILIPS.

SIEMENS.

PAK FAN.

PSO.

PBS.

CALTEX.

KSB PUMPS.

PROTECTON: (HEAVY DUTY COATINGS)

NATIONAL REFINERY.

PAK ARAB REFINERY.

KARACHI FISH HARBOUR.

WHITE OIL PIPELINE PROJECT.

TELECOMMUNICATION TOWERS OF UFONE, TELENOR, MOBILINK, PAKTEL AND

AL WARID.

POWDER PAINTS:

APPLIANCES OF PEL, WAVES, PHILIPS , DAWLENCE


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BERGER ROAD SAFETY. PAINTS FOR ROAD AND RUNWAY MARKINGS:

• ISLAMABAD – ALL CDA ROADS.

• MOTORWAY.

• KOHAT TUNNEL.

• DHA, KARACHI.

• KARACHI – HYDERABAD HIGHWAY.

• MAI KOLACHI ROAD.

• SHAHBAZ AIRFIELD.

• BAHRIA TOWN.

• LAHORE -SHEIKHUPURA EXPRESSWAY.

DEFENCE MARINE PAINTS:

SPECIALIZED PAINTS FOR ARMY, NAVY, AIR FORCE, SHIPYARD AND FISH HARBOUR.


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UNIT # 01


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ENVIRONMENT AND HEALTH SAFETYRecently posted department EHS is trying to grow as a vital part of firm. Serving people and creating awareness in between people with frequent training programs, lectures, and prosessions, department is trying that at the end each individual should be fully aware of all the tactics that include FIRE FIGHTING , USE OF PPE(person protective equipments), awareness with dangers , since there is handsome chance of catching fire in fire industry, first aid , and quick response to emergency call.

AREA UNDER CONSIDERATION TO EHS

1. Environmental

Air Emissions and Ambient Air Quality Energy Conservation Wastewater and Ambient Water Quality Water Conservation Hazardous Materials Management Waste Management Noise Contaminated Land and Remediation

2. Occupational Health and Safety

General Facility Design and Operation Communication and Training Physical Hazards Chemical Hazards Biological Hazards Radiological Hazards Personal Protective Equipment (PPE) Special Hazard Environments Monitoring


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3. Community Health and Safety

Water Quality and Availability Structural Safety of Project Infrastructure Life and Fire Safety (L&FS) Traffic Safety Transport of Hazardous Materials Disease Prevention Emergency Preparedness and Response

4. Construction and Decommissioning

Environment Occupational Health and Safety Community Health and Safety

EHS IN BERGER AT THE MOMENT

After fire incident of BERGER in 2008, think tanks are looking to accommodate EHS at there maximum , so that further incidents can be made avoided. So far people in EHS are focusing in following aspects.

FIRE: If fire ignites there are fire points where quick response team defined for each department from workers that are trained, have to get there and launch fire extinguishing plan, as decided.

ADDICTION TO FUMES: Paint have a very strong relations with volatility ; since almost chemicals are found fuming and INHALATION of chemicals produce addict people those feels suffocations if they don’t inhale these chemicals regularly. So department is found showing keen interest in rectifying this problem.

SKIN PROBLEMS AND IRRITATION: Few chemicals including caustic soda used for cleaning , cause skin problems and irritation among people ; causing itching , and irritations.

SLIPPAGE: due to leakage of chemical , and lubricants ; there are slippage problems in plant sites that may cause serious accidents by chance. EHS is trying to point out these sort of imperfections and rectify them.

EYE CONTACT: If contact is made with the eyes, then hold your eyes open and flood them with luke warm water for at least 5 minutes and then immediately consult a doctor.

IF SWALLOWED: Do not induce vomiting. Drink plenty of water and seek immediate medical help.


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PPE(person protective equipments)

Personal protective equipment (PPE) refers to protective clothing, helmets, goggles, or other garment designed to protect the wearer's body from injury by blunt impacts, electrical hazards, heat, chemicals, and infection, for job-related occupational safety and health purposes, and in sports, martial arts, combat, etc. Personal armor is combat-specialized protective gear. In British legislation the term PPE does not cover items such as armor. The terms "protective gear" and "protective clothing" are in many cases interchangeable; "protective clothing" is applied to traditional categories of clothing, and "gear" is a more general term and preferably means uniquely protective categories, such as pads, guards, shields, masks, etc.

PPE can also be used to protect the working environment from pesticide application, pollution or infection from the worker (for example in a microchip factory). The protection may be important in both ways, as with the use of disposable gloves by surgeons and dentists.


http://en.wikipedia.org/wiki/Dentist

http://en.wikipedia.org/wiki/Surgery

http://en.wikipedia.org/wiki/Glove

http://en.wikipedia.org/wiki/Protection

http://en.wikipedia.org/wiki/Die_(integrated_circuit)

http://en.wikipedia.org/wiki/Infection

http://en.wikipedia.org/wiki/Pollution

http://en.wikipedia.org/wiki/Pesticide_application

http://en.wikipedia.org/wiki/Pesticide_application

http://en.wikipedia.org/wiki/Legislation

http://en.wikipedia.org/wiki/Personal_armor

http://en.wikipedia.org/wiki/Combat

http://en.wikipedia.org/wiki/Martial_arts

http://en.wikipedia.org/wiki/Sports

http://en.wikipedia.org/wiki/Occupational_safety_and_health

http://en.wikipedia.org/wiki/Chemicals

http://en.wikipedia.org/wiki/Injury

http://en.wikipedia.org/wiki/Goggles

http://en.wikipedia.org/wiki/Helmets

http://en.wikipedia.org/wiki/Clothing

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UNIT # 02


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TECHNICAL / QUALITY CONTROLTechnical and quality assurance department is one of the back bone of any industry specifically chemical industry. Chemistry is involved in attestation of raw, intermediate, and finished products. Under the eyes of expertise , frequent research is carried out , color matching , and testing the grade , reliability , and quality of products are maintained and fixed.Following are few tests as carried in lab are mentioned; in RAW , INTERMEDIATE , FINISHED lab.Starting with abbreviation description;

E ExtendersP PigmentsR ResinsO OilsX,Y,Z ChemicalsH Dryers C CelluloseW WaxS Solvents


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MACHINE ROOMMachine room is a sort of pilot plant where R & D work is carried out.

Room contains HSD (high speed dispersers) ,and iterators that are used for pigment size reduction, and to produce mixing as well; here is a detail of all equipments;

High speed dispersion machine(interior) Iterator(solid pigment dispersed) HSD(exterior / clearer paint, thinner) Spatula mixing (color matching)

UNIVERSITY OF ENGINEERING AND TECHNOLOGY , LAHOREDispersion operation

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UNIT # 03


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RESINSResin is a natural or synthetic compound which begins in a highly viscous state and hardens with treatment. Typically, resin is soluble in alcohol, but not in water. There are a number of different classes of resin, depending on exact chemical composition and potential uses. There are numerous applications for resins, ranging from art to polymer production, and many consumers interact with products which contain resin on a daily basis.

Natural resin comes from plants. A classic example is pine sap, which has the characteristic sharp odor of terpene compounds. As anyone who has interacted with pine sap knows, the substance is very viscous, but it hardens over time. A number of other plants produce resins, and plant resins have been used by humans for thousands of years. Some plants exude a similar substance called gum or gum resin which does interact with water. Gum tends to be softer and more malleable than resin.

Plant resin can be clear to dark brown in color, and it varies in opacity and hardness. Some plant resin is also extremely volatile, since it contains unstable compounds. Misidentification of resinous trees can sometimes lead to unfortunate accidents, since some resins contain heptanes, flammable and potentially explosive hydrocarbons. The popular decorative material amber is fossilized plant resin. The rich golden color of amber is a common shade for plant resins, but amber can also be found in more rare colors, like blue.


INSECT TRAPPED IN RESIN

http://www.wisegeek.com/what-are-hydrocarbons.htm

http://www.wisegeek.com/what-is-natural-resin.htm

http://www.wisegeek.com/what-are-polymers.htm

http://www.wisegeek.com/what-is-a-chemical.htm

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BASIC CHEMISTRY

CONDENSATION POLYMERISATION OIL BASED (ALKYD RESIN)

ADDITION POLYMERISATION CO-POLYMERISATION WATER BASED


CURING AGENTAIR DRYINGLOW BAKESTOVINGALKYD RESINACRYLIC RESINQUICK DRYING

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PVA;WATER BASED RESIN PRODUCTION UNIT

Acrylic paint is fast drying paint containing pigment suspension in acrylic polymer emulsion. Acrylic paints can be diluted with water, but become water-resistant when dry. Depending on how much the paint is diluted (with water) or modified with acrylic gels, media, or pastes, the finished acrylic painting can resemble a watercolor or an oil painting, or have its own unique characteristics not attainable with other media.

ADDITION POLYMERIZATION

An addition polymer is a polymer which is formed by an addition reaction, where many monomers bond together via rearrangement of bonds without the loss of any atom or molecule. This is in contrast to a condensation polymer which is formed by a condensation reaction where a molecule, usually water, is lost during the formation.

CO POLYMERIZATION

A heteropolymer or copolymer is a polymer derived from two (or more) monomeric species, as opposed to a homopolymer where only one monomer is used. Copolymerization refers to methods used to chemically synthesize a copolymer.


http://en.wikipedia.org/wiki/Homopolymer

http://en.wikipedia.org/wiki/Monomer

http://en.wikipedia.org/wiki/Polymer

http://en.wikipedia.org/wiki/Condensation_polymer

http://en.wikipedia.org/wiki/Monomer

http://en.wikipedia.org/wiki/Addition_reaction

http://en.wikipedia.org/wiki/Oil_painting

http://en.wikipedia.org/wiki/Watercolor_painting

http://en.wikipedia.org/wiki/Emulsion

http://en.wiktionary.org/wiki/acrylic

http://en.wikipedia.org/wiki/Paint

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WHAT UNIT CONATINS??

Unit consists of 5 reactor tanks and 4 monomer tanks with different capacity , each tank is provided with individual valve control arrangement, 2 cooling towers serving for purpose of cooling water for circulation. All reactor tanks contains jacketed coils that are used to provide heat to system or run cool water for cooling. Fired heater is available that produces water at 90 0C to carry out polymerization reaction.

REACTOR TANK


FIRED HEATER

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PRODUCTION OF BERLITH GLUE ( FINISHED PRODUCT);

It is a two stage process, providing homogeneous mixing.

PROCESS

Set heater put 500Kg water in it along with chemical A 6 bags (6*25) at 700C; with this addition heat jumps to 82-83 0C, and keep in hold for 2 hours. put monomer on above tank using air diaphragm pump to pump monomer ingredients into tank so that It may not catch fire. Chemical B added on kettle reactor tank and first stage is started. STAGE ONE; Catalyst C is added gradually in small amount and hang on till all of the catalyst is added. After 5 min hold, start STAGE TWO , monomer takes 4-4.5 hours to completely added to tank while heat jumps to 90 0C. start cooling and add chemical D,E,F in formulated amount. This is the finished GLUE , which is filtered and packed in pouch of 0.5, 1 Kg size.

There are further 4 products that are intermediate and drummed directly to be used in production section.

NOTE:DUE TO FORMULATION SECRECY THERE PROCESS AS WELL AS PRODUCTION FLOW SHEET IS NOT ALLOWED TO MENTION IN REPORT.


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RESIN PRODUCTION UNIT;OIL BASED

CHEMISTRY FOLLOWED IN THIS SECTION IS Condensation polymerization;

Condensation polymers are any kind of polymers formed through a condensation reaction, releasing small molecules as by-products such as water or methanol, as opposed to addition polymers which involve the reaction of unsaturated monomers. Types of condensation polymers include polyamides, polyacetals and polyesters.

Condensation polymerization, a form of step-growth polymerization, is a process by which two molecules join together, resulting loss of small molecules which is often water. The type of end product resulting from a condensation polymerization is dependent on the number of functional end groups of the monomer which can react.

Monomers with only one reactive group terminate a growing chain, and thus give end products with a lower molecular weight. Linear polymers are created using monomers with two reactive end groups and monomers with more than two end groups give three dimensional polymers which are cross linked.


http://en.wikipedia.org/wiki/Step-growth_polymerization

http://en.wikipedia.org/wiki/Polyester

http://en.wikipedia.org/wiki/Polyacetal

http://en.wikipedia.org/wiki/Polyamide

http://en.wikipedia.org/wiki/Unsaturated_monomer

http://en.wikipedia.org/wiki/Addition_polymer

http://en.wikipedia.org/wiki/Condensation_reaction

http://en.wikipedia.org/wiki/Condensation_reaction

http://en.wikipedia.org/wiki/Polymer

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An Alkyd is a polyester modified by the addition of fatty acids and other components. They are derived from polyols and a dicarboxylic acidor carboxylic acid anhydride. The term alkyd is a modification of the original name "alcid", reflecting the fact that they are derived from alcohol and organic acids. The inclusion of the fatty acid confers a tendency to form flexible coating. Alkyds are used in paints and in moulds forcasting. They are the dominant resin or "binder" in most commercial "oil-based" coatings. Approximately 200,000 tons of alkyd resins are produced each year.

Alkyd coatings are typically sold in three classes; Long, Medium, and Short. These terms represent the relative fraction of drying oil component in the resin. Long oil alkyds have a high percentage of drying oil content and are generally sold as medium duty coatings for the consumer market. Medium oil alkyds have less drying oil and have a higher percentage of large molecular weight polyester backbone. They dry slower and are employed as high gloss coatings and wood finishes. At the bottom end are short oil alkyds where the percentage of drying oil is very low in relation to the base polyester polymer or backbone chain. These coatings will not air dry or harden unless heated. Short oil alkyds are employed as baking enamels for finished metal products.

Because the major components of an alkyd coating, i.e. fatty acids and triglyceride oils, are derived from low cost renewable resources this has kept the cost of alkyd coatings very low despite ever increasing cost of petroleum which is the predominant raw material source of most other coatings such as vinyls, acrylics, epoxies, and polyurethanes. Typical sources of drying oils for alkyd coatings are sunflower oil , safflower oil, walnut oil, soybean oil, fish oil, corn oil, and tall oil (resinous oil by-product from pulp and paper manufacturing).


http://en.wikipedia.org/wiki/Tall_oil

http://en.wikipedia.org/wiki/Corn_oil

http://en.wikipedia.org/wiki/Fish_oil

http://en.wikipedia.org/wiki/Fish_oil

http://en.wikipedia.org/wiki/Soybean_oil

http://en.wikipedia.org/wiki/Walnut_oil

http://en.wikipedia.org/wiki/Safflower_oil

http://en.wikipedia.org/wiki/Sunflower_oil

http://en.wikipedia.org/wiki/Polyurethane

http://en.wikipedia.org/wiki/Epoxy

http://en.wikipedia.org/wiki/Acrylic_paint

http://en.wikipedia.org/wiki/Vinyl

http://en.wikipedia.org/wiki/Petroleum

http://en.wikipedia.org/wiki/Enamel_paint

http://en.wikipedia.org/wiki/Resin

http://en.wikipedia.org/wiki/Casting

http://en.wikipedia.org/wiki/Paint

http://en.wikipedia.org/wiki/Carboxylic_acid_anhydride

http://en.wikipedia.org/wiki/Carboxylic_acid_anhydride

http://en.wikipedia.org/wiki/Dicarboxylic_acid

http://en.wikipedia.org/wiki/Polyol

http://en.wikipedia.org/wiki/Fatty_acid

http://en.wikipedia.org/wiki/Polyester

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WHAT UNIT CONATINS??

Unit contains kettle reactors along with condenser and monomer tank , and separate vertical condenser. Except a kettle that is used for research purpose with capacity 700-800 Kg is provided with separate catalyst tank, all other tanks don’t not require catalyst tank and all the ingredients are poured directly into the tank.

A birds eye view of process can be presented as;

TWO STAGE RECYCLE PROCESS;Initially reactor is cleared from pre produced process, solvent is added in tank to clear it and feed to final product to thin product and clear tank. At stage I feed is charged and material is feed to desired temperature , with gradually changes in temperature. Material is set on hold for 3-4 hours , with product cleared.Stage II batch is charged and cooked until desired range of viscosity is centi poise and acid value is achieved, it is moved to mixer tank, until viscosity of desired value is achieved , finished product is sent to storage tank.Carbondioxide is passed into tank kettle directly , since solvent is volatile enough to catch fire inside and carbondioxide is used to extinguish fire if any and moving chemistry so that fire catching capacity can not produce.

Reaction temperature is 280 0C to carry out reaction, and to carry out reaction at such an elevated temperature e series of 3 fired heaters are available that uses thermal oil as an heating media. Few words on thermal oil are as follow, under.

Tests are repeatedly carried to check viscosity and PH level of charge.


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THERMAL OIL HEATERS

Thermal oils are heat transfer fluids that transfer the heat from one hot source to another process. This could be from a combustion chamber or from any exothermic process. The main application is in fluid phase heat transfer.

They are available in chemically different forms as:

Synthetic oil, which are aromatic compounds. Petroleum based oils, which are paraffin’s. Synthetic glycol based fluids.

Thermal oils are available in a wide range of specifications to suit the needs of various processes. Currently available thermal oils have a maximum temperature limit of around 400 °C. There are thermal oils that are in use in cryogenic fields up to -100 °C

Thermal oil heaters functionally are similar to steam boilers. The combustion chamber that burns fuel oil, bio fuel, coal or any other fuel with all necessary safety devices is the same. Since there is, no evaporation the oil passes through simple heater coils placed in the radiant or convection zones. The oil pumped through these coils heats up and flows to the process heat exchanger. The cooler oil returns to a tank and then back to the pump. An expansion tank takes care of the thermal expansion. The tanks have provisions to prevent the oxidation and vaporization of the oil.


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IS THERE NEED OF IMPROVEMENT???Following flaws are observed that need to be eyed immediately , so that further mismanagement is conducted.

Most of the instrumentation was found dying; temperature gauge of stack emission tower, pressure gauges and temperature gauges inside oil based resin plant was found dead, make it difficult to record temperature and pressure reading to carry out energy audit of plant.

In this time of energy crisis , world is facing a real hawk of energy, but oil based resin plant play a game show of energy wastage.

Cooled water that is used to cool kettles reactor containing internal jackets coil release cooling media in form of steam mean at temperature nearby 100-110 0C. it is found that this stream from kettle is directly wasted.

HOW TO UTILIZE THIS ENERGY ; IT DEMANDS A FEWER CHANGES IN EXISTING PLANT AND CAN BE FURNISHED IF DESIRED.

Stack tower was found releasing flue gases at temperature about 100 0C. If it is paid attention this energy can be made useful, and plays an important role in reducing the energy consumptions of plant.

Since plant contains burners running on natural gas; and heating thermal oil as heating media. Its found that valves joining headers that contains rubber gas kits, but thermal oil from burner is almost at 280 0C causing rubber made gaskits to melt and produce slippage and loss in strength of thermal oil, since highly flammable chemicals producing dense volatile vapors are observed around, that are waiting for flash of fire. So it is advised to immediately take action in rectifying the risk of catching fire and setting life of workers to high risk.

In resins water based section packing of berlith glue is carried out using pneumatic machine, and it is found that machine was causing mis weight age. Its filling section was injection random weight jet of glue in pouch and remarkable difference in weight of bag pouch was observed, that should be rectified to maintain standards of BERGER.


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UNIT # 04


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POWDER COATINGWHAT IS POWDER COATING + BRIEF HISTORY…

Powder coating is by far the youngest of the surface finishing techniques in common use today. It was first used in Australia about 1967.

Powder coating is the technique of applying dry paint to a part. The final cured coating is the same as a 2-pack wet paint. In normal wet painting such as house paints, the solids are in suspension in a liquid carrier, which must evaporate before the solid paint coating is produced.

In powder coating, the powdered paint may be applied by either of two techniques.

The item is lowered into a fluidised bed of the powder, which may or may not be electrostatically charged, or

The powdered paint is electrostatically charged and sprayed onto the part.

The part is then placed in an oven and the powder particles melt and coalesce to form a continuous film.

There are two main types of powder available to the surface finisher:

Thermoplastic powders that will remelt when heated, and Thermosetting powders that will not remelt upon reheating. During the

curing process (in the oven) a chemical cross-linking reaction is triggered at the curing temperature and it is this chemical reaction which gives the powder coating many of its desirable properties


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APPLICATION AND INDUSTRIAL CONSUMERS

Aluminum coating

M-S

Washing machine industry

Pak Fans

Geysers

PEL

GFC fan

Royal fan

Pak fan

Electronic instrumentation console coat

ADVANTAGE OF USING POWDER COATING;

In comparison with plastic , which is incapable because range of plastic range of melting is 20-30 0C while powder coating is applied at 200-300 0C, so it is capable of using at surface withstanding high temperature.

PRODUCT RANGE;

Plain powder coat Texture pattern Sparkle plain Sparkle antique Sahara


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For the production of all of the above range the procedure of process is same, as quoted below.


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METHOD OF APPLICATION OF POWDER COAT

ELECTROSTATIC CHARGING;

Powdery material is filled in electrostatic gun and sprayed over charged metal sheet. Afterward it is heated to 200 0C till melted , taking 10-15 min, powder coated metal sheet is ready.


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POWDER COATING SECTION CONSISTS OF FOLLOWING SECTION;

PRODUCTION UNIT LABORATORY

PRODUCTION UNIT; Unit consists of 6 regular extruding machines three AVMz and 4 mixers. Material to be produced in ; is charged in mixers, which are actually mixer tumblers , a tumble of mixer charged is moved into extruder feeding duct. A screw driven motor moves powdery charge in extruder ,. Where two rollers provided with internal cooling coils are used to cool down the charge , making paste type material to solid. Before getting into rollers , material had to pass through heating coils, which melts down material turning into paste. It contains three different tooth screw rollers. Material comes out of rollers as plain sheet form heated due to screws and provide heat. Over conveyer where chilled water via convectional cools metal surface , reduces temperature of sheet further. Conveyor leads material into crusher (toothed) running at opposite pace, making chips out of it.Since material undergo screwing , its temperature enhances that tends to melt material and cooling produce material in chips form.

ACM(AIR COMPRESSION MACHINE);

This is a combination of no of units involving cyclone, separator , centrifugal , serving as blower , filter, cloths, etc.

System is made vacuum via centrifugal blower running at its anti chips are lifted manually , which are transported from extruder to crushed via ho cart. Material is taken upward and passed through a cyclone , where classification into three categories take place, Coarse , fine , standard.

Fines are passed up (since light) and filtered via provided filter arrangement , and stored. Coarse are separated from bottom side end of cyclone. Particles of required size passes test of passing through sieve of required , size. product is collected and bagged.

NOTE; A product 326-MATT was reversed by costumer during my stay over unit. Since it was not weight properly as mentioned . 35 Kg out of total was missing, this was because a temporary sort of seal packing used here.


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Humidity control is necessary , since its excess cause powder to deposit or form lump. So , its temperature is controlled , so that gave control floor temperature.

Aerosols or Al2O3 is added along charge in ACM, cause moisture absorbent and remove water out.

TUMBLER MIXER; is provided to give metallic coloration, metallic is added in powder from ACM , and tumbled till required quality, composition is obtain, it is bagged and dispatched. This tumbler is specially used for antique sparkle finishes.


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POWDER COATING LABORATORY

MOISTURE METER

COATING THICKNESS DEPARTMENT

TRI MICRO GLASS 30 DERGEE

ADHESION CROSS CUT

REFLECTO METER

CONICAL MANDREL

FALLING WEIGHT TEST

PARTICLE SIZE ANALYZER

SPRAY BOOTH

HEATER

COFFEE GRINDER


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UNIT # 05


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PRINTING INKPrinting is widely used in our society to pass on information and to decorate objects. This has resulted in printing being used on many different surfaces ranging from aluminum cans and plastic bottles through to paper. Different inks have been developed for use in these different situations.

Each time we pick up a news paper or packet of biscuits we are looking at examples of printing. Printing of one form or another has been with us for centuries and whilst the technologies of both the printing process and ink formulation have changed considerably the main function of decoration and information remains.

HISTORY OF INK PRODUCTION:

Writing inks were first manufactured in both ancient Egypt and China in about 2500BC. These inks were composed of soot bound together with gums. This paste was formed into rods and dried, then mixed with water immediately before use.

Printing ink was invented by the Chinese about 300 years later. They used a mixture of colored earth, soot and plant matter for pigments, again mixed with gums for binder. By 1440, when Johannes Guttenberg invented the first printing press with moveable type, ink was made of soot bound either linseed oil or varnish similar materials to those used for black inks today. Coloured inks were introduced in 1772 and drying agents were first used in the nineteenth century.


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PRINTING INK TYPES

Printing ink can be classified into two basic types

1) Liquids2) Pastes

These types are further classified into subclasses according to the printing process.

The composition of printing ink and its physical properties are determined greatly by the nature of the printing process used to transfer an image from the printing surface to substrate.

There are five basic printing processes

1) Letterpress2) Flexography3) Gravure4) Offset 5) Screen Printing


Printing inkLiquidsGravureTop Printingwater basedPastes

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The exact recipe for a given ink depends on two factors

Type of surface on which it will be printing Printing method that will be used

Flexography:

DESCRIPTION

Flexography is a printing process which utilizes a flexible relief plate that can be adhered to a printing cylinder. It can be used for printing on almost any type of substrate including plastic, metallic films, cellophane, and paper. It is widely used for printing on the non-porous substrates required for various types of food packaging. It is also well suited for printing large areas of solid color.

APPLICATIONS

Flexography continues to be one of the fastest growing print processes and is no longer reserved just for printing specialty items. The ability of flexography to print on a variety of substrates allows the process to be used for a wide range of printed products. Food packaging is an important market because of the ability of flexography to print on non-porous substrates. This ability makes it useful for printing on plastic bags as well. Other common applications printed with flexography include gift wrap, wall covering, magazines, newspaper inserts, paperback books, telephone directories, and business forms.

PRINTING PROCESS:

The relief plate used for flexography is made of molded rubber or photopolymer materials with the image areas raised above the non-image areas of the plate.

Flexography is a direct printing method in that the inked plate applies the image directly to the substrate. An inked roller known as the "anilox roller", applies ink to the raised portions of the plate which is then transferred to the substrate. The anilox roller has cells that carry a specific amount


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of ink to the plate. The number of cells per linear inch can vary according to the type of print job and the quality required.

The name "anilox" is derived from the ink that was used for the process until the 1950's. Anilox ink was manufactured with "aniline" dyes which, in the 1950's, were discovered to be health hazards, so pigment based inks were developed and have been used ever since. The ink carrying roller has continued to be called the "anilox roller" even though the aniline dye inks are no longer used for flexography. The current inks are very fluid and dry rapidly and are most often water based.

Gravure:

Gravure is a high quality printing process capable of producing printed images which have a continuous tone effect similar to a photograph. The gravure process utilizes a metal printing cylinder onto which the image is etched. The gravure cylinder can be created with analog or digital plating processes.


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APPLICATIONS

Gravure is used for many packaging applications, magazines, and pressure sensitive labels. Gravure is the preferred method of producing magazines and catalogs that have large circulations. An example of a high volume, high quality publication that utilizes rotogravure is the "National Geographic" magazine.

There are also many specialty items that are created with rotogravure including gift wrap, wallpaper, plastic laminates, printed upholstery, imitation wood grain finishes, and vinyl flooring. Many of the specialty items are printed on very wide presses. Some of them, such as those that print patterns on floor coverings, are up to 150 inches wide.

A gravure sheet-fed process is used for smaller runs for such items as limited edition prints and other artwork, photographic books, high denomination postage stamps, stock certificates, and some advertising pieces.

PRINTING PROCESS

Because of the expense of the cylinders, gravure is largely performed as a rotary web process (rotogravure). It is most often used for very long runs of up to a million and many times the press runs are greater than that. For runs of a million or more, the cylinders are plated with chromium to provide extra durability. If the


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chromium begins to wear, it is removed from the cylinder and a new coating is applied.

During the printing process, the gravure cylinder revolves in an ink fountain where it is coated with a very fluid ink. A stainless steel blade (doctor blade) clears the ink from the unwanted areas, leaving the ink in the depressions of the cylinder. The substrate passes between the gravure cylinder and an impression cylinder covered in rubber. The substrate passes between the two cylinders and the ink from the cells is deposited onto the substrate.

Besides being very thin and fluid, the ink colors used with process color applications differ in hue than the inks used with other processes. Instead of the usual cyan, magenta, yellow, and black used with offset lithography, blue, red, yellow, and black are used. Standards have been established by the Gravure Association of America for the correct ink types and colors that should be used for different types of substrates and printing applications.

Gravure is a direct printing method so there is no need to utilize fountain solution to keep the non-image areas clean. Eliminating this variable allows for better print quality control and jobs can be run at higher speeds. Some applications can be run as high as 3,000 feet per minute. The microscopic depressions on the gravure cylinder create an almost continuous tone image on the printed surface, which is why it is often used for high quality image reproduction.

Ink has been designed to print on a wide range of surfaces from metals, plastics and fabrics through papers. The various printing methods are all similar, in that ink is applied to a plate/cylinder and this is applied to the surface to be printed. However, the plate/ cylinder can be made of metal or rubber, and the image can be raised up above the surface of the plate, in the plate but chemically treated to attract the ink, or etched into the plate and the excess ink scraped off. Different inks are produced to suit these conditions.


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EQUIPMENTS USED IN THE PRODUCTION OF PRINTING INKS

Following types of equipments are used during the production of ink.

1. Weighting Balance

Weighting balance is used to weight the material. It is a large electronic spring scale that is permanently mounted on a concrete foundation. The deflection of a beam supporting the unknown weight is measured using a strain gauge which consists of an insulating flexible backing which supports a metallic foil pattern. As the object is deformed, the foil is deformed causing its electric resistance to change which is measured form which we calculate weight using gauge factor (The ratio of electrical resistance to the mechanical strain that is relative change in length).

REASON FOR USE OF WEIGHTING BALANCE:

Weighting balance is used for the following purposes in ink production To check the weight of the raw material provided by the store To add exact amount of raw material according to the batch size during the charging of the material.

2. Pots (Agitated vessel):

Steel Pots are used as an agitated vessel. Top of the vessel is open to air which is covered with steel sheet during agitation. Different sizes of pots are used according to the batch size. Tank bottom is rounded, not flat to eliminate sharp corners or regions into which fluid current will not penetrate.

REASON FOR USE OF POTS

Pots are used as a storage tank during the production of ink. All the raw material is added to the pot which leaves the pot only when the product is formed whether it is varnish or ink.

3. High speed disperser (HSD):

Mixing is applied to the process to reduce the degree of Non-uniformity and make viscosity of the raw material constant throughout the solvent. Mechanical agitation


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is used for mixing of suspended in liquid. High speed disperser (HSD) is being used for this purpose.

Construction:

HSD (High Speed Disperser) consist of an overhung shaft and a high disk type shear blade. Maximum revolution of HSD (High speed disperser) being used is 1400 rpm.

RUNNING PROCESS OF HSD:

The primary purpose of the “HSD” is to break down dry agglomerates (Resins) into a liquid vehicle thus producing a uniform, stable dispersion with the finest particle size possible. The blade creates a vortex that pull in the contents of the vessel to the blade sharp edges, the blade surface then tear apart solids thereby reducing their size and at the same time dispersing them among liquids. A revolving propeller traces a perfect helix in the fluid.

“HSD” batch is started at a fairly low level, or volume, of fluid and no dry product. The fluid volume is 66% of the final batch. The low speed produces a deep vortex that the dry powder ingredients can be added into if we add the entire ingredient vortex will not form. Dry ingredients are added after vortex is formed .Increase the speed as needed to maintain the vortex as viscosity increase. After all the ingredients have been added HSD is run at a maximum speed for the time specified in batch paper. HSD is stopped only when resin is completely dissolved.

MIXING MECHANISM

As the solution formed is of low viscosity the bulk flow pattern in mixing vessel is turbulent. Fluid undergoes shear when one area of fluid travels with a different velocity relative to an adjacent area. The velocity, or tip speed of the fluid at the outside diameter of the rotor will be higher than the velocity at the centre of the rotor, and it is this that creates shear.

The inertia imparted by the liquid by the rotating impeller is sufficient to cause the liquid to circulate throughout the vessel and return to the impeller. Turbulent eddy diffusion takes place throughout the vessel but is maximum in the vicinity of the impeller. Eddy diffusion is inherently much faster


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than molecular diffusion and consequently turbulent mixing occurs much more rapidly than laminar mixing. Ultimately homogenization at the molecular level depends on the molecular diffusion which takes place more rapidly in low viscous liquids.FLOW PATTERN:

The impeller creates an axial flow which is upward. Circulation pattern like these are useful in avoiding dead zone.

TIME OF MIXING

High shear mixers are used in industry to produce standard mixtures of ingredients that do not naturally mix. When the total fluid is composed of two or more liquids, the final result is an emulsion.

To achieve a standard mix, the technique of equilibrium mixing is used. A target characteristic is identified, such that once the mixed product has acquired that characteristic, it will not change significantly thereafter, no matter how long the product is processed. For dispersions, this is the equilibrium particle size. For emulsions, it is the equilibrium droplet size. The amount of mixing required to achieve equilibrium mixing is measured in tank turnover - the number of times the volume of material must pass through the high shear zone.

DYNA MILL:

Dyna Mill is a type of ball mill and consists of following parts

1. Grinding Cylinder2. Water Jacket3. Air filtration4. Mechanical Seal lubrication feed tank5. Grinding medium6. Agitator disc

Grinding Cylinder:


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Dyna mill consist of a hollow cylinder, partially filled with balls, with is at horizontal axis. The material to be fed is in through a hollow trunnion at one end and the product leaves through a similar trunnion at one end and the product leaves through a small trunnion at the other end. The outlet is normally covered with a coarse screen to prevent the escape of the balls.

Agitator disc:

Agitator disc are used for agitation of the feed. Six agitator disc are used for this purpose which rotate due to the movement of the shaft and the material is agitated.

Water jacket:

Grinding chamber is manufactured with a water space around the areas that will receive most heat. This is known as water jacket. The water jacket surrounds the cylinders of the machine, the grinding chamber, and the cooling copper coil in the Mechanical seal lubrication tank.

The inlet of cooling water is located at the bottom of the grinding cylinder and the outlet at the top. The cooling water has the important task of cooling the grinding chamber, where the water jacket surrounds the grinding chamber will indirectly cooling the grinding material, and reduce the wear inside the grinding chamber due to heating. Water is taken from the chiller which is circulated through the water jacket and is later returned to the chiller about 800-1500 liter per hour water is circulated through the water jacket with a pressure of 6 kg/s.

Air Filter :( Compressed air lubrication)

Air to be used for centrifugal pump which is used for the pumping of paste is filtered first by passing it through compressed air lubrication solution to remove any dust particles that may the machine and disturb our product.

Rising Circulation tank for Mechanical Seal Lubrication Fluid Tank:(Main shaft sealing)

Mechanical Seal Lubrication tank contains the lubricating oil which is used for the cooing of the seal. The shaft seal of the mill has one set lubricating Mechanical seal and Lip seal. The lubricating liquid is circulated at the flow rate of 10-30 Liters/Hour. When machine runs the circulation fluid begins to flow through the machine sealing system. Lubricating oil perform two-fold duties of lubricating and cooling. Types of lubricating oil being used are


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For water based: Mixture of water and Glycol For Solvent base: Butyl Cellusolve For Oil Base: Mineral oil

The lubricating liquid is liable to a slight discoloration from the product being grounded and it must be replaced at regular intervals.

GRINDING MEDIA:

To prevent heavy wearing at inner surfaces of the cylinder and better performance of the grinding output, suitable grinding media and ratio of grinding beads must be carefully applied. 60-65 kilograms of Chrome Steel balls are being used. Grinding element must be topped at the ratio of 1.5 kg for every 200 hours.

Cleaning:

For solvent based grinding:

After completion of the each grinding, pump in some resins into the grinding chamber for cleaning out as much as possible the retaining color pastes. Subsequently, pump in some solvent to clean thoroughly the left over paste and let the cleaning pumping solvents discharge from the front cover discharge valve.

For water oil base grinding:

After completion of each grinding, pump in some oil or water thoroughly the left over color paste.

Reason for use of Dyna Mill:

Dyna mill is used for further grinding of the pigments and resin so that we reach our particle size standard that is 2-3 miacro meter.


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RAW MATERIALS:

Raw materials used in ink production are

1) Pigments2) Binders3) Solvents4) Additives

Solvents:

Solvents are liquids capable of dissolving another substance without undergoing a change in chemical state or physical properties. In a typical printing ink solvent ratio is about 50-70 percent.

Solvents are used to keep the ink liquid form when it is applied to the printing plate or cylinder until it has been transferred to the surface to be printed. At this point the solvent must separate from the body of the ink to allow the image to dry and bind to the surface.

Printing processes like gravure and flexography processes require a solvent that evaporates rapidly. These use volatile solvents (i.e. those with boiling point below 120 C) .Ink formulators and printers select solvents based on

Resin system Press speed Cost Toxicity of solvent

Classification of Solvents:

All Solvents can be classified into two types based upon their ability to dissolve a polymer and resin.

a) Activeb) Latent c) Diluents


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a) Active

Active Solvents dissolve a resin by themselves

b) Latent:

Latent Solvent do not dissolve Resin but becomes active in presence of an active solvent

c) Diluents: Diluents are non solvent but are added to reduce the viscosity of the ink

RESINS: Resins commonly referred to as vehicle is the substance in the ink mixture which carries the pigment and binds it to the printed surface. The vehicle must have the ability to be in liquid form during the printing process, but dry rapidly when it reaches the printing surface. Selection of binder is purely dependent on the substrate on which the printing ink will eventually be used. We use about 20-25 percent resin in a batch of ink. The most commonly used resins are listed below Cellulose derivatives Acrylics Ketones Alkydes Formaldehydes Phenolics

Pigments:

A pigment is a material that changes the color of reflected or transmitted light as a result of wavelength select absorption. Pigments are used to impart color to any substance.

Pigments are insoluble and are applied not as solutions but as finely ground solid particles mixed with a liquid. In general, the same pigments are employed in oil and water based paints, printing inks, and plastics. Pigments may be organic or inorganic.


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The majorities of inorganic pigments are brighter and last longer than organic ones. Organic pigments made from natural sources have been used for centuries, but most pigments used today are either inorganic or synthetic organic ones. Synthetic organic pigments are derived from coal tar and other petrochemicals. Inorganic pigments are made by chemical reactions – notably oxidation- or are found naturally as earths.

Inorganic pigments include white opaque pigments used to provide opacity and to lighten other colours. The most important member of this class is titanium dioxide. White extender pigments are added to paints to lower their cost or to improve their properties. This class includes calcium carbonate, calcium sulfate, and china clays. Carbon black is used to give black colour to printing ink.

ADDITIVES:

Additives produce a specific property not obtainable through a resin alone. Many different types of additives are used to alter the final properties of the ink. The most common types of additives used are

Types FunctionPlasticiser Enhances the flexibility of the

printed inkWax Promotes rub resistanceDrier Catalyses the oxidation

reaction of inks which dry by oxidation

Chelating agent Increase the viscosity of the ink(aluminium chelate) and promotes adhesion( titanium chelate)

Antioxidant Delays the onset of oxidation polymerization

Deformer Reduce the water tension in water based inks, meaning that stable bubbles cannot exist

Alkali Controls the viscosity /solubility of acrylic resins in


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water based inks

PRODUCTION OF PRINTING INK:The composition of printing ink and its physical properties are determined greatly by the nature of the printing process used to transfer an image from the printing surface to substrate. Ink is produced in two steps

Semi Finish

Finish

Semi Finish:

In Semi finish steps we make different products that may or may not be used in a particular ink. These products are

1. Varnish2. Pastes

Varnishes:

Varnish is a clear liquid that solidifies as a thin film. It binds the pigment to the printed surface, provides the printability of ink and wets the pigment particles. Varnish produced are simple resin solutions and do not need a high temperature to effect a reaction.

MANUFACTURING PROCESS OF VARNISHES:

They are manufactured by breaking up the resin particles and dissolving them in a solvent by using HSD (High speed disperser) Manufacturing Process of Varnishes can be divided into two parts

1. Weighting of raw materials2. Dispersion using HSD

Weighting of raw materials:

Solvents are weighed on the weighting balance. The fluid volume is about 66 percent of the final batch. Rest of the material is added during mixing taking place in “HSD”


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Dispersion using HSD:

The primary purpose of the “HSD” is to break down dry agglomerates (Resins) into a liquid vehicle thus producing a uniform, stable dispersion with the finest particle size possible. The blade creates a vortex that pull in the contents of the vessel to the blade sharp edges, the blade surface then tear apart solids thereby reducing their size and at the same time dispersing them among liquids. A revolving propeller traces a perfect helix in the fluid. “HSD” batch is started at a fairly low level, or volume, of fluid and no dry product. The fluid volume is 66% of the final batch. The low speed produces a deep vortex that the dry powder ingredients can be added into if we add the entire ingredient vortex will not form. Dry ingredients are added after vortex is formed. After all the ingredients have been added HSD is run at a maximum speed for the time specified in batch paper. HSD is stopped only when resin is completely dissolved.

Types of Varnishes:

Different kinds of varnish are produced by adding different types of resins in it. Resins are responsible of carrying the pigment and binding it to the printing surface. As there are different kind of printing surfaces like plastic and paper, A single resin will not be able to bind the pigment to all printing surface so we add different resins according to the substrate resulting in different kinds of varnishes.

1. Pastes:

Pastes are semi finish form of inks which are processed further to produce different kinds of inks. There are four pastes currently being made

Yellow

Magenta

Cyan

Black


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Manufacturing Process of Pastes:

Manufacturing Process of Pastes can be divided into three parts

1. Weighting of raw material2. Dispersion using HSD3. Grinding using Dyna Mill

Weighting of raw material:

Solvents and varnishes are weighed on the weighting balanc.The fluid volume is about 66 percent of the final batch. Rest of the material is added during mixing taking place in “HSD”

Dispersion using High speed disperser(HSD):

HSD” is used to break down dry agglomerates (Pigmets) into a liquid vehicle thus producing a uniform, stable dispersion with the finest particle size possible. The blade creates a vortex that pull in the contents of the vessel to the blade sharp edges, the blade surface then tear apart solids thereby reducing their size and at the same time dispersing them among liquids. A revolving propeller traces a perfect helix in the fluid.

“HSD” batch is started at a fairly low level, or volume, of fluid and no dry product. The fluid volume is 66% of the final batch. The low speed produces a deep vortex that the dry powder ingredients can be added into if we add the entire ingredient vortex will not form. Dry ingredients are added after vortex is formed. After all the ingredients have been added HSD is run at a maximum speed for the time specified in batch paper. HSD is stopped only when Pigments are completely dissolved and required viscosity is achieved.

Types of Pastes:

Pastes can be divided into different types on the basis of two factors

1. Varnish used in Paste2. Pigments used in Paste


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Varnish used determines the Substrate on which ink can be used and pigment that we will use determines the colour that we will get thus by variation of these two factors we get different kinds of pastes.

Production of ink

Before discussing the Manufacturing process of ink let us first discuss the basis of production of different kinds of inks.

The science of colour

Modern colour printing technologies are based on the Young-Helmholtz theory of three colour vision. Young and Helmholtz observed that although white light is composed of light from a continuous spectrum of wavelengths, humans only perceive three broad bands of this light. These bands are seen as blue, green and red light. Any other colour of light can be created from an appropriate mixture of these three. In particular, red and blue light together produce magenta, blue and green produce cyan and red and green produce yellow. These colours are known as subtractive colours because they are produced by 'subtracting' one of the three primary colours from white light.

When white light hits an object, some of the light is absorbed and the remainder reflected. The colour of the reflected light is the colour that we perceive as the colour of the object, thus a leaf appears green because it absorbs all colours except green. Printing is usually done using four different colours of ink: cyan, magenta, yellow and black. The subtractive colours are chosen because by 'overprinting' these inks, all other colours can be formed. For example, red is produced by overprinting yellow and magenta, as the yellow absorbs the blue light (because yellow is the emission of red and green light) and magenta absorbs the green light, leaving behind pure red light. Black ink is used because although in theory cyan, magenta and yellow should add together to give black, in practice they usually give brown.

Manufacturing Process of ink

Manufacturing Process of ink can be divided into three parts

1. Weighting of raw material


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2. Mixing of raw material

Weighting of raw material:

Pastes of different colors are added into the pot according to the ratio provided in batch paper. These different pastes are selected on the basis of Young and Helmholtz theory which on mixing give us our desired colour.

Mixing of raw material:

Raw materials are mixed together using a mixer. Revolution time is around 10 to 20 minutes which give us our required color of ink.

Post-Production:

After ink is produced two steps are performed

1. Filtration of ink2. Packing of ink

1. Filtration of ink:2. Ink is filtered using a 200 mesh cloth on the filtration machine.

Mesh cloth is vibrated from time to time using a motor which shake the whole frame of filtration machine.

3. Packing of ink: After ink is filtered it is packed in 25 kg cans and delivered to the customer.

4. Posting of batch paper: After a particular batch is produced it bath paper is posted i-e the information of that batch along with the values of the Quality control is entered into the computer system.


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QUALITY CONTROL

To ensure quality of ink every bath that is produced is checked in the lab. Following Test are performed to test the quality of Printing ink.

1. Viscosity Test2. Shade Test3. Nail Test4. Tape Test5. Particle Size Test6. Rubbing Test

Let us discuss them in detail one by one.

1. Viscosity Test:

Viscosity test is used to find the viscosity of sample.

Equipment used: No 2 Zahn Cup Din cup

Zahn Cup (No 2):

It is a stainless steel cup with a tiny hole drilled in the center of the bottom of the cup. There is also a long handle attached to the sides. There are five cup specifications, labeled Zahn cup #x, where x is the number from one through five. Use large number cup sizes when viscosity is high, use low number cup sizes when viscosity is low.

The time taken by ink to completely drain out of the cup is called “efflux time”.

On ink standard specifications, one denotes viscosity in this manner: efflux time, Zahn cup number.

Conversion

One can convert efflux time to kinematic viscosity by using an equation for each cup specification number, where t is the efflux time and ν is the kinematic viscosity in centistokes.


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Zahn Cup #1: ν = 1.1(t - 29)

Zahn Cup #2: ν = 3.5(t - 14)

Zahn Cup #3: ν = 11.7(t - 7.5)

Zahn Cup #4: ν = 14.8(t - 5)

Zahn Cup #5: ν = 23t

IN Berger it is being used to find the viscosities of Gravery based ink.

Din cup:

It is a simple gravity based device that permits the timed flow of liquid from an orifice that is located at the bottom of the cup. It is used for water based ink having low viscosity. In ideal conditions flow rate is equal to that of the kinematic viscosity.

Viscosity Calculations:

To find viscosity of ink, the cup is dipped and completely filled with it. After lifting the cup out of the substance the user measures the time until the liquid streaming out of it breaks up, this is the corresponding "efflux time" which is then converted into viscosities by using above conversion table.

Shade Test:

Shade Test is used to check the shade of the batch with the standard. For this purpose two types of equipment are being used

Print coater Control Coater

Print Coater:


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Print Coater has gravues in it. This equipment is used to match the shade of Gravure ink.

Control Coater:Control Coater is used to match the shade of the flexo based ink

Process:

Two tiny dots one from batch and one from standard are taken. Viscosity of batch is matched to that of the standard before taking shade. Two dots one from ink and other from our standard are taken. A print of ink on the substrate (The surface on which the ink is to be applied) is taken after applying two dots on the machine one from batch produced and other from our standard. These two are then compared if the shade is light more pigments are added in our batch to strengthnize its color. If its sharp more solvent is added.

Nail Test:

Nail Test is used to find the adhesion of the ink to the substrate. After ink has dried we try to starch the ink with the help of nails, if the ink is scratched it means that ink has not properly attached to the surface. We add more resin to the ink to increase its adhesion strength.

Tape Test:

Tape test also used to find the adhesion of the ink to the surface. Sometimes ink passes the Tape test but fail nail test. In Tape test after ink has dried a tape is attached to the substrate and removed with full strength if ink is removed along the surface of the tape it fails the test. We add resin to increase the strength of the ink

Tack Test:

Tack test is used to find the stickness of the ink. In some printing process printing material is rolled in the form of rolls after printing. This Stickness is high ink will join two sheets of rolls together resulting in loss of printing material.


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Rubbing Test:

Rubbing test is performed to check the rub resistance of ink against another ink or surface to check how much ink is removed when two surfaces are rub against one another.

RESEARCH AND DEVELOPMENT

Following activities regarding Research and Development are performed in Research and development department of Berger.

New resin and Pigment are supplied by the supplier along the literature for lab testing.

Resin Testing:

For resin testing a new varnish is produced in attritor. For varnish production, solvent and resin are added in a mixer. Mixer is run until resin is completely mixed.

Following test are performed to check the suitability of Resin for a particular ink.

1. Viscosity2. Tack Test3. Gloss4. Stability5. Physical Appearance

Viscosity Test:Viscosity of manufactured varnish is compared to that of the standard. If the viscosity is high or very low then given resin is rejected because high viscosity means that our shade will show low strength because we will need more solvent addition and low viscosity means that we will have to add more resin resulting in the increase of the manufacturing cost.

Tack Test:Tack test is used to find the stickiness of produced varnish. Tack test is performed manually using fingers to compare it to that of our standard varnish tackiness. If


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tackiness is out of range it is rejected because if tackiness is high it will result in the adhesion of the films and if it is to low it will result in the loss of adhesion for inks.

Gloss Test: Gloss of produced ink is compared to that of our standard if the gloss is less than the standard then the given resin is not rejected but we will need to reduce the quantity of wax.

Stability:Varnish is checked after some days to check if any chemical reactions have taken place or not if chemical reaction has occurred then the resin is rejected.

Physical Appearance:Physical Appearance of produced varnish is checked after some days if varnish has changed colors and has become opaque while it was transparent before than the resin is rejected.

Pigment Testing: Ink or paste is made by using the new pigment in the hymeter. After ink is

produced following test are performed to check the suitability of the pigment.

Shade Test: Shade test is performed as defined to before. Shade is then compared if

shades are same then pigment is passed.


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VEHICLE FURNISHING/STOVING PAINTS

Vehicle Refinishes Division caters to touch-up or

complete repainting of automobiles. For such

types of coatings, conformance with original color

is essential and BERGER's technical experts

ensure this in its laboratories.

BERGER offers three different systems for

refinishes designed to enable application without

heat treatment. These finishes are high glossed,

durable, quick drying and exactly matched with

OEM colors. Along with finishes, ancillaries are

also included in refinishes range such as primer,

putty, all kinds of thinners and COB Lacquer. This

makes BERGER's products a complete repainting

system for vehicles, which is highly demanded

across the nation.


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In production unit of varnishes ; it consists of plain cold mixer and iterators, Z

shape mixers and ball mill.

These varnishes are applied in following sequence during repairing / maintenance

of car.

What is sanding sealer and lacquer??

Sanding sealer ; it is filler In wood

Lacquer ; shiner over surface + water resistant, when car is dented , surface

is coated with putty then sealer and washed , then it is made level with sand paper.

Sand sealer finished surface

Sand sealer finished surface


Lacquer finished surface

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BERGER VR PRODUCTS;

LOW FLASH

1)VITON

Auto speed NC grey putty and primer

016 coarse silver 0045 white

2)NITRO

NC grey putty & primer k-78 VL gold 0045 white

3)DURA

Jet black 8/18 LKA blue 002 black U-26 suzuki white T/C solid Acid catt matt lacq Wood lacq T/C sanding sealer (mark) / NC sanding sealer (industry)

BUXLY PRODUCTS

217 automotive lacq court grey 217 automotive lacq thinner Epoxy , CP, mixing thinner

BERGER THINNER

Bell flushing solvent thinner IMC


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HONDA THINNER

T/C os reducer thinner for T/C white T/C SPM reducer thinner M/C OP reducer thinner T-801 THINNER T A619 725 PK B/P THINNER High gloss for refinishes

TYPES OF LACQ.

Wood lacq Acid catt matt lacq for high quality.

UNIT OPERATIONS;

Ball mill produces N/C grey petty for resin grind which are solid coarse. Z shaped mixer N/C + ball mill gives produces paste grey putty used as

surface filler in denting.


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UNIT # 06


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BERDEX AND INDUSTRIAL CHEMICALSA TOTAL SOLUTION COMPANY

To become the “Complete Solution Provider” for construction challenges in Pakistan, BERDEX Construction Chemicals was established. Berdex construction Chemicals (PVT) Ltd. A joint venture between BERGER PAINTS PAKISTAN Ltd. And DADEX Eternit Limited. Was founded in the year 2000 with the sole purpose to provide a single shop stop for all the construction and infrastructural needs of the customers.The core objective was to become the best “Complete Solution Provider” backed by innovative chemical technology solutions & enhance our resources and skills to meet the ever-changing business environmentDuring this brief span of its operations, Berdex has established itself as a brand known for its quality, products and services. It has also made a landmark achievement of 100% success levels in all its projects. The clientele base of Berdex varies from various well renowned commercial, industrial and government organizations.As BERDEX grew and assumed a major role in the construction chemical industry of Pakistan, the product range of BERDEX also grew accordingly.

BERDEX AND INDUSTRIAL CHEMICALS

What are Industrial Chemicals???

Chemicals developed or manufactured for use in industrial operations or research by industry, government, or academia. These chemicals are not primarily manufactured for the specific purpose of producing human casualties or rendering equipment, facilities, or areas dangerous for human use. Hydrogen cyanide, cyanogen chloride, phosgene, and chloropicrin are industrial chemicals that also can be military chemical agents.

There are number of products produced as per name of berdex, that are basically industrial chemicals. These include moisture absorbent paints, whether resistant, floor coatings, tile fillers and variety of products that produces.

This includes admixture to cement as well as concrete, as concrete require hydrant to carry out reaction, therefore these admixtures are added in cement as per proportion to get a film/coating that does not allow water to step out of it.


http://lahore.olx.com.pk/services-cat-191

http://www.dadex.com.pk/

http://www.berger.com.pk/

http://www.berger.com.pk/

http://www.olx.com.pk/

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CORE FOCUS OF BERDEX PRODUCTS:

BERDEX’s products offer the following1. Admixtures for Concrete:An ingredient of concrete or mortar added to the batch prior to or during mixing. These Admixtures alter the properties of cement / concrete to increase its strength, setting time, water tightness etc. It augments high quality concrete of lower permeability and improves durability. It is non Hazardous and Environmental friendly. Admixtures are usually used in the construction of bridges, large concrete buildings, heavily reinforced structures, pump able concrete / delayed concreting, marine/coastal structures, plants and in large foundations of complexes.Types of AdmixturesChemical Admixtures are,

Accelerators, Retarders Water reducers, Super plasticizers, Integral Water proofing Air entraining admixtures, Anti-washout agents, etc.

2. Protection SystemsAs globalization has assumed the central role and the world has become a global village, ensuring cost effectiveness has become inevitable for any business entity to sustain the cut throat competition prevalent all over. The corrosion control product of BERDEX has been industries’ partner in protective systems for a long time. As the leader in the market in terms of technology, polymer linings, coatings and flooring systems. It has made a significant contribution in reducing costs and assuring a smooth performance with a long operating life of the asset.Some of the unique polymer formulations produced at BERDEX are:

Flake reinforced linings/coatings Monolithic lining and flooring systems Sanitary floor toppings Static-dissipating floors

3. Waterproofing / Surface ImprovementMembranes / coating based water proofing systems are available for protection of water seepage on new and old constructions. Elastic membranes are also available


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that can withstand internal and external water pressure in concrete structures. Cement based coatings take care of water seepage as well as cracking due to extreme temperatures. These provide excellent water resistance, considerable flexibility and elongation of concrete. Ideally suited for new buildings as well as repair of old structures, it ensures, resistance to ultra violet radiation, anti carbonation and chemical resistant coating, thermal insulation and weatherproof protective coating.

Water proofing is used for, Water retaining structures, Terraces, Tunnels, Basements, Water Tanks, Internal / External Plastering, Underground construction, Underpasses, Canals / Concrete Pipelines.

4. Precision GroutsA high quality, properly placed grout is essential to the stability and operating life of heavy machinery. It must maintain precise machine alignment in the face of many destabilizing forces.

BERDEX offers a vast variety of cementation grouts, proven over time and capable of fulfilling the requirements for any sort of installation.It provides a vital link between machinery or structural components and their foundations. They are mainly useful in the protection of the asset from repair, replacement and the ever haunting downtime costs that usually exceed the original outlay on quality installation products.

5. Concrete RepairNeed of repair is inevitable in concrete structures. Causes of concrete deteriorations are physical, chemical, thermal & biological. Solutions offered by BERDEX for concrete related issues include, patching mortars, polymer-modified mortars and concrete, epoxy mortars and concrete, surface sealers, free flowing, non-shrink, helps in rapid installation and gains high strength resistant to acids and alkalis. It is also capable of transmitting high stresses & is capable of withstanding repetitive dynamic loading. It ensures high compression, flexural and tensile strength, Bonds monolithically with base concrete.

6. Flooring SystemsBERDEX develops and applies various flooring solutions that are customizable as per the requirements. They are self balancing epoxy and resin based floorings.It is Ideal for Industrial plants, Pharmaceuticals, Food, Beverage Plants, Automobile workshops, Hospital etc.


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7. Epoxy Floors:Epoxy is one of the most commonly used flooring solutions in industrial concerns. Epoxy flooring is attractive and seamless that leaves no crevices where dirt and bacteria can dwell in, hence hygienic standards are maintained. Epoxy flooring solution is Abrasion resistant, non-tainting, and non-dusting bearing a hard wearing floor finish.

PRODUCT RANGE

BER FLEX

Single component acrylic co-polymer liquid water proofing membrane.

It is single component acrylic polymer based water proof membrane coating having excellent flexibility and water proofing characteristic.

IWP is liquid water proofing admixture which can be used in concrete and cement mortar. It reduces water demand and also improves impermeability of concrete.

BERTEX MORTAR

Multi-component, heavy duty epoxy resin based screed system designed to provide continuous protection and repair solution to concrete floors in medium to heavy duty situations.

BER TOP

Good protection to concrete in light to medium duty situation. Ease to clean chemical resistant floor coating with non-slip finish.

BER HARDFLOOR

Ready to use composition consisting of polymer modified binders and graded quartz, aggregates, formulated for dry shakes on application.Ensure non-metallic abrasion resistant surface to concrete floors by dry shake on system.

BER ACRYL

High grade solvent type, ringle component, methylacrylate based protective coating for concrete, and stucco against environmental pollution.


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It develops a right but controlled expansion beginning at time of placement, resulting in excellent dimensional reliability.

BER SHIELD

Hygienic self leveling epoxy resin flooring for medium duty load conditions.

BER LASTIC

Hydrate type flexible water proofing material based on special synthetic resin dispersion and a blend of selected cements mixed with well graded sand, and high performance polymer.

BER POLYCURE W

Wax based concrete curing compound which when applied on concrete forms a seamless film, and prevent evaporation of water from capillaries of concrete.

BER LATEX SBR

SBR is styrene butadiene rubber copolymer which has been specifically designed for use with cement composition. It is used to form water and vapor resistant bond coating.

BER PROOF WP

Liquid integral water proofing compound for cement mortar and concrete.

BER PLAST

High grade retarding water reducer based on high grade modified naphthalene sulphate, specifically formulated with combination of resin.


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ROAD MAKING AND PAINTS

Product berger cataphos thermoplastic.

Paints for road marking is produced out there, this unit consists of three mixing units. Batch is charged into it, mixing via blade mixers takes place. Each unit have capacity of one ton. Material is discharged, parked and bagged.

METHOD OF APPLICATION OF THERMOPLASTIC: As far as thermoplastic application is concerned , it is charged in a heated metal body , melted to apply over surface and allowed air drying.


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UNIT # 07


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MAINTENANCE ENGINEERING DEPARTMENTIN every industrial state maintenance department or operating department make it possible to deliver smooth and un restricted operation of any machine / process based industry.

Berger contain engineering department that covers following:

Electrical maintenance Mechanical maintenance Civil works

Newly set engineering department is striving to be a permanent part of it, although there are engineers and technical staff available yet they are mostly found in trying to maintain out of order machinery and satisfying operations by deads in out.

Following are some applications that are facilitated by engineering department;

General maintenance Preventive maintenance Breakdown maintenance Over see new projects + keep plant in

running condition

It is found that most of time engineering department is found trying repairing , maintaining what is called routine work, while the basic definition of engineering dictates that it should be a non routine work to do so. There are no of aspects in plant that can be managed if, produce wonders, by maintenance department, resin HEATERS are an open examples for it.


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UNIT # 08


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PRODUCTION DEPARTMENT

Production department comprises of following division

OIL BASEDCHARGING SECTION; to feed charge it is required that pigment should have a specified size range so that it may not lost its characteristics, to do so , no of size reduction mills are available including;

Sand mill Ball size 2.5mmBucket mill Ball size 6mmiterators Ball size 10-12mm


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For oil based production unit, binder hold tanks are installed, so it is pumped directly into overhead tank 3 in no from where it can be poured into mills by

gravity through pumping system. Since powdery material is involved , so proper duct emission system is installed in both water and oil based sections.

In tank area iterated feed is distribute into no of mixers where as per formulation mixing is carried out , QC and color matching and charge is blended until desire is achieved. It is by gravity withdrawn from base , packed, bagged, and dispatched.

WATER BASE SECTIONFor water based production in charging area since only powder from ingredients are added , along with water , so for melting mixing HSDz , iterators and wall putty is used. Since material charged Is added with water as a result thick slurry is obtained , that is directly used into mixing tank, and for color matching purpose strainers are added in liquid form added in mixing tank in tank area while pigments in powder form is added from charging section.

WALL PUTTYAs far as mixing operation is concerned in chemical engineering , where it is asserted that for perfect mixing , mixer should operate in tank along diameter in all dimensions, so that dead areas may not form. Wall putty contains a mixer centralized that can change angle of orientation, also a thresher to remove sticky viscous material that may stick along wal, with different RPMz . Jansoline wall putty is made from it and used for weather resistant coating and long life exterior , reliable coating.


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UNIT # 09


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AUTOMOBILE PRODUCTION

There are no of classifications that can be made to describe this class.

Two wheeler application Four wheeler application

For all the automobile paints need stoving as to melt paint and create a film over newly made metal automobile.

What unit conatins???

Zentch mill (ball mill)

Sand mill

itertors

HSD ( not size reducer , only mixer)


Zentch mill(Ball mill)

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AREA DIVISION;

Mixing area;

Cold mixing plain operation to convert semi finish product to finished, color matching and properties are adjusted by adding stainer, while pigment in powder form is charged already while forming base in chagrining area. In mixing section where stainer is added , only shade is provided.

Packing area;

In auto production unit, there is no as such division , packing section contains some mills that are directly packed in same floor, separate units for pretreatment and road marking in auto is established.

Humidifcation and temperature control;

Auto section deals with high flammable and fire catching volatile vaporos chemicals. So if humidity and temperature is not maintained, there are sure chances of catching fire, here minimum limit of humidity (relative) is 65%, while a regular cycle process (humidifier) is located that keep air in circulation and removes volatiled air and replaced with fresh air.


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PRODUCTION OF ROAD MARKING CHEMICALS(LIQUID)

It is necessary to mention the difference between road marking producted here while that produced in industrial chemical production unit.

Road marking produced here is in liquid form and can be applied over foot paths, road pavements , etc while that produce in berdex is in powder form , that is applied by melting powder , and film is applied over flat surface. As far as inclined or tall surface is concerned , it is impossible to apply this melt , using melt heater machine over there, so liquid road marking is produced over in automobile production unit as well.

COMPARISON


Road marking (liquid based) thermo plastic melting over surface

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PRE-TREATMENT

Chemicals produced are made dust , rust ,and oil free before primer / under coat is applied.

Zinc phosphate , chemical produces used for bonding paint and surface.

Process calligraphy is as follow;

Degreasing rinsing water derusting water phosphating

rinsing

passivation (solution to maintain phosphating)

acid value control (reduces if high/ increase if low)

INDUSTRIAL RANGE OF AUTOMOBILE PRODUCTION UNIT

tower coating (EPOXY) heat resistant , kiln heat insulation coat etc. boiler paint road marking pipe surface coat (gas line) pipe internal coat (lining) fan industry


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CONCLUSIONSIt was a good experience spending 28 days in berger. Being a chemical engineer, it’s a new tactic to stay in a process where batch process is carried out. In engineering courses it is steady continuous process that is considered, therefore this experience definitely provide a newer mind set.

As far as improvement is concerned , YES there is always a need of improvement, some of which are explained as before, and I hope that if they can be rectified definitely improves standard of BERGER and a step a head toward energy conservation, as mentioned below along few others;

Most of the instrumentation was found dying; temperature gauge of stack emission tower, pressure gauges and temperature gauges inside oil based resin plant was found dead, make it difficult to record temperature and pressure reading to carry out energy audit of plant.

In this time of energy crisis , world is facing a real hawk of energy, but oil based resin plant play a game show of energy wastage.

Cooled water that is used to cool kettles reactor containing internal jackets coil release cooling media in form of steam mean at temperature nearby 100-110 0C. it is found that this stream from kettle is directly wasted.

HOW TO UTILIZE THIS ENERGY ; IT DEMANDS A FEWER CHANGES IN EXISTING PLANT AND CAN BE FURNISHED IF DESIRED.

Stack tower was found releasing flue gases at temperature about 100 0C. If it is paid attention this energy can be made useful, and plays an important role in reducing the energy consumptions of plant.

Since plant contains burners running on natural gas; and heating thermal oil as heating media. Its found that valves joining headers that contains rubber gas kits, but thermal oil from burner is almost at 280 0C causing rubber made gaskits to melt and produce slippage and loss in strength of thermal oil, since highly flammable chemicals producing dense volatile vapors are observed around, that are waiting for flash of fire. So it is advised to immediately take action in rectifying the risk of catching fire and setting life of workers to high risk.

In resins water based section packing of berlith glue is carried out using pneumatic machine, and it is found that machine was causing mis weight age. Its filling section was injection random weight jet of glue in pouch and remarkable difference in weight of bag pouch was observed, that should be rectified to maintain standards of BERGER.


Internship Report 2010

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