1 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 4 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