1

IN -Plant Training project Report on

Development of 2K PU Clear-Coat
And
Cycle time Reduction of epoxy primer batch by reducing grinding time

A TRAINING REPORT SUBMITTED TO

KAVAYATRI BAHINABAI CHAUDHARI NORTH MAHARASHTRA
UNIVERSITY, JALGAON

FOR THE DEGREE OF

BACHELORS OF TECHNOLOGY
(PAINT TECHNOLOGY)

SUBMITED BY
RITTIKA N SHRISATH
Under The Guidance of

Dr. R.G. PURI Mr. Brijesh Mishra

Head of Department Of Paint Technology, Manager (Refinish Technology),
University Institute of Chemical Technology, PPG Asian Paints,
KBCNMU, Jalgaon. Navi Mumbai.

UNIVERSITY INSTITUTE OF CHEMICAL TECHNOLOGY

KAVAYATRI BAHINABAI CHAUDHARI NORTH
MAHARASHTRA UNIVERSITY, JALGAON
(2023-24)
 2

UNIVERSITY INSTITUTE OF CHEMICAL TECHNOLOGY

KAVAYATRI BAHINABAI CHAUDHARI NORTH
MAHARASHTRA UNIVERSITY, JALGAON

CERTIFICATE

This is to certify that Ms. Rittika Niranjan Shrisath has satisfactorily completed the
dissertation work entitled “Auto Refinish (Product development)” for the partial fulfilment of
the Degree of Bachelor of Technology, specialization in Paint Technology, Kavayitri Bahinabai
Chaudhari North Maharashtra University, Jalgaon is record of bona fide work carried out by his
under guidance and supervision in academic year 2023-24 .

PROJECT GUIDE:
Dr. R G Puri
Head of Department Of Paint Technology,
University Institute of Chemical Technology,
KBCNMU, Jalgaon.
 3

INDEX
Fig no. Figure Name Page
Number
SR.N CONTENT PAGE NO
O 1. Dyno mill grinding Container
List 1 2. Acknowledgement
High speed blade 4 of
2 3. Company profile
High speedPPG Asian Paints
disperser flow 5
4 Overview of Auto Refinish 6
4. High speed disperser machine
5 General Manufacturing process 7-10
5. Size Distribution on Hegman Gauge
6 Paint Testing 11-20
6. B4 Ford Cup
7 Project work 1 21-32
7. Impact tester
8 Project work 2 33-42
9. 8. Short Wave
Health andand Long Wave
safety 43
10 9. Equipment QUV 313B
References 44

Figures 10. Humidity Tester

11. Salt Spray Tester

12. Weatherometer Tester

13. Sprectrophotometer

14. Cross-linking reaction of 2k PU

15. General reaction of epoxy

16. BPA-ECH epoxy resin reaction

17. Standard epoxy

18. Experimental epoxy

 4

List of Table
Table Table Name Page
No. No.
1. Gloss value

2. Exposure Condition for QUV B test

3. Exposure Condition for Humidity test

4. Exposure condition for SST

5. Exposure Condition for Weatherometer

6. Formulation of standard clear

7. Resin A and Resin B OH value and NVM

8. Formulation of clear EXP. N0.2

9. Formulation of clear EXP.NO.3

10. Comparison of liquid properties of clear coat

11. Appearance property

12. Testing of Mechanical properties

13. Testing of Chemical Properties

14. Long Term Testing Results

15. Standard Epoxy primer Formulation

16. Formulation of Epoxy primer EXP.1

17. Formulation of Epoxy primer EXP.2

18. Formulation of Epoxy primer EXP.3

19. Final Formulation of Epoxy Primer

20. Testing of Primer

 5

ACKNOWLEDGEMENT

This acknowledgement is a humble attempt to earnestly thank all those who were directly or indirectly
involved in my training and helped me.

I am thankful to Mr. Rajesh Tiwari for giving me the projects I worked on here during my training and for his
guidance and valuable inputs regarding these projects. I would also like to thank Mr. Brijesh Mishra, Mr.
Abbas Inamdar, Mr. Chandrashekhar Sarwade for their constant guidance and useful discussions during the
tenure of my training.

I would like to express my gratitude towards all the members of PPG Asian paints for their kind co-operation
and encouragement, which helped me in completion of this project. I would also like to thank all the managers,
executives, officers and in general, the entire staff of PPG Asian Paints for their constant support and valuable
guidance, which has surely enriched me in a great way.

I am also thankful to Prof. Dr. Ravindra Puri (HOD of Paint Technology Department, UICT, Jalgaon)
for helping me in securing in plant training in this esteemed organization and for his great support throughout
the duration of this training.

Rittika Shrisath

UICT, JALGAON
 6

COMPANY PROFILE
PPG Asian Paints Pvt Ltd is a 50:50 joint venture between PPG USA, world’s leading Coatings company, and
Asian Paints Ltd, India’s largest producer of Paints and Coatings. Incorporated on February 1997, PPG Asian
Paints offers a better value through closely tailoring its offerings to customer requirements and providing
superior services. Today, PPG Asian Paints is a leading supplier of paints and coatings in diverse markets such
as Automotive OEM, Automotive Refinishes, Industrial, Marine and Packaging.

 February 1997, starting with automotive OEM coatings and Industrial Coatings.
 1999, PPG Asian paints was further expanded with addition of Automotive refinish business under its
umbrella.
 In March 2007, with the acquisition of the advanced refinish 2k business from ICI India limited, PPG Asian
paints became the market leader in automotive refinish business.
 In 2012, two key businesses namely marine coatings and packaging coatings were added to PPG Asian
paints.
 PPG global acquisition of Revocoat in April 2015 adds adhesives and sealants business with automotive OEM
coatings.

PPG Asian Paints has 5 major business units as follow -

1. Automotive OEM Coatings:
2. Auto Refinishes:
3. Industrial Coatings:
4. Packaging Coatings:
5. Marine Coatings:
 7

OVERVIEW ON AUTO REFINESH

Auto Refinish Business History-

PPG Asian Paints refinish business from 1997 has travelled a long way from a humble Rs. 19 Crores business to
being the market leader today with revenues in excess of Rs. 600 Crores. The business started with three brands
Aspa, Apca and Deltron. Aspa and Apca came from Asian Paints and Deltron GRS came from PPG. PPG Asian
Paints Refinish division took almost three years to carve itself out of its parent companies. For the first three
years, the Aspa and Apca were in fact Asian Paints brands. In the year 1999-2000, PPG Asian Paints had grown
to Rs. 24 Crores in revenues, and had carved itself out of the parent companies when Aspa and Apca became
PPG Asian Paints brands.
 8

1.GENERAL MANUFACTURING PROCESS OF PAINTS

1.1.PRE-MIXING:-
This step involves just mixing of pigments, binder & solvent under high speed stirrer. The pigment – binder
ratio is determined on the basis of oil absorption value. During this step the aggregates & agglomerates are
broken & binder wets each & every particle of pigment.

1.2.GRINDING :-
Grinding is done on sand mill, bead mill, during this stage the pigment is the completely wet by the binder. The
amount of sand is about 70% of the total charge the diameter of the ceramic balls is 0.8 mm to 1.2 mm &
density is 2.5 gm/ cc. Pigment grinding means the dispersion of the pigment particles completely in to the
binder. Paint is passed from the bottom of a vertical cylinder with a rotating shaft through its center on which
there are two or more impellers the rotating impeller causes the sand – paste mixture near there surfaces to
rotate faster than outline material. The difference in the velocity of adjacent layer produces required shearing
action the grinding is checked with the help of the Hegman Gauge. The charge gets ground & when grinding is
obtained the charge is then filtered from the top. During these step wetting agents are also added to affect to
grinding.

1.3.LET –DOWN:-
This is the final step involved in the paint production. During this sufficient amount of solvent is added to adjust
viscosity. Then sufficient resin along with other additive also added to get the required properties such as
flexibility, impact resistance, adhesion & so on. The final adjustments in paint such as solid content, viscosity,
shade matching is done during this stage.

1.4.PACKING:-
After the fulfillment of all the requirements as per specification. The paint is then packed in the tins of various
capacities as per the requirement. Manufacturing carries out its operations using various equipments like mills,
dispersers, filling machines etc. The mills include bead mills such as Dyno mills. Dispersers include high speed
dispersers, slow speed dispersers, dissolvers, blenders, reactors etc.
 9

2.HEAVY DUTY MACHINES USED IN PAINT MANUFACTURING

2.1 .BEAD MILL:-

Available for Quartz-glass bead, Zirconium bead, Chrome steel bead, bead size 1-3mm diameter.

A)Vertical bead mill:-

It consists of following parts
 Impellers
 Enclosed vessel
 Grinding vessel
 Jacket arrangement

B) Horizontal bead mill:-

 Operates in either circulation or continuous mode
 Grinding media from 2mm to as small as 0.3mm available.

Figure 1 : - Dyno mill Grinding containers

The Dyno-Mill is an agitator bead mill with horizontal grinding container for dispersion and finest wet grinding
in a completely enclosed system. The DYNO-Mill is suitable for all kinds of products.
 10

Specially designed agitator discs, mounted symmetrically on a shaft, transfer the energy required for dispersion
and wet grinding to the spherical grinding beads. An external pump feeds the product into the mill.

2.2. HIGH SPEED DISPERSER:-

High Speed Dispersers consist of a driven vertical shaft and a high shear disk type blade. The blade rotates at
up to 5000 fpm and creates a radial flow pattern within a stationary mix vessel. The blade creates a vortex that
pulls in the contents of the vessel to the blades sharp edges. The blade surfaces then mechanically tear apart
solids thereby reducing their size, and at the same time dispersing them among the liquid used as the carrier
fluid. High Speed Dispersers are ideal for dispersions that are up to a maximum of approx. 50,000 centipoises.

Figure 2 :- High speed blade Figure 3 :- High speed disperser flow

Figure 4:- High speed disperser machine

3.STEPS IN PROCESSING OF FORMULATION:-

 11

• Grinding: Grinding is the first stage in paint processing the paint processing, resin, pigment, solvent or
solvent combination, additives are taken in a grinding vessel for grinding. The vessel can be a sand mill,
attriators, High speed disk disperser or HSD, media mill. The mill used for this processing of paint is sand
mill. The grinding media used in this sand mill is zirconium beads. The grinding is done until we obtain the
particle size or called fineness up to 6 or 6.5 on the hegman gauge or grind gauge.
 Fineness of Hegman Gauge: Many types of solid materials must be ground or milled into finer particles for
dispersion in appropriate liquid vehicles. The physical properties of the resulting dispersions, often called
"grinds", depend not only on the actual size of the individual particles, but also on the degree to which they
are dispersed.

Figure 5 : - Size distribution on Hegman Gauge

The Fineness of Grind Gage is used to indicate the fineness of grind or the presence of coarse particles or
agglomerates in dispersion. It does not determine particle size or particle size distribution. Grind gages are used
in controlling the production, storage, and application of dispersion products produced by milling in the paint,
plastic, pigment, printing ink, paper, ceramic, pharmaceutical, food, and many other industries.

 Stabilization: The next stage after grinding is the stabilization of the mill base, as given in the above
formulation, the stabilization is the addition of resin and solvent in the mill base after obtaining the
required

 Thinning: The last stage in the paint formulation is the thinning process, in thinning stage resin,
properties enhancing additives are added in the mil base. These additives include other than wetting and
 12

dispersing additives. After thinning the viscosity of the paint is adjusted according to the specification
and the paint is applied on the panel for 1-component system, similarly for 2- component system the
appropriate amount of hardener is calculated as per given resin backbone in the formulation and the
mixing ratio is decided.

3.TESTING OF PAINT AND COATING THEORY

After the application of the coating on the panel, different types of testing are carried out. For this the following
properties of paint prepared are checked as per standard and costumer specification.

3.1.LIQUID PROPERTIES OF PAINT ARE:

a) Degree of dispersion:
Purpose: Hegman gauge is the most common apparatus to find the fineness of grind. Hegman gauge gives the
degree of dispersion of pigment/extender in vehicle systems.

b) Viscosity:
Purpose: Viscosity is essential for modern production lines and other applications involving supply.
A number of instruments are in use for its determination:
 B4 Ford Cup
 Cone and Plate viscometer
 Brookfield viscometer
 The Stormer viscometer
 Gardner tube

Figure 6 :- B4 Ford cup

c) Weight per liter:

 13

Purpose: Weight per liter is generally measured in a specially designed fixed volume cup of 100 ml. The cup
has an accurately fitting lid which has an orifice at the center. When the lid is placed on the cup almost full with
the paint all the air and excess material in the cup should be expelled through the vent hole in lid. For heat
resistance black paint it should be in range of 1-1.3 kg.

Procedure: - (It is expressed as Kg / liter)

1. Take an accurate tare weight of weight per liter cup with lid (W0)
2. See that cup and liquid are at the same temperature.
3. Fill the cup almost up to the brim avoiding air bubbles.
4. Put the lid on cup without tilting.
5. Remove the overflowing liquid and weigh again (W1).
6. Weight for 100 ml = (W1 – W0) gm
7. Weight for 10 liters = 0.1(W1 – W0) Kg.

d) Nonvolatile matter content or Percent solid content:

Purpose: NVM is a useful check on composition and is, of course, necessary for transport and shipping. This is
expressed as the % solid material (pigment, Binder and additives) in the paint. The solid content of a wet paint
ultimately gives the dried film. It is the time required by the liquid paint film to become solid hard film.
A flat bottom circular dish of tin plate was weighed to the nearest milligrams with a U Clip Pin kept in it.
Approximately 1.0 gm of well mixed sample was transferred to the dish and the weight was noted. The material
was spread evenly over the bottom of the dish by tilting and with the use of U clip pin. The dish with heated
with the contents (including U Clip Pins) in an oven at 120°C for 1 hr. it was then cooled to room temperature
and weighed. The test was performed in duplicate. % NVM was calculated using the formula.

Mass of residue in gms

Non-volatile matter % = x 100
Mass of sample in gms
 14

3.2.MECHANICAL PROPERTIES OF PAINT:

I) Adhesion: Adhesion may be defined as the state in which two dissimilar surfaces are held together by
forces, which may consist of valance attractions, or interfacial forces or combination of both.
Method:
 100 squares of dimension 2x2 mm are Drawn with a sharp edged knife.
 One end of recommended/specified tape is stuck on the squares drawn and rubbed
properly to ensure the proper covering of cuts.
 Now the other end of tape is kept at an inclination of 45 degree and lifted with a jerk.
 The no. of squares lifted out gives a measure of adhesion of coating to the substrate.

2) Recoat adhesion: This test is performed on recoat of the coating to be tested in the same manner as in
adhesion test.
3) Flexibility: It is the degree to which a paint film after drying is able to confirm the movement or deformation
of supporting surface without cracking or flaking. This test requires specially designed apparatus consisting
mandrel from 1 inch. Diameter to 1/8 inch

4) Hardness testing
a.) Pencil Hardness: on-standard but well-accepted measure of the hardness of pencil leads (made of different
proportions of graphite and clay), commonly ranging from 6B (maximum graphite, hence Softest) to 6H (least
amount of graphite, hence the hardest) with HB (roughly equal amounts of graphite and clay, hence medium
soft/hard) in the middle. Pencil hardness is used in indicating the extent of reaction of the coating (XLD) of
surface coatings by testing which number pencil-lead can scratch it.

Method:
 15

The surface of paint film coated on panel is stroked with pencils of decreasing softness or increasing hardness
until one is found which damages the coating. Ideally all films should be tested under same temperature and
same pressure at which pencil is pulled over surface

6B 5B 4B 3B 2B B HB F H 2H 3H 4H 5H 6H 7H 8H 9H

Softest -------------------------------------------------- Hardest

b.) Scratch hardness

Outline: For determining the scratch hardness of ready mixed paints, which is the minimum load required to
produce a scratch showing the bare metal surface of the painted panel.
Equipment: For this test, an automatic scratch hardness instrument is used. The instrument consists of hard
steel needle having a hemispherical shape and 1mm in diameter.
In this method, the resistance to scratching under a specified load of a dried film of the paint is tested.
c.) Impact test: An Impact Test is used to determine the adherence Characteristics of paint. Test samples are
coated and then subjected to a strike by a weight from a predetermined level. The level of the strike determine
show many pounds the paint should withstand before losing adherence. If the paint holds to the surface, the test
is a success.

Figure 7:- Impact Tester

Figure 7:-Impact Tester

d.) Cupping: This enables the quantitative assessment of the technological properties of paints and plastic
coatings. The instrument is designed to produce stresses comparable to those which occur in practice and is
particularly suited for use in the development of high quality paints. The bead is formed to a depth where the
deformation limit of the stamping paint is reached.
 16

3.3APPEARANCE TESTINGS:

a.) Gloss: Gloss is a measure of the proportion of light that has a specular reflection from the surface. A surface
such as a mirror has a high gloss, where a surface such as chalk has less because the light reflected is diffused.
Portable micro-TRI-gloss meter has 3 measuring angles and gloss range up 2,000 gloss units for measuring
paint, plastic, and highly reflective metals.

Table 1:- Gloss value

Gloss Range Values Angle

High Gloss >80 GU 20°

Medium Gloss 10 - 70 GU 60°

Low Gloss <10 GU 85°

Three measurement angles are specified to cover the majority of industrial coatings applications. The angle is
selected for a particular application based on the anticipated gloss range.
b.) Appearance: The appearance of a finish can be described by its brilliance and “smoothness”, also referred
as DOI (Distinction of Image) and orange peel.

c.) DOI
Distinction of image is the measurement of brilliance of the reflected surface. It determines the
dullness/brightness and sharpness of the reflection. Focusing on the reflected image of an object allows one to
obtain information about the image-forming qualities, also called brilliance or distinctness of image (DOI).
The lines of the image will either appear distinct or blurred. If the outline of the image appears distinct, a
reflected light source will look brilliant. However, if the outline of the image is blurred, a reflected light source
will look diffused.

d.) R Value (Wave scan value)

In general, coating appearance can be defined with two characteristics: waviness and brilliance. Focusing on
the surface, one acquires information about the waviness characteristic. Specifically, information is obtained
 17

about the size, depth, and shape of surface structures formed through the deposition of paint particles on the
surface of the vehicle. As the particles are sprayed, they align themselves relative to each other in groups or
structures
LW & SW values
Short wave Long wave

Figure 8 :- short wave & long wave

Appearance changes in relation to structure size.

To pass the test: long wave < 13 units
Shortwave = 10-30

3.4.LONG TEARM TESTINGS: Long terms

testings are generally affected by three main factors of
weathering are solar radiation (light energy), temperature, and
moisture. Different types of solar radiation, different phases
of moisture and temperature cycling have a significant effect
on materials on exposure.
A) QUV Accelerated Weathering Tester (Artificial
UV exposure): UV light is responsible for almost all photo
degradation of durable materials exposed outdoors.
The QUV accelerated weathering tester reproduces the damage caused by sunlight, rain and dew. In a few days
or weeks, the QUV tester can reproduce the damage that occurs over months or years outdoors. To simulate
outdoor weathering, the QUV tester exposes materials to alternating cycles of UV light and moisture at
controlled, elevated temperatures. It simulates the effects of sunlight using special fluorescent UV lamps. It
simulates dew and rain with condensing humidity and/or water spray.
 18

Figure 9:-Equipment QUV 313B (As per ASTM G-53-96)

Outline: This test is carried out by subjecting painted panels to exposure with fluorescent ultraviolet (UV)
radiation and condensation to simulate the deterioration caused by sunlight and water as rain or dew

Table 2 :- Exposure condition for QUV B test

Cycle UV / 4hrs. At 50 ± 1ºC follows by

Condensation/4hrs. At 45 ± 1ºC

UV light (WL) 280 to 350 nm (UV radiation)

Irradiance level -0.55 ± 0.01 watt /m2 /m

B.) Humidity Test:

Outline: Humidity chamber testing is widely used, and it emphasizes the sensitivity of the material or coating
tested to water exposure. In a closed humidity chamber, the humidity is raised to a value chosen as appropriate
to the material under test. The temperature is generally cycled, so that the specimen is exposed to alternating
humid air and condensation.
This test is carried out by subjecting painted panels to exposure with completely humid condition as per
following conditions. In addition, Examine for blistering.
 19

Figure 10 : -Humidity Tester (As per IS-101 Method)

This test is carried out by subjecting painted panels to exposure with completely humid condition as per
following conditions. And Examine for blistering.

Table 3:- Exposure condition for humidity test

Temp. Cycle 42ºC- 48 ºC-42ºC (within 60 ± 15 min.)

Relative 100%
humidity

C) Salt Spray Test:

Outline: The Salt Water Spraying/Corrosive Resistant Chambers are specialized to test the performance of the
products for its surfaces of various materials after treatment of corrosive protection by means of painting,
coating, galvanizing, anodizing and of lubricant.
Since, coating can provide a high corrosion resistance through the intended life of part in use, it is necessary to
check corrosion resistance by other means. Salt spray test is an accelerated corrosion test that produces a
corrosive attack to the coated samples in order to predict its suitability in use as a protective finish.
This test is carried out by subjecting painted panels to exposure with salted fog at controlled temperature.
Examine for rusting and blistering.
 20

Figure11:-Salt Spray Tester (As per ASTM B 117 Method)

Table 4:-Exposure condition for SST

Cabinet temp. 30 to 36 ºC

Relative 95-98%
humidity

Salt solution 5 ± 1% NaCl

Fog collection 1.0 – 2.0 ml / sec for 80 sq.cm.

Flow rate 0.3-0.5 lit / hr.

D) Weather-o-meter:

Xenon Lamp Systems: Xenon arc lamps are equipped with filter systems as which adapt the spectral
distribution to different conditions required by the automotive industry, particularly in the ultraviolet and visible
spectrum. Among others, this enables good simulation of sunlight or sunlight behind a 3-mm-thick window
pane in the visible spectrum too. As regard to the degradation of the tested materials, this is only required for
testing a few pigments.

The time of the tests is further reduced by a quartz-boron filter combination. This allows a smaller but more
energetic portion of short-wave UVB irradiation below the solar cut off of 290 nm to the samples. The 4-hour
dew cycle in accordance with ISO 11507 offers a more realistic simulation to natural nigh time humidity from
dew.
 21

Outline: The paint film is examined for the degree of deterioration by irradiating light from carbon arc and
spraying water at regular intervals of time.

Figure 12 : - Weatherometer tester

Table 5 :- Exposure condition for weatherometer

Cycle light cycle of 18 hrs per one trim

Water spray Initial 18 min. in every 2 hrs.

Black panel 63 ± 3 ºC
temp.

3.5.SPECIFIC TESTINGS:
a.) Water Resistance
 22

Outline: The purpose of this test is to access the resistance of a surface coating to immersion in distilled water.
The test is carried out in a thermostatically controlled water bath equipped with mechanical stirring. A
rectangular laboratory water bath 151 liter capacity is suitable; the water is heated electrically to 38 0C the
coated panels are packed in pairs, back to back vertically in the panel racks. The racks are placed across the tank
so that the water, which is circulated by a propeller situated at one end, can pass across the face of panel.
Examine: After 24 hrs immersion, the panels are removed from the tank and gently wiped Dry with a Dry soft
cloth, & examined immediately for blistering and for loss of gloss.

4.SPECTROPHOTOMETER :
• Color spectrophotometer is an instrument used to measure coloristic value of different panels.
• Spectrophotometry is the quantitative method to measure the reflection or transmission properties of a
material as a function of wavelength. Spectrophotometers measure reflected or transmitted light across the
spectrum and create a visual curve that describes the color on that substrate, under that lighting condition.
• L is light to dark and is illustrated as a vertical measurement. The minimum for L is zero which is black
Whereas the maximum for L is 100, a perfect reflecting diffuser.
• A is green to red and is illustrated in a horizontal axis, left to right measurement. It has no specific
numerical limit. Positive is red and negative is green.
• B is yellow to blue and is illustrated in a horizontal axis. Back to front measurement. Positive is blue and
negative is yellow.
• Delta E* (Total Color Difference) is calculated based on delta L*, a*, b* color differences and represents
the distance of a line between the sample and standard.
• L* indicates lightness/ darkness.

• A* is the red/green coordinate.

• B* is the yellow/blue coordinate.
• C* is the Chroma.
• H is the hue angle .
• Deltas for L* (ΔL*), a* (Δa*) and b* (Δb*) may be positive (+) or negative (-)
 23

Figure 13 :-Spectrophotometer

PROJECT NO. - 1
Title: Development of 2K PU clear coat.

What is Clear-coat: The clear coat is a transparent layer of paint that can be used to cover the colored coat.
Clear coat is usually the last coat of paint that is applied to a panel/Substrate. On average DFT can be between
35 and 45 micron.
 24

Function of clear coat:

• The main purpose of the clear coat is to provide a protective layer over the base coat to reduce the risk
of scratching .
• Clear coat protects color coat and primer coat of paint from UV rays, oxidation, and damages from
harmful contaminants such as acid rain, road tar, road salt .

Background:
As we know, clear is unpigmented paint. We have developed the 2k acrylic PU based clear coat, which is
applied on metallic basecoat. While improving properties like gloss, appearance, DoI, adhesion, and stability of
clear coat. The main role of clear coat are appearance and provide protection from various weathering
conditions. We have developed new clear which passes all long term testing like Humidity, water dip test, salt
spray test, weatherometer test. This is 2 component PU system in which clear is acrylic resin based ,cross link
with Hardener containing NCO group and forms PU clear coat.

Objective: We need to develop clear coat which has following properties

1. High viscosity
2. High coverage
3. Fast drying
4. Good Appearance

Two-Component (2K) Polyurethane Clear Coat :

2K polyurethane clear coats are widely used in the European car industry, but are used to a lesser extent
globally. The chemical reaction by which the Coating cures involves reaction of the polyisocyanate with the
hydroxyl group of a polyol to form a urethane cross-link as illustrated in Figure. The reactivity of the hydroxyl
isocyanate reaction to a pot life of typically 4–8 hours, which prohibits one-component packaging. However,
this reactivity does enable cure over a broader range of curing conditions. Such systems are cured at 60-80 ⁰C,
but are also used as air dry paint. In contrast to hydroxyl-melamine-based Coatings, hydrolysis plays a minor
role in degradation of a urethane coating. These Coatings show improved appearance and acid rain resistance.
 25

Figure 14:- Crosslinking reaction of 2K PU

The low molecular weight polyisocyanates have a high tendency to dissolve the base coat, which leads to a
misorientation of the effect pigments, also described asstrike-in or mottling. In combination with waterborne
base coats, the effect is small as these are made of higher molecular weight latex binders, which are more stable
toward strike-in. The acrylic and polyester polyols are in development for further VOC reduction .

Procedure For applying clear coat.

1. Firstly panel /metal substrate is sanded by sanding paper (P180 /P220)

2. After sanding panel spirit wipe required for cleaning of panel, to make panel dust free.
3. After that epoxy primer is applied with DFT of 30 – 35 microns.
4. After applying primer 15 min flash off is given to primer.
5. Then we bake primer panel at 60°C for 30 min.
6. After baking, sanding of primer is done with sanding paper (P180 /P220).
7. Then spirit wipe to primer panel.
8. Then metallic basecoat is applied on primer.
9. After 10-15 min flash off, Clear coat is applied (with 2:1 ratio)

Liquid properties of clear are:-

1. NVM
2. Viscosity
 26

3. Pot Life
4. WPL

Dry properties of clear are:-

1. DOI
2. Gloss
3. Acetone rubs(20 rubs)
4. Xylene rubs (20 rubs)
5. Acid resistance
6. Alkali resistance
7. Flexibility test
8. Impact
9. Polishbility
 27

PROJECT WORK

Clear 1 is an existing clear with low viscosity and solids. By taking into account the formulation of this clear,
we have developed a new clear Coat.

• Existing clear solid =47.37%

• Existing clear viscosity=87 sec.

EXPERIMENT NO. - 1

Table 6 :- Formulation of Standard clear

Sr. Ingredients Weight

No. percent
1 Acrylic resin A 75-80
2 Catalyst (5% sol) 0.1-0.2
3 Surface additive 0.15-0.25
4 Light Stabilizer 0.60-0.70

5 UV absorber 1 0.90-1.0
6 Solvent A 1.0-2.0
7 Solvent B 4.0-6.0
8 Solvent C 7.O-9.0

Properties of clear coat :

• NVM : 47 -49%
• Viscosity : 80 Sec.
• Gloss: : 80
 28

CONCLUSION

 We want clear with higher viscosity and higher solid.

 Also want a good appearance of clear coat.
 So, for this reason incorporated Acrylic resin B in formulation.

Table 7:-Resin A and Resin B OH value and NVM

Resin OH value NVM

Resin A 130-150 55-59%

Resin B 70 – 90 68-72%
 29

EXPERIMENT NO. – 2

Addition of new low-cost acrylic resin B

 We add the new acrylic resin into the formulation for reduction of cost.
 Resin B OH Value is 70-73.

Table 8:-Formulation EXP.2 Clear

Sr. Ingredients Weight percent

No
1 Acrylic Resin A 65-69

2 Acrylic Resin B 10-14

3 Catalyst 0.10 -0.2

4 Surface additive 0.10-20

5 Light stabilizer 0.60-0.8

6 UV absorber A 0.90-1.0

7 Solvent A 7.0 -9.0

8 Solvent B 1.0-2.0

9 Solvent C 9.0-10

Properties of clear coat:

• NVM :51.21%
• Viscosity : 139 sec
• Gloss : 85-87

CONCLUSION:
 30

 In the second experiment, we are getting required viscosity, but the appearance (DoI) was not as
expected.
 To address this, we introduced a flow and leveling additive & UV additive.
 Additionally, to enhance the gloss, we incorporated more resin B.
 However, if we aim to increase the amount of resin A, it would result in higher costs. Thus, we opted to
increase the quantity of resin B instead.

EXPERIMENT NO. – 3
 31

 Optimization OF Resin B.
 Reduced the catalyst concentration from 5% to 2%.
 Addition of new UV additive and flow additive.

Table 9:- Formulation of clear exp. 3

Sr. Ingredients Quantity %

No.
1 Acrylic Resin A 58-61

2 Acrylic Resin B 20-25

3 Catalyst 0.2-1.0
(2%)
4 Flow & leveling agent 0.1-0.5
A
5 Slip additive 0.1-0.5

6 Light stabilizer B 0.1-1.0

7 UV absorber B 0.5-0.9

8 Solvent A 0.9-1.2

9 Solvent B 3.0-4.5

10 Solvent C 6.5-7.2

Properties of clear coat :

 NVM/solid: 53.64%
 Viscosity:156 sec.
 WPL:0.99
 Gloss@20= 90-91
 Mixing ratio of Base and hardener. – 2:1
 Thinner intake:-36%
 Application viscosity:-18-21 sec.

CONCLUSION

 In the third experiment, we included various UV absorbers and stabilizers.

 32

 We also used a flow and leveling agent. Unlike experiments 1 and 2 which had 5% catalyst solutions,
experiment 3 used 2% catalyst solution to make the film more flexible.
 Additionally, we added 60% of resin B in this experiment to cut down on costs.

Table 10:-Comparison Of Liquid Properties of Clear Coat

CLEAR NVM VISCOSITY ( B4 WPL

CUP)
Clear 1 (std clear) 47.37% 87 sec 0.97
Clear2 51% 139 sec 0.98
Clear 3 (developed 2:1 53.63% 156sec 0.99
clear)

Table 11 :- Appearance Property

CLEAR GLOSS @20 DOI

Clear 1(std clear) 79-80 85
Clear 2 85-87 80
Clear3 (developed 2:1 clear) 90-91 87

Table 12 :-Testing Of Mechanical Properties

 33

PROPERTIES RESULTS

Adhesion (ASTM D3359) 5B

Flexibility conical mandrel (ASTM D522/D- Passes 6mm

1737)

Impact (ASTM D2794-93) 60cm direct Passes

Pencil Hardness (ASTM D3363) Passes HB

Table 13:-Testing Of Chemical Properties

PROPERTIES RESULTS

Acid resistance (0.1N Hcl drop test 24hr) No change in gloss, No fading of clear coat

Alkali resistance (0.1 NaOH) No change in gloss, , No fading of clear coat

Acetone rubs (20rubs) No change in gloss, No fading of clear coat

Xylene rubs(20rubs) No change in gloss, , No fading of clear coat

Table 14 :-Long Term Testing Result

TESTING RESULTS
Humidity (500 hrs) (ASTM D870-15) No blistering observed

Weatherometer for 1000 hours No yellowing (no change in Lab

value), 85% Gloss retention
Salt spray test (500 hrs) (ASTM Passes No creepage
B117)
Water dip test (200 hrs) No blistering observed

CONCLUSION :
 34

By incorporating acrylic resin B into the formulation we have increased the NVM and viscosity. also by adding
suitable and compatible flow and leveling additive we have improved the appearance.

PROJECT NO. - 02
 35

Aim -Cycle time reduction of epoxy primer batch by reducing grinding time.

Background - We have our existing epoxy based primer. While the time of grinding viscosity increases, and
mill get blocked. This results in affecting the efficiency of mill, increased grinding time to achieve desired
finish of primer (which is 6+, 25 microns)

Objective
 To reduce grinding time.
 To get required finish.

Role of primer-
 Primers in paints are preparatory coatings applied to surfaces before painting.
 They enhance adhesion, provide a uniform base, seal porous surfaces, and improve paint durability.
 Primers can also block stains, inhibit rust, or offer other specific benefits based on the surface type and
the intended paint application.
 Main role of primer is to provide intercoat adhesion to base coat .
 Primer is applied in the DFT of approximately 30 - 35 microns.

Epoxy resin chemistry:-

 Epoxy resin are very important class of synthetic polymers, characterized by presence of three members
epoxy rings also called as oxirane/epoxide rings, where an oxygen atom is bonded to two carbon atom
which are already covantly bonded.
 They may also contain secondary -OH group spaced along the chain, especially in the epoxy resin used
for the coating purposes.

Synthesis of epoxy resin:-

Epoxy resin is synthesized by reacting ECH with active hydrogen containing compound followed by
dehydrochlorinations.
BPA means bisphenol A is most widely used active hydrogen containing compound other compound like
phenol, phenolic compound ,glycerin, n -butanol, various acid amine are also used for special purpose. For
example, to make reactive diluent and hardener.
 36

Figure 15:-Geneal reaction of epoxy

This reaction involves catalyst such as NaoH , lithium salts, quaternary ammonium salts etc.

BPA-ECH epoxy resin

This resins are called as BPA glycidyl ether resins are produced by reacting BPA with ECH in presence of
caustic.

Figure 16:-BPA-ECH Epoxy reaction

Molecular weight and physical form of resin is depend on n th value.

 For example a thin liquid, highly viscous liquid and solid

 The value of n is dependent on BPA and ECH ratio.
 Molecular weight is depend on BPA and ECH ratio
 So that these resins are different in properties like viscosity, melting point , solubility epoxy hydroxyl
content.
 Resin with low molecular weight 360-500 are liquid.
 Resin with molecular wt >500to 2000 are semi solid.
 And above 3000 are solid.
 37

 The epoxide equivalent weight is defined as the weight of resin in gram, which contain one gram
equivalent to epoxide.

Important properties of epoxies.:-

 High chemical and corrosion resistance

 Good mechanical, thermal and electrical properties.
 Outstanding adhesion to various substrate
 Low shrinkage on curing and flexibility.
 Epoxy coating can be formulated as one pack two pack , co cure system ranging from solvent based to
high solid coating, powder coating and water based coating
 Air-dried and baked system.

Commonly used epoxy curing agent are:-

 Aliphatic polyamines and their adducts

 Polyamides and polyamide adducts

 Tertiary amines

 Aromatic polyamines

 Ketamine’s

 Acid and acid anhydride

 UF/MF resins

 Phenolic resins

 Acrylic resins
 38

 Isocyanates

 Mercaptans

 Lewis acids (BF, complexes etc.)

In my project work I am dealing with the Epoxy-Amide system.

Polyamide:-

 These are reaction products of the polyamine with dimerized fatty acids.
 Dimerized fatty acids are complex mixtures , which have C36 dicarboxylic acids as major component
along with mono and trimer fatty acids.
 Crosslinking occurs through primary and secondary H of amine.
 Polyamide cured epoxies show better flexibility and water resistant and give longer pot life
 These systems are slower drying produce films , which are softer and reduced chemical resistance than
poly amine cured one.
 39

PROJECT WORK

Table 15:-Standard epoxy primer formulation

Sr. Ingredients Weight Percent

No. %
1 Epoxy Resin A 15-20
2 Rheology modifier (powder) 0.2-0.5
3 Solvent A 10-13
4 Solvent B 1-2
5 Wetting and dispersing additive 0.4-1.0
6 Antisettling agent 0.1-0.5
7 Extender 1 6-10
8 White pigment 1 8-10
9 White pigment 2 7-10
10 Extender 2 7-10
11 Extender 3 8-10
12 Thickening agent 0.9-1.0
13 Solvent 1 0.5-2.0
14 Intermediate ( fast drying) 1.0-3.0
15 Solvent A 1.0-3.0
16 Intermediate 1.0-3.0
17 Solvent A 1.5-1.9
18 Adhesion promotor 0.3-0.7
19 Solvent A 3.0-5.0
20 Intermediate 9-12

Mill base viscosity - 555 gm.

 There is a problem in grinding while processing primer.

 Desired finish of the primer was not achieved.
 We performed the various experiments is as follows.
 40

EXPERIMENT NO. - 1

 Replacement of the rheology modifier powder by Intermediate (Jelly)

 Extender 2 is totally substituted by extender 3 for the reduction of cost .
 Extender 2 have same property similar to extender 3.

Table 16:- formulation of epoxy primer ex. 1

Sr. Ingredients Weight Percent %

No.
1 Epoxy Resin A 15-20
2 Rheology modifier (jelly) 2-4
3 Solvent A 10-13
4 Solvent B 1-2
5 Wetting and dispersing additive 0.4-1.0
6 Antisettling agent 0.1-0.5
7 Extender 1 6-10
8 White pigment 1 8-10
9 White pigment 2 7-10
10 Extender 3 7-10
11 Extender 3 8-10
12 Thickening agent 0.9-1.0
13 Solvent 1 0.5-2.0
14 Intermediate ( fast drying) 1.0-3.0
15 Solvent A 1.0-3.0
16 Intermediate 1.0-3.0
17 Solvent A 1.5-1.9
18 Adhesion promotor 0.3-0.7
19 Solvent A 1-3
20 Intermediate 9-12

CONCLUSION

 As we know jelly is easier to mix in paint than the powder.

 So that we observe the little change on the processing, but it does not affect to required extent.
 41

EXPERIMENT NO-2

Table 17:- Formulation of epoxy primer

Sr. No. Ingredients Weight Percent
%
1 Epoxy Resin A 16-18
2 Rheology modifier (jelly ) 2-4
3 Solvent A 11-13
4 Solvent B 0.5-2
5 Wetting and dispersing additive 1 0.3-0.7
6 Wetting and dispersing additive 2 0.4-0.5
7 Antisettling agent 0.1-0.5
8 Extender 1 6-8
9 White pigment 1 8-10
10 White pigment 2 6-9
11 Extender 3 6.5-7
12 Extender 3 8-9
13 Thickening agent 0.9-1.2
14 Solvent 1 0.9-1.00
15 Intermediate ( fast drying) 1-3
16 Solvent A 1-3
17 Intermediate 1-3
18 Solvent A 1-3
19 Adhesion promotor 0.4-0.6
20 Solvent A 2.0-2.5
21 Intermediate 10-12

CONCLUSION

 By adding the new Wetting and dispersing additive. We don’t get any results.
 So we decided to increase the quantity of W&D agent 1.
 42

EXPERIMENT NO. – 3

Table 18:-Formulation of epoxy primer exp.3

Sr. No. Ingredients Weight percent

1 Epoxy Resin A 16-18

2 Rheology modifier (jelly ) 2-4

3 Solvent A 11-13
4 Solvent B 0.5-2
5 W& D agent 1 0.9-2
6 Antisettling agent 0.1-0.5
7 Extender 1 6-8
8 White pigment 1 8-10
9 White pigment 2 6-9
10 Extender 3 6.5-7
11 Extender 3 8-9
12 Thickening agent 0.9-1.2
13 Solvent 1 0.9-1.00
14 Intermediate ( fast drying) 1-3
15 Solvent A 1-3
16 Intermediate 1-3
17 Solvent A 1-3
18 Adhesion promotor 0.4-0.6
19 Solvent A 2.0-2.5
20 Intermediate 10-12

CONCLUSION

 We obtain the desired result.

 The reason for blocking of mill is that the pigment/extender is not get sufficiently wetted by Wetting
and dispersing additive.
 43

 So we need to increase the quantity of wetting and dispersing additive, by doing this we can conclude
that W & D agent plays a very important role in dispersion of primer.

FINAL IMPROVED FORMULATION

Table 19:- final formulation of epoxy

Sr. No. Ingredients Weight percent %
1 Epoxy Resin A 16-18
2 Rheology modifier (jelly ) 2-4
3 Solvent A 11-13
4 Solvent B 0.5-2
5 W& D agent 1 0.9-2
6 Antisettling agent 0.1-0.5
7 Extender 1 6-8
8 White pigment 1 8-10
9 White pigment 2 6-9
10 Extender 3 6.5-7
11 Extender 3 8-9
12 Thickening agent 0.9-1.2
13 Solvent 1 0.9-1.00
14 Intermediate ( fast drying) 1-3
15 Solvent A 1-3
16 Intermediate 1-3
17 Solvent A 1-3
18 Adhesion promotor 0.4-0.6
19 Solvent A 2.0-2.5
20 Intermediate 10-12
21 Black tinter 1-2
 44

Table 20:-TESTING OF PRIMER

Epoxy primer Values

Mill base viscosity 347 gm
Pot life 3-4 hr
WPL 1.20
Surface dry ½ hr
Tack free dry 1 hr
Hard dry 2hr

Figure:- Standard epoxy primer. Figure:- Experimental epoxy

primer
 45

CONCLUSION:

Proper wetting of pigment is important in paint manufacturing if not correctly optimized it directly affects the
dispersion of pigment in the resin media, grinding time of Mill base and stability of paint. we had to optimize
wetting and dispersing agent into the formulation.
 46

HEALTH AND SAFETY

PPG Asian Paints follows following Environment Health and Safety Policy:
1. We consider compliance to statutory environment, health, and safety requirements as the
Minimum performance standard.

2. We shall give priority and attention to the health and safety of workers.

3. We shall ensure that all process and equipment, machinery and materials provided are safe for the people
and environment.

4. We will ensure our products are developed, used and disposed of in a safe and environmentally sound
manner.

5. Additional policies and procedures are added from time to time for improvement.

Rules for workplace safety:

1. You are responsible for your own safety and for the safety of others.

2. All accidents are preventable.

3. Do not take short cuts. Always follow the rules.

4. If you are not trained, don't do it.

5. Use the right tools & equipment and use them in the right way

6. Assess the risks before you approach your work.

7. Never wear loose clothes or slippery footwear.

8. Do not indulge in horseplay while at work.

9. Practice good housekeeping.

10. Always wear PPES.

 47

REFERENCES

1. www.ppgasianpaints
2. www.wikipedia.com
3. Outline of paint technology W.M Morgan
4. Organic coatings Ed Pappas
5. Basic of paint technology V.C.MALSHE