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A
SUMMER TRANING PROJECT REPORT
ON
“AUTOMOBILE PAINTS MANUFACTURING”
AT
KANSAI NEROLAC PAINTS LTD.
AT
BAWAL
Submitted to: Submitted by:
Mr. Ashok Singh Yatin Khandelwal
B.Tech 7th sem. 2
Acknowledgement
It is my pleasure to be indebted to various people, who directly or indirectly contributed in development of this work and who influenced my thinking, behavior and acts during the course of study.
I express my sincere gratitude to Mr. Ganesh Harbola worthy Principal to providing me an opportunity to under go summer training at Kansai Nerolac Paints Ltd. at Bawal.
I am thankful to Mr. Ashok Kr. Gupta for his support, cooperation, and motivation provided to me during the training for constant inspiration, presence and blessings.
I also extend my sincere appreciation to Mr. Narendra Kr. Garg who provided his valuable suggestion and precious time in accomplishing my project report.
Lastly I would like to thank the almighty and my parents for their moral support and my friends with whom I shared my day-to-day experience and receive lot of suggestions that improve my quality of work.
Yatin Khandelwal 3
Declaration
I, Yatin Khandelwal student of B.Tech ,6th Semester, Chemical Branch, studying at Jaipur National University, Jaipur, Rajasthan, hereby declare that the summer training report on “Automobile Paints Manufacturing” submitted to Jaipur Nation University, Jaipur, Rajasthan in partial fulfillment of Degree of Bachelor of Technology in Chemical Branch is the original work conducted by me.
The information and data given in the report is authentic to the best of my knowledge.
This summer training report is not being submitted to any other University for award of any Degree and Fellowship.
Yatin Khandelwal
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Content
Topic Names Page No.
1. About Kansai Nerolac Paints 5
2. Introduction of Automobile Paints 5
3. Products in Automotive Coating 6
3. Strategic Partnership 9
4. Key Customers 9
5. Colour Research & Development 9
6. Introduction of Paints 10
7. Main Ingredients of Paints 10
8. Types of Resins 11
9. Paints Processing Flow Diagram 13
10. Process Description 14
11. Quality Control 16
12. Defects of Paints 17-22
13. Conclusion 23 5
About Kansai Nerolac Paints:
Kansai Nerolac has been a cherished name in millions of households across the length and breadth of India. The company manufactures a diversified range of products for every surface. It is the second largest coating company in India and the market leader in automotive and powder coating. Nerolac paints as it is known popularly is an established brand in decorative paints.
Introduction of Automotive Paints:
Kansai Nerolac is the Market Leader in the automotive coating segment in India with a dominant market share with global technology acquired from Kansai Paint Co. Ltd, Japan. Kansai Nerolac offers the latest technology in automotive painting systems to the Indian automotive industry. In Automotive Coatings, Kansai Paints is one of the top five manufacturers in the world and is having a dominant market share in Asia Pacific in Automotive Coatings. In Japan, it is the largest Automotive Paint Company.
AUTOMOTIVE PAINTS segment has undergone a metamorphosis in past 3 decades in India. The paint technology for automobiles has undergone a complete transformation. Kansai Nerolac is proud to be associated with this path breaking change when it forged a technical collaboration with Kansai Paint Co. Japan by introducing contemporary paint technology for Maruti. Kansai Nerolac been in forefront to introduce new technologies in automotive sector in India from time to time be it Cathodic Electrocoats, TSA/Polyester based top coats, Mar Resistant Clear Coats, 3 Wet Coatings technology, Acrylic CED etc.
Through its various strategic collaborations, Kansai Nerolac offers a total painting system to auto makers in India with a range of products, starting from Pretreatment Chemicals, Electro Deposition Primers, Intermediate Coats/primer Surfacers, Solid & Metallic Top Coats, Clear Coats & Touch-up Paints. The products are approved by most Global Auto Majors.
Kansai Nerolac has a strong customer focus, one of the key factors behind our success. Working closely with our Customers, we jointly develop Products & Processes with focus on cost improvement, better productivity and energy savings.
Kansai Nerolac has strong reputation for innovation, Superior Technology, Value Engineering, Quality and Service. More than 85 Technical Service Team members are located at customer sites to support application processes, controlling the process parameters and jointly participate in improvement and optimization plans with customers.
Kansai Nerolac is the largest supplier of CED Coatings in India- catering over 75% of requirements in India. 6
Products in Automotive Coating:
Kansai Nerolac offers a very comprehensive product range, technical support & service to cater to the specific needs of Auto OEMs & Components Suppliers keeping in mind the latest global trends.
SOC (Substances Of Concern) FREE AUTOMOTIVE PRODUCTS
Kansai Nerolac has pioneered the activity in India to remove SOCs from its automotive coatings to meet stringent environmental standards of global automotive customers.
A list of products is as under, though it is not exhaustive as we keep on developing newer products to meet customer requirements.
Pretreatment (PT) chemicals:
All automotive metallic surfaces need to be cleaned before the painting process.
Kansai Nerolac along with its collaborator Nihon Parkerizing Co., Japan offers Pretreatment Chemicals for cleaning various substrates and prepares these surfaces for improved Paint bonding & corrosion resistance. Pre treatment chemicals play a significant role in corrosion management along with E-coat and subsequent Primers. Zinc Phosphate Conversion Coating is widely used process in Automotive Industry.
Product Range
The product range consists of High & Low Temperature Degreasing Chemicals, De-rusting Chemicals, Di-cationic and Tri- cationic Phosphate Chemicals, Activation & Passivation Chemicals, Surface Conditioners & Pre Treatment Chemicals for Plastics.
Through its JV – Nipa Chemicals Ltd., Kansai Nerolac services all Pre- treatment requirements of Automotive Industry, Powder Coating Plants, Auto Ancillaries & General Industries segments with excellent line service & analytical support.
Electrodeposition (ED) Technology:
In E-Coat the metal substrate is immersed in an aqueous bath solution & coated with a charged organic primer under the influence of electric field.
The distinct Advantages of E-Coat are- Uniform coverage without pinholes or other surface defect leading to less paint consumption; Better edge protection resulting in Corrosion Resistance ; Coating / access to recessed areas like Box-sections etc. It is a single coat Environment friendly Water-based coating system. The E-Coat process is a fully automated process leading to less manpower requirement and cost effective process with possibility of a high paint recovery ratio (up to 99.5% with Ultra Filtrate & Reverse Osmosis system). 7
Product Range
In CED, our product range consists of lead free Polybutadine Based Anodic Electro- deposition Primer (AED); Epoxy Resin Based Cathodic Electro-deposition Primer (CED) & Acrylic Resin Based Cathodic Electro-deposition Primer (ACED). The product ACED won an Innovation award for being first in the world for usage of a single coat application system for coating of Motorcycle frames.
Our CED is heavy metals free and meets the stringent environmental norms of Automotive Industry.
Intermediate Coats / Primer Surfacers:
The Primer Surfacer is the second functional layer and it acts as an intermediate coat between E-coat and the topcoats. It also provides excellent stone chip protection and protection against UV rays to the E-coat film. The Intermediate Coats are available in White, Light Grey, Dark Grey, Red, Blue and other specific colours as required by OE manufacturers. Water borne Dipping Primers are also developed with an eye on safer environment.
Kansai Nerolac also manufactures special Intermediate coats such as Anti Chip Primers and Non Sanding Primers and Wet on Wet Primers etc.
Top Coats:
Top Coats provide Colour, aesthetics and weather protection to the coating system in Automotives. Kansai Nerolac manufactures a large variety of Top Coats based on various resin backbones designed as per specific technical specifications of customers. Containing an extensive range of colored pigments and effect pigments, it plays a significant role in establishing the visual image. A general distinction can be drawn between a solid-color and a metallic paint finish in this segment. Various types of Metallic & Mica finishes are available.
New technologies in Top coats such as 3 Wet Coating Systems are available which are being adopted by various automotive customers to improve productivity, reduction in costs and meeting the environmental norms.
Clear Coats:
The Clear coat is the top layer in a Paint System which provides resistance to sunlight and weather and also to Chemicals and biological materials such as bird droppings. It helps provide a scratch resistant final coat to the coating system. Kansai Nerolac offers Clear Coats of various functionalities such as scratch resistance, acid & alkali resistance, UV resistance, mar resistance etc.
Touch up Paints & Auto Refinishing Products: 8
Kansai Nerolac manufactures various types of Touch Paints which are used to undertake small touch ups if the paint film is damaged. Kansai Nerolac offers a complete range of Auto Refinish product range to service requirements of Body Shops for repair coatings.
Heat Resistant Paints:
Kansai Nerolac manufactures specialty paints such as heat resistant paints, both for interior & exterior surfaces of motorcycle mufflers. These are made to withstand high temperature conditions up to 600 degree C.
Underbody Paints & PVC Sealants:
Kansai Nerolac manufactures Bitumen & PVC type Underbody Compounds for application on underbody surfaces of automotive bodies to impart anti chipping & sound deadening properties.
Rapgard Transit Protection Films:
Kansai Nerolac supplies Rapgard Transit Protection Films which are used for protection of automotive vehicles during transit from dust, chemicals, bird droppings and damages to the paint film. Films are available for protection of metal & plastics surfaces.
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Strategic Partnerships:
Kansai Nerolac has tie-up with the global players for product range offered to automotive and industrial customers. Kansai Nerolac has entered into collaboration with the following players for specific product range:
Company Product Category ED Primers, Automotive & Industrial Coatings, Kansai Paint Co., Japan Auto –Refinishing System Nihon Parkerizing Co., Pre-Treatment Chemicals ( JV- NIPA CHEMICALS LTD, Japan Chennai) Oshima Kogyo, Japan Heat Resisting Paints
Key Customers:
Kansai Nerolac is market Leader in Automotive Industry in India. Some of our main customers are:
Maruti Suzuki, Toyota Kirloskar, Honda Siel, General Motors, Tata Motors, Mahindra & Mahindra, Renault, Fiat, Hindustan Motors (Mitsubishi), Renault Nissan, Hero Honda, Yamaha, TVS Motors, Bajaj Auto, Honda Motorcycle & Scooters, Suzuki Motorcycle , Volvo India, Ashok Leyland, TAFE, Eicher Motors, TACO, Motherson Auto, Visteon, Wheels India etc. The list is long & growing. The Largest costumer of Nerolac is Maruti Suzuki is 80%.
Colour Research & Development:
Kansai Nerolac has a well equipped Colour R&D centre at Lower Parel, Mumbai which is backed by Kansai Paint Co., Japan to service ever expanding need of OEM industry for newer shades & finishes. The Colour Development Cell of Kansai Nerolac organizes Colour Presentations at customers’ locations to give wide choice of colour introductions and follows it through a rigorous activity from development to standardization.
There is a regular activity to liaise with automotive customers’ Styling & Marketing departments to continuously work for introduction of new shades for new models and refresh existing models as per need of the market.
Colour Development Cell also collects data on Indian and global Colour Trends. 10
Introduction to Paints:
Paint is homogeneous mixer of Pigment, resin, solvent & additives. .
The functions of paint are “Protection” and “Beautification” of object.
Paint manufacturing process comprises of 4 categories.
1. Solid Paint
2. Metallic Paint
3. Lacquer
4. Thinners
Main Ingredients of Paints:
The main Ingrediants of paint are:
1. Pigment: These are insoluble solids that provide opacity and color. They can also provide improved surface adhesion, weather resistance, and corrosion resistance
2. Solvent or Volatile Material: This is a grouping of all other minor quantity but major role ingredients, such as dispersing agents , antioxidants, dryers, flow agents, anti-sagging agent, anti popping etc.
3. Resin or Binders: This is the polymerised viscous material that holds the pigments together, bonding them to the surface. Paints are often classified by the type of binder they contain, for example an Alkyd, Polyester, Acrylic & M.F.
4. Additives: This is a grouping of all other minor quantity but major role ingredients, such as antioxidants, dryers, flow agents, anti-sagging agent, anti popping etc.