Internship Report 2010

INTERNSHI
P REPORT
2010
BERGER PAINTS ,
PAKISTAN
MEER SALMAN MUDDASAR

CHEMICAL ENGINEERING
DEPTT.
UNIVERSITY OF ENGINEERING
& TECHNOLOGY , LAHORE
MEER SALMAN (2007-CHEM-53)
UNIVERSITY OF ENGINEERING2 AND TECHNOLOGY , LAHORE

INTERNSHIP REPORT
FOR
BERGER PAINTS PRIVATE LIMITED
28-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

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

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


AUTHORIZATION

ACKNOWLEDGEMENT
A 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.

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.

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.
10AND TECHNOLOGY , LAHORE

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.

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.
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.


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.

D
M
M
D
ORGANIZATIONAL CHART

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


PAINT
FROM 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 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
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
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.

BRIEF MANUFACTURING PROCESS
Container Div.
Orders (Tins)
PDP Colour Matching + Quality Control Tin

(B.O.M.) (2-3 days) Preparation
Production Filling
Planning (1 day)
Tanks Pots
(Large Batch) (Small Batch)
Store Ink Jet
(Raw Material) Printing
Charging Grinding Quality Store

(1-2 hours) (5-6 hours) Control (Finish Goods)

 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.

 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.

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

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.

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

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.

UNIT # 01

ENVIRONMENT AND HEALTH SAFETY

Recently 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

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.

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.

UNIT # 02

TECHNICAL / QUALITY CONTROL

Technical 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 Extenders
P Pigments
R Resins
O Oils
X,Y,Z Chemicals
H Dryers
C Cellulose
W Wax
S Solvents


MACHINE ROOM
Machine 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 35AND TECHNOLOGY , LAHORE

Dispersion operation
UNIT # 03


RESINS
Resin 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 INSECT TRAPPED IN RESIN
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.

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BASIC CHEMISTRY
 CONDENSATION POLYMERISATION OIL BASED (ALKYD RESIN)
 ADDITION POLYMERISATION
 CO-POLYMERISATION WATER BASED

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.

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.
FIRED HEATER
REACTOR TANK

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 70 0C; 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.

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.

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).

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.

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.

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.

UNIT # 04

POWDER COATING
WHAT 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

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

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

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.

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.

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.

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

UNIT # 05

PRINTING INK
Printing 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.

PRINTING INK TYPES

Printing ink can be classified into two basic types
1) Liquids
2) 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) Letterpress
2) Flexography
3) Gravure
4) Offset
5) Screen Printing
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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

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.

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

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.

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

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

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 Cylinder
2. Water Jacket
3. Air filtration
4. Mechanical Seal lubrication feed tank
5. Grinding medium
6. Agitator disc

Grinding Cylinder:
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
 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.

RAW MATERIALS:
Raw materials used in ink production are
1) Pigments
2) Binders
3) Solvents
4) 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) Active
b) Latent
c) Diluents

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.
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 Function
Plasticiser Enhances the flexibility of the
printed ink
Wax Promotes rub resistance
Drier 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
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. Varnish
2. 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 materials
2. 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”
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
Manufacturing Process of Pastes:
Manufacturing Process of Pastes can be divided into three parts
1. Weighting of raw material

2. Dispersion using HSD
3. 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 Paste

2. Pigments used in Paste
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

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 ink
2. 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.

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 Test
2. Shade Test
3. Nail Test
4. Tape Test
5. Particle Size Test
6. 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.

 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:

 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.

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. Viscosity
2. Tack Test
3. Gloss
4. Stability
5. 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

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.


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.

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

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
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.

UNIT # 06

BERDEX AND INDUSTRIAL CHEMICALS

A 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 environment
During 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.

CORE FOCUS OF BERDEX PRODUCTS:
BERDEX’s products offer the following

1. 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 Admixtures
Chemical Admixtures are,
 Accelerators, Retarders
 Water reducers,
 Super plasticizers,
 Integral Water proofing
 Air entraining admixtures,
 Anti-washout agents, etc.
2. Protection Systems
As 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 Improvement

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

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 Grouts
A 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 Repair
Need 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 Systems
BERDEX 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.

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.

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.

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.

UNIT # 07

MAINTENANCE ENGINEERING DEPARTMENT

IN 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.

UNIT # 08

PRODUCTION DEPARTMENT
Production department comprises of following division
OIL BASED
CHARGING 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 2.5mm

Bucket mill Ball size 6mm
iterators Ball size 10-12mm

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 SECTION

For 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 PUTTY
As 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.

UNIT # 09

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)

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.

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

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

CONCLUSIONS
It 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.


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INTERNSHI

MEER SALMAN MUDDASAR

UNIVERSITY OF ENGINEERING2 AND TECHNOLOGY , LAHORE

IN FULFILLMENT OF FOUR WEEK

CHEMICAL ENGINEERING DEPARTMENT

UNIVERSITY OF ENGINEERING3 AND TECHNOLOGY , LAHORE

TO MY PARENTS WHO BROUGHT ME , SO THAT I

UNIVERSITY OF ENGINEERING4 AND TECHNOLOGY , LAHORE

UNIVERSITY OF ENGINEERING5 AND TECHNOLOGY , LAHORE

UNIVERSITY OF ENGINEERING6 AND TECHNOLOGY , LAHORE

UNIVERSITY OF ENGINEERING7 AND TECHNOLOGY , LAHORE

UNIVERSITY OF ENGINEERING8 AND TECHNOLOGY , LAHORE

“INTERNSHIP REPORT / FIELD MANUAL”

UNIVERSITY OF ENGINEERING9 AND TECHNOLOGY , LAHORE

In 1760 a young color chemist living in London,

In 1916, the 150 year old Lewis Berger & Sons

In 1923 Berger and other famous Australian brands,

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

10AND TECHNOLOGY , LAHORE

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

11AND TECHNOLOGY , LAHORE

ALL ABOUT BERGER – PAKISTAN

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

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

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

12AND TECHNOLOGY , LAHORE

13AND TECHNOLOGY , LAHORE

Company have a slogans:

 WE WILL VIGOROUSLY PROMOTE AND SAFEGUARD THE INTERESTS OF OUR EMPLOYEES,

 WE WILL ACHIEVE CORPORATE SUCCESS THROUGH AN UNWAVERING COMMITMENT TO

14AND TECHNOLOGY , LAHORE

15AND TECHNOLOGY , LAHORE

DEPARTMENTS COVERED IN REPORT

 PRINTING INKS/ VEHICLE REFINISHES

 AUTOMOTIVE PAINTS PRODUCTION

 BERDEX & CONSTRUCTIONAL CHEMICALS

16AND TECHNOLOGY , LAHORE

17AND TECHNOLOGY , LAHORE

Pigments are granular solids incorporated into the paint

18AND TECHNOLOGY , LAHORE

19AND TECHNOLOGY , LAHORE

20AND TECHNOLOGY , LAHORE

BRIEF MANUFACTURING PROCESS

PDP Colour Matching + Quality Control Tin

Charging Grinding Quality Store

21AND TECHNOLOGY , LAHORE

 MATERIAL ACQUISITION FROM STORE: Store is controlled by the

 CHARGING: it is the phase of production in which the raw materials are

 GRINDING: Grinding the raw material of solid form and mixing of 

 MIXING: after grinding raw materials are mixed.

 FINISHING: Raw materials for the durability, bonding and glossiness of

 COLOUR MATCHING: Colour is added and checked according to the

22AND TECHNOLOGY , LAHORE

23AND TECHNOLOGY , LAHORE

BERGER PRODUCTS & COSTUMERS

BERGER HAS 600 PRODUCTS IN ALL AND 1800 SKU’S DEPENDING ON

4 TIMBERCOAT RANGE OF PAINTS

5 BERGER ROAD SAFETY