Macro Polymer

TRAINING REPORT ON MACRO POLYMER PLANTAT G.V.M.M, ODHAV, AHMEDABAD BY RONAK A. SHAH B.E CHEMICAL LUKHDHIRJI ENGINEERING COLLEGE, MORBI, GUJARAT. Acknowledgement It gives me great pleasure to submit this in plant training report on completion of my industrial training during 6.06.2011 to 24.06.2011 at the MACRO POLYMER PLANT, ODHAV G.V.M.M, AHEMEDABAD. It was a great experience for me at this esteemed organization, which I will cherish forever. I express my sincere thanks to Mr. Mayank Parikh[DIRECTOR] for giving me the opportunity to pursue my industrial training at the MACRO POLYMER PLANT. I am highly indebted to Mr. Pankaj Parmar[MANAGER] for guiding me throughout my training report. I’d also like to express my gratitude to all the staff of MACRO POLYMER PLANT for their support and cooperation. Thank you all once again. RONAK A. SHAH B.E. CHEMICAL L.E. COLLEGE, MORBI INDEX SER NO 1 2 3 4 5 6 7 8 TOPIC NAME INTRODUCTION OVERVIEW HIGHLIGHTS DETAIL DESCRIPTION APPLICATION FORMULATION TYPES OF PAINTS OTHER PRODUCTS PAGE NO and now we are achieving 15. The credit of the company’s rapid progress is largely attributed to the most valued customers for patronizing the products of the company. hard work done by all the employees and an unprecedented support extended by all the stack holders and well wishers. The company is built on a foundation of technocrats who have experience of five decades in the manufacture of Synthetic Resin for Paints.INTRODUCTION We MACRO POLYMERS is a private limited & an ISO 9001:2008 certified company located at ODHAV & MORAIYA at Gujarat in Western India. Shirish Parikh started factory in 1962. Our Chairman Mr.000 tones per annum. Printing Inks and Adhesive Industries. Currently we are one of the leading manufacturer of resins in India and . In 1995 we turned into Private Limited Company. Since the inception of the company in 1995 with an installed capacity of just 500 tones per year. The norms of Quality Assurance Department are being strictly followed. without any compromise and deviation from the standards. We can provide performance guarantee for the material supplied by us. processing parameters and specification of the finished goods testing in detail. We laid down stringent specification and procedures for the purchase of raw materials. stringent control of processing parameters. Asian and south east Asian Countries. We have manufacturing capacity so as to give full container load with one single batch. . its analytical testing and approval before consumption. intermediate quality monitoring and approval of the finished products before dispatch. We are known for our consistent quality and uninterrupted supply position. Africa. This assurance begins from the purchase of the raw materials. We are committed to deliver customers consistent quality products and an assurance of the quality for the entire range of the products.exporting to Middle East. Maleic Modified Rosin Ester..OVERVIEW Manufacturer of Alkyd Resins. We Macro Polymers is a private limited & an ISO 9001:2000 certified company located at Odhav &Moraiya at Gujarat in Western India. Butylated Melamine Formaldehyde Resin. Epoxy Resin. Printing Inks and Adhesive Industries. Acrylic Resins. Butylated Urea Formaldehyde Resins.. . The company is built on a foundation of technocrates who have experience of five decades in the manufacturer of Synthetic Resin for Paint. Epoxy Hardner & Ketone Resin. Research & Development Centre We have good facilities to develop and standardize resin and varnishes to suit customer’s requirements and specifications. Our R&D Centre is recognized by Department of Scientific & Industrial Technology.S. Shirish M. Government of India. . Parikh is a qualified Chemical Engineer from UDCT Bombay University and has master degree in Chemical Engineering from U.A. Ministry of Science & Technology. Our Chairman Mr. D. Our Chairman has worked in Production and in research & development facilities abroad and in India in renowned paint and synthetic resins manufacturing companies. Mayank S. Parikh is also a Chemical Engineer from L.Our Director Mr. . Engineering College of Engineering Ahmedabad. alkyd air drying paint Alkyd air drying paint Nitrocellulose lacquer.HIGHLIGHTS Product:   Butylated MF Resin Butylated UF Resin Production of UF Resin: Production of MF Resin: Applications:         PU Automotive Paint and Automotive Refinishing Paint Paint for specific use Wood coating Amino-alkyd baking coating. polyurethane paint Alkyd for polyurethane paint Polyester Resin for coil coating . Formulations:     Air Drying Paint NC Paints Stoving Paint Wood Coating Types of Paints:        Stoving enamel/varnish Air Drying enamel/varnish NC lacquer/Sanding sealer/paint Stoving finishes Air Drying finishes Melamine wood finishes PU wood finishes Polyurathane (PU) finishes  . DETAIL DESCRIPTION PRODUCTION OF UREA FORMALDEHYDE RESIN: Structure: Properties: Urea-formaldehyde resin's attributes include high tensile strength. elongation at break. high surface hardness. and volume resistance. low water absorption. flexural modulus and heat distortion temperature. . mould shrinkage. Chemical structure: The chemical structure of UF resins can be described as polymethylene. These are grouped by their average molar mass and the content of different functional groups. Changing synthesis conditions of the resins give good designing possibilities for the structure and resin properties. Raw material:       Butanol Formaline Urea Seperat solution [Toluene] Tri Ethanol Amine [T.A] Recover Butanol [RCB] Process description:  In this manufacturing process.  This vessel should be rounded at the bottom. add butanol and formaline in the close vessel for agitation. is directly to the shaft. which is supported from above.  After addition of material add 10%of caustic solution and set pH. This description leaves the details of the structure undetermined which can vary linearly and branched.  pH should always be an equal to 6.  The shaft is driven by motor. .E.  An impeller is mounted on an overhung shaft.  We can get this water as a byproduct which as a steam is condenced in the vertical condenser and separate in the separator.  At that time temperature will be increase. addition of 940 ltr. add formic acid and if it is less than. add catalyst. butanol.  Addition of RCB is connected to the removal of water. we can get two by product water and RCB.  After completion of this again start to heating and wait for getting reflux. If it is greater than. oxalic acid.  We can get this temperature then close heating and under stirring this mixture up to 90 min but do not change of temperature. When the temperature of vessel will reach to 70°C-80°C .  Approx. recover butanol and also catalyst. Types:    UF-8 UF-8LFF UF-8NFF . RCB. then add toluene.  This solution is completely miscible then add urea and start to heat this vessel from the boiler.  Catalyst is the mixture of phthalic powder.  We can get reflux after 30-45min. add 10% caustic and set pH.  Here toluene is used as a seperat solution.  After that. the product goes through the packing by filtration.  Heating is started in the vessel.  In all this process. Urea Formaldehyde Resin: Ser Product no Code Type Solvent % Non Viscosity Acid Mineral Volatiles in poises Value Spirit (±2) at 25* C KOH/gm Tolerance ml/10gm resin 60 10-20 P 3 10-20 1 UF-8 Butylated Butanol UF Notes : Very fast. . RPM-20 3Max Notes : To be used for wood coating in acid cure application partially no free formaldehyde.5% max. 3 UF-8 NFF Butylated Butanol 60 UF Brook Field RVT/S-3. 2 UF-8 LFF Butylated Butanol 60 UF 10-20 P 3 30-50 Notes : Low Free Formaldehyde content (0. low odor.) used for acid curing wood coatings. low temperature acid curing screen and wood lacquers. PRODUCTION OF MELAMINE FORMALDEHYDE RESIN: Structure: Raw Material:       Butenol Formeline Methanol Toluene Urea RCB .  Then set the viscosity at 10 poise.  Take reading at 1hr interval and taking reading from reflux for 15hr check tolerance by using o-xylene and MTO. start heating.  After getting 70°C temp. TYPES:    MF-268 MF-970 MF-910 .  After pH value is set add melamine and urea.  After 90 min.Process description:  In this manufacturing process.  Lastly pack the product by filtration process.  When water came out then add RCB and catalyst.  Again check the pH value and if it is less than 7 then again add 10% costic and if it is more than 7 then add formic acid.  Then by stirring process add 10% costic and set pH value 7 and add methanol. at about 96°C-97°C we will get reflux. stop heating and keep it under stirring for 90 min.  After 30 min.  Then close the vessel and give heat till 70°C. add butenol and catalyst in the close vessel for mixing and also add formeline.  After getting reflux add RCB. . Useful for MTO based finishes and anti wrinkling agent for Rosinated alkyd based stoving finishes. 2 MF-970 Butylated Butanol MF 68 8-12 3 Infinite Notes : Wide compatibility. low temperature curing flexible lacquers for metalized plastic articles.5 30-50 Notes : Highly efficient.5 30-50 1 MF-268 Butylated Butanol MF Notes : High gloss stoving enamels with alkyds. fast curing colour retentive stoving enamels resistant to overbaking.Melamine formaldehyde resin: Ser Product Type Code no Solvent % Non Viscosity Acid Mineral Volatiles in poises Value Spirit (±2) at 30* C KOH/gm Tolerance resin 60 10-15 2. 3 MF-910 Butylated Butanol MF 60 10-15 2. epoxy and acrylic systems. PU Automotive Paint and Automotoive Refinishing Paint  Polyester Resin  Acrylic polyol  Thermoplastic Acrylic 2.Application 1. solid varnishes Aluminium paint for motor of agricultural automobile Heat resistant paint Paint for aluminium single pack system Glazing for paper Special Resin for hammer tone coating Special Resin for traffic paint Special Resin for leather coating F class insulating varnish Fast drying electrical insulation General use electrical insulation Coil coating application Water clear stoving varnish Glass sleeve coating Resin Auto refinishing chain stopped air drying paint Machinery paints for faster and better drying Machinery parts touchup or fast drying paint which dries as fast as stoving paints . Paint for specific use                     Anticorrosion for container Electroplating article Resin for dipping and air drying for long/large article Glass painting. Alkyd air drying paint  Air drying paint  Air drying modified paint 6. quick drying baking coating Wet on wet coatings application 5.3. alkyd air drying paint        Automotive finish Miscellaneous car and high grade industrial baking coating Universal type Solid finishing cost Hammer tone paint Low temp. Nitrocellulose lacquer. polyurethane paint  Resin for grind  Nitrocellulose coloured paint  Leather varnish . Amino-alkyd baking coating. Wood coating        One component patty/sealer Alkyd Resin for melamine finish UF Resin for melamine wood finishes Resin for clear or matte paints Resin for PU bright finish Resin for nitrocellulose lacquer Polyester Resin for lamination coating 4. 7.1030 excellent yellowing resistance 8.4035 excellent leveling and weathering resistance  C .1032 economy. Polyester Resin for coil coating  P-11  UF-8 . Alkyd for polyurethane paint  C . universally  F . Stoving enamels for steel furniture Varnish resistant to boiling alkalis . Air Drying Paint      White decorative enamel for interior & exterior use Tinted decorative enamel Yellow decorative enamel for interior use Knifing paste filler Air drying varnish 2. Stoving Paint               Silver gray automotive baking finish White stoving enamel for hot spraying Blue automotive stoving enamel Stoving primer White stoving primer Gray stoving primer Polyurethane spraying sealer Black spraying enamel for tracks & bases General purpose white stoving enamel Polishing lacquer for furniture White stoving enamel (poor shelf life) White stoving enamel for boilers. electrical heaters.Formulations 1. NC Paints     Nitrocellulose primer Nitrocellulose lacquer General purpose white stoving enamel Polishing lacquer for furniture Polishing lacquer for furniture  3. 4. Air drying enamel/varnish            TPA-2001M HV TPA-2001 S-5060 (IPA) STRY-25 Acry-30 ACRY-25 F-4035 L-6060 S-5060 L-6050 R S-5050 . Stoving enamel/varnish          TSA-1001 C-1052 (IPA+TMP) D-2040 HV D-2040L C-1032 C-1030 MF-970 MF-268 UF-8 2. Wood coating   General purpose white stoving enamel Polishing lacquer for furniture Types of paints 1. Stoving finishes            TSA-1001 C-1032 (IPA+TMP) C-1052 (IPA+TMP) C-1030 D-2040L D-2040 HV MF-268 MF-910 C-1032 D-2040M UF-8 .     D-2060 F-4043 F-4038 D-2050 R D-2050 3. NC lacquer/sanding sealer/paint        TPA-2001 CA-3045 CA-3035 D-2040L D-2040M C-1032 C-1030 4. Melamine wood finish      C-1030 C-1032 S-5030 UF-8 UF-8LFF 7.5. Air drying finished                 TPA-2001 TPA-2001 M HV ACRY-25 Acry-30 STRY-25 S-5060 (IPA) D-2050 D-2050 R D-2060 S-5050 L-6050 R S-5060 L-6060 F-4035 F-4038 F-4043 6. PU wood finish  TSA-1003 8. Polyurethane (PU) finishes  TSA-1003  Polyol-32  Polyol-280 . 2 MR Penta Maleic modified solid rosin Penta ester 25 100 Notes : MTO Compatible used with Long / medium Alkyd .OTHER PRODUCTS Maleic Modified Rosin Ester Serno Product Code Type % Solid Acid value Capillary Melting KOH/gm point in deg. C 25 100-110 1 MR Gly Maleic modified solid rosin glycerine ester Notes : NC compatible hence used in NC formulation. Not compatible with MTO. 2 C-1031 Saturated Fatty Acid type Non oxidising short oil length 70 Xylene 5-15 175-225 seconds in FC4 1 Notes : White baking enamels and 2k as plasticizer for NC lacquers and for Acid Curing / Wood Coating. household appliances and printing inks. Residual hydroxyl of DCO usefull as co-reactant in polyurethane finishes. water filter and hospital appliances and as plasticizer for NC lacquers wood coating. Very useful for cold catalysed lacquers with UF Resin used in textile printing screen. .Alkyd Resins Serno Product Code Oil Type & Length % Solvent Acid Value Viscosity in Solid KOH/gm seconds at (±2) 30 C in FC4* Saturated Fatty Acid type Non oxidising short oil length 70 Xylene 5-15 225-300 seconds in FC4 Colour on Gardner Scale 50% solution of resin(max) 1 1 C-1030 Notes : Non yellowing white baking enamels and 2k as plasticizer for NC lacquers and for Acid Curing / Wood Coating. 3 C-1032 Coconut oil Acid 70 Non oxidising short oil length Xylene 5-15 225-300 seconds in FC4 2 Notes : White baking enamels for refrigerators. 4 D-2040M Dehydrated Castor 70 oil. type semi oxidising short oil Xylene 5-15 80 – 100 Sec 8 Notes : Fast drying general purpose baking enamels for industrial equipments. machineries. washing machines. ball pen inks and in casting resins. . nail lacquers Etc. printing inks for paper. In surface coatings.Epoxy Resin Serno Product Type Code % Solvent Colour Viscosity Epoxide Epoxide Solid Gardner poises at Value Equivelant (±2) 25*C Xylene 2 65-100 as 3 is 450-500 1 Epoxy450 Bisphenol 75 Epoxy Resin Characteristics : For Two pack Epoxy Paints. Ketone Resin Serno Product % Hydroxyl Code Solid value KOH/gm 1 KF-10 100 250 Min Melting Point Capillary 85-105 Viscosity Solubility at 30*C Compitibility 35-50 in 60% Toluene Alchols ester ketones & glycol ethers cholrinated hydrocarbons Ester & alchol soluble Nitrocellulose short oil alkyds aminos phenolics polyurethanes PVB resins natural & synthetic rubber & commonly used plasticizer Notes : For all types of NC lacquers. plastisols. it improves gloss & adhesion. 3 SP-140 Polyamide Resin 100 Solvent Less 10 such in Brook Field LVT/S-4.Polyamide Hardner Serno Product Code 1 SP-115 Type % Solvent Solid 100 Solvent Less Colour Gardner 10 Viscosity poises at 25*C Amine Value Polyamide Resin as such in Brook Field LVT/S-4. RPM-6 at 25’C: 130-170 Poise 350-400 Characteristics : Floor Coating for Construction and Solvent Less Coatings. Good chemical resistance for faster curing. . 2 SP-125 Polyamide Resin 100 Solvent Less 10 as such in Brook Field LVT/S-4. 4 SP-160 Polyamide Resin 100 Solvent Less 10 as such in Brook Field LVT/S-4. 210-230 RPM-6 at 40’C: 450-650 Poise Characteristics : Hardner for Epoxy. 2290-320 RPM-6 at 25’C: 400-550 Poise Characteristics : Coating for Paint and Adhesive. 350-400 RPM-6 at 25’C: 3-6 Poise Characteristics : Floor Coating for Construction and Solvent Less Coatings. C 100-110 Notes : Paints.Phenolic Resin Serno Product Code 1 P-260 Colour on gardner scale 50% Solution of Resin: 12Max % Solid 100 Acid value 25 Capillary Melting point in deg. Printing Inks. Printing Inks. Insulating Varnishes. Insulating Varnishes. 4 P-263 50% Solution of Resin: 12Max 100 25 150-160 Notes : Paints. . Printing Inks. oil Varnishes etc. oil Varnishes etc. 2 P-261 50% Solution of Resin: 13Max 100 25 135-145 Notes : Lithographic and Gravure Printing Inks 3 P-262 50% Solution of Resin: 12Max 100 20 (Ball & Ring) 125-135 Notes : Paints. Insulating Varnishes. oil Varnishes etc. RPM-12 at 25’C . 2 Butoxy ethanol Mix Xylene 10 90 – 110 Sec in FC4 Cup at 30'C 3 3 P-12 60 10 75 – 95 Sec in FC4 Cup at 3 30'C 4 P-13 65-70 Styrene 22 5 – 8 Poise as such in BF 7 RVT/S-3.Poluester Resin Serno Product Code 1 P-10 Solid (+ Solvent 2%) 55 Styrene Acid value mgKOH/gm 15 Viscosity Colour on Gardner Scale 1 25-35 Sec in FC4 Cup at 25'C 2 P-11 65 3.4:1 CIX.