A TECHNICAL REPORT ON

STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME

(SIWES)
UNDERTAKEN AT
MOTION PAINT AND DECORATION COMPANY
OSASOGIE, BENIN CITY
EDO STATE

BY
BRIGHT
ENG

FACULTY OF ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
UNIVERSITY OF BENIN

SUBMITTED IN PARTIAL FULFILMENT OF THE AWARD OF BACHELOR OF

ENGINEERING (B.ENG) IN CHEMICAL ENGINEERING, IN THE FACULTY
OF ENGINEERING, UNIVERSITY OF BENIN, UGBOWO, BENIN CITY, EDO
STATE

AUGUST, 2021.

i
 DEDICATION

This work is dedicated to the Almighty God without whom nothing could be possible, and to my
parent for their moral and financial support.

ii
ACKNOWLEDGMENTS

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 ABSTRACT

This write up is about the experience I gained during my six months industrial training. The report is

basically on paint production and their kinds, like emulsion, textured and gloss with quality control

and assurance in paint production.

In general Motion Paint and Decoration company is bent on producing premium high quality paint

and also help in training students in paint production and other chemical allied products

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 Table of Contents

DEDICATION .................................................................................................................................... ii

ACKNOWLEDGMENTS ................................................................................................................. iii

ABSTRACT ........................................................................................................................................iv

LIST OF FIGURES ......................................................................................................................... viii

CHAPTER ONE ..................................................................................................................................1

INTRODUCTION ............................................................................................................................... 1

1.1. OBJECTIVES OF THE STUDENTS’ INDUSTRIAL EXPERIENCE SCHEME (SIWES)2

1.1.1. TRAINING IN THE FORMATION OF SET GRADUATES .......................................... 3

1.1.2. EXPECTATIONS AND PERCEPTIONS OF EMPLOYERS .......................................... 3

1.2. RELEVANCE OF SIWES ..................................................................................................... 3

1.3. BENEFITS OF INDUSTRIAL TRAINING TO STUDENTS .............................................. 4

1.4. PLACE OF INTERNSHIP .................................................................................................... 6

1.5. BRIEF HISTORY OF MOTION PAINT AND DECORATION COMPANY .................... 6

1.6. AIMS AND OBJECTIVES OF MOTION PAINT AND DECORATION COMPANY .........7

1.7. FUNCTION OF SOME CHEMICALS IN PAINT ................................................................... 8

1.8. ORGANOGRAM OF THE COMPANY................................................................................... 9

CHAPTER TWO ............................................................................................................................... 10

DETAILED ACTIVITIES AND PRODUCTION ............................................................................10

2.1. DEFINITION OF PAINT ........................................................................................................ 10

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 2.2. THE HISTORY OF PAINTS .................................................................................................. 10

2.3. COMPONENT OF PAINTS.................................................................................................... 12

2.3.1. BINDER OR FILM FORMER ......................................................................................... 12

2.3.2. DILUTENT OR SOLVENT ............................................................................................. 12

2.3.3. PIGMENT AND FILLER ................................................................................................. 13

2.4. RAW MATERIALS USED IN PAINT PRODUCTION ........................................................ 13

2.5. SOME KIND OF PAINT AND THEIR USES ....................................................................... 15

2.5.1. Water base paint i.e. emulsion or latex paint .................................................................... 16

2.5.2. Gloss paint ......................................................................................................................... 16

2.5.3. Textured or tex-coat paint ................................................................................................. 17

2.5.4. Emulsion gloss or semi-gloss paint ................................................................................... 18

2.6. DESCRIPTION OF OPERATIONAL SECTIONS AND UNITS IN MOTION PAINT AND

DECORATION COMPANY.......................................................................................................... 19

2.7. SOME EQUIPMENT AND THEIR USES IN THE PRODUCTION OF PAINTS .............. 21

2.7.1. PAINTS MIXING EQUIPMENTS ................................................................................... 22

2.7.2. MEASURING EQUIPMENTS ......................................................................................... 27

CHAPTER THREE............................................................................................................................ 30

PROCESS INVOLVED IN PAINT PRODUCTION ........................................................................30

3.1. PAINT PRODUCTION STEPS .............................................................................................. 30

3.2. PRODUCTION OF 200 LITRES OF CREAM EMULSION PAINT ................................... 32

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 3.3. PRODUCTION OF 40 LITRES OF GREEN GLOSS PAINT ............................................... 33

3.4. PRODUCTION OF 100 LITRES OF BROWN SEMI GLOSS PAINT ................................. 33

3.5. PRODUCTION OF 300 LITERS OF WHITE TEX – COAT PAINT .......................................34

CHAPTER FOUR .............................................................................................................................. 35

QUANITY CONTROL / ASSURANCE MEASURES IN PAINT PRODUCTION........................35

CHAPTER FIVE................................................................................................................................ 38

CONCLUSION AND RECOMMENDATIONS ...............................................................................38

5.1. CONCLUSION ........................................................................................................................ 38

5.2. RECOMMENDATION ........................................................................................................... 38

REFERENCES...................................................................................................................................39

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 LIST OF FIGURES

Figure 1. 1: Organogram of the company............................................................................................. 9

Figure 2. 1: Water based Paint............................................................................................................ 16
Figure 2. 2: Gloss Paint ...................................................................................................................... 17
Figure 2. 3: Tex-coat Paint ................................................................................................................. 18
Figure 2. 4: Emulsion gloss paint ....................................................................................................... 19
Figure 2. 5: Texcote paints mixing equipmrnt ................................................................................... 23
Figure 2. 6: Gloss Paints Mixing Equipment ..................................................................................... 24
Figure 2. 7: Gloss Paints Impeller blade and pebble balls.................................................................. 24
Figure 2. 8: Emulsion paints mixing equipments (i) .......................................................................... 25
Figure 2. 9: Emulsion paints mixing equipments (ii) ........................................................................ 25
Figure 2. 10: Emulsion paints mixing equipments (iii) ..................................................................... 26
Figure 2. 11: Emulsion paints mixing equipments and shafts ........................................................... 26
Figure 2. 12: 240Kg Capacity Platform Weighing Scale ................................................................... 27
Figure 2. 13: Viscometer clamp with ford viscosity cup .................................................................... 28
Figure 2. 14: High Precision 30Kg Electronic/Digital Weighing Scale ........................................... 29
Figure 2. 15: Mercury in glass thermometer ...................................................................................... 29

Figure 3. 1: Making of paste ............................................................................................................... 30

Figure 3. 2: Dispersal Mixer ............................................................................................................... 31
Figure 3. 3: Canning of paint .............................................................................................................. 32

viii
 CHAPTER ONE

INTRODUCTION

The Students’ Industrial Work Experience Scheme (SIWES) was started in 1974 by Industrial

Training Fund (ITF) with about 748 students from 11 institutions of higher learning. This became

very necessary when it is discovered that theoretical knowledge alone would not usually prepare an

educated person for the world of work. Therefore, the need to set up a scheme to train students

(particularly for those pursuing careers in sciences, engineering and technology disciplines SET) not

only to be knowledgeable in their fields but to be able to apply the acquired knowledge and skills to

perform defined jobs or work. There is a demand for a new cadre of workers having a range of skills

across related disciplines and not theoretical experts in a single discipline. Such a wide range of

skills, as being demanded by the world of works today, cannot be readily acquired through

theoretical training alone but in combination with training. By 1978, the scope participation in the

scheme had increased to about 5,000 students from 32 institutions.

The Students’ Industrial Work Experience Scheme (SIWES) is a Skill Training Programme

designed to prepare and expose students of the University to the industrial work situation they are

likely to meet after graduation. The need for the establishment of the scheme arose when there is a

growing concern among industrialists that graduates of institutions of higher learning lacked

adequate practical background required for employment in industries.

The Students Industrial Work Experience Scheme has contributed immensely to the building the

common pool of technical and allied skills available to the Nigerian economy which are needed for

the nation’s industrial development. These contributions and achievements have been possible

because of regular innovations and improvement in the modalities employed for the management of

1
the scheme. SIWES forms part of approved minimum academic standard in the various degree

programmes for all the Nigerian Universities. It serves as an effort to bridge the gap existing

between theoretical knowledge Obtained during lectures with the actual industrial conditions.

1.1. OBJECTIVES OF THE STUDENTS’ INDUSTRIAL EXPERIENCE SCHEME (SIWES)

Theoretical Knowledge alone would not usually prepare an educated person for the world of work.

The worker or productive individual must not only be knowledgeable but must also be versatile in

the application of skills to perform defined jobs or work.

SIWES is an integral part of most degree and diploma programmes in institutions of higher learning

in Nigeria. The scheme is designed to take place in institutions outside the schools and it has a

realistic relevance to development of manpower in Nigeria.

The reality of the programme can be illustrated using a simple analogy. While it is possible for

someone to learn and imbibe all the available information on driving a car in the classroom, it is

unlikely that the individual would, based on the knowledge alone, be able to drive a car at the first

opportunity. On the other hand, someone else without the theoretical information on how to drive a

car, on being told and shown what to do, followed by hands-on practice and supervision by an

instructor, would at the day be able to drive a car successfully. Of course, someone who has been

exposed to both theoretical underpinnings of driving a car and the hands-on experience of doing so

would and should be a better driver.

Consequently, there are two basic forms of learning – education and training – both of which are

indispensable to the production world of work and the functioning of the society at large. In the

illustration given above, the first individual had abundant education on how to drive a car; the

second individual had adequate training on how to drive a car; the third individual had the advantage

of being able to combine theoretical knowledge with practical skills to become a better driver.

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Some other reasons why the training is indispensable in the formation of competent and productive

SET graduates include those mentioned below

1.1.1. TRAINING IN THE FORMATION OF SET GRADUATES

Scientists, engineer and technologists cannot be produced purely by education. They need practical

training to equip them with the tools of their trade in order to enable them make contributions to

industrial development. It is impossible for a fresh SET graduate from a university or polytechnic to

be competent to carry out the functions of his or her chosen field effectively. The knowledge in

one’s head does not translate directly into goods and services. It is though the intermediation of

practical application that theoretical knowledge becomes productive. While institutions of learning

provide the basic education, competence in carrying out tasks, jobs, work and functions is acquired

through training in the work place. Industrial training, therefore, provides the avenue for

undergraduates to acquire the basic tools of their future professions while still being students.

1.1.2. EXPECTATIONS AND PERCEPTIONS OF EMPLOYERS

Gap between the learning acquired by graduates of Nigeria’s tertiary institutions, particularly SET

graduates and the skills repertoire required in the workplace. Employers believe that Nigeria

graduates bring sufficient theoretical knowledge to the job but that they generally lack hands-on or

practical skills and orientation that would make them productive. Industrial training provide a

veritable means of addressing and redressing the gaps between the skills repertoire possessed by

students and the relevant production skills (RPSs) required by employers.

1.2. RELEVANCE OF SIWES

One of the significant features of advanced industrial societies is the degree to which they have

achieved progress in the field of science and technology. This had enabled the citizens to enjoy a

good standard of living, which exceeds that of the developing Countries. Thus, formal education

3
comprising of field or industrial work is vital for the production of graduates with increasingly

specialized skill.

Therefore, Students Industrial Work Experience Scheme (SIWES) is relevant for;

 Improvement of science and technological education

 Skilled manpower development

 Creation of a community with increased standard of living

 Development of critical and scientific approach to problems and their solutions.

 New innovations in the field of science and technology.

As a matter of fact, the student’s industrial work Experience scheme (SIWES) is a promotion for the

growth of science and technology, Engineering, Agriculture, Medical, Management, and other

professional programmes in the Nigerian Tertiary Institutions.

1.3. BENEFITS OF INDUSTRIAL TRAINING TO STUDENTS

The major benefits accruing to students who participate conscientiously in industrial training are the

skills and competencies they acquire. These relevant production skills (RPSs) remain a part of the

recipients of industrial training as lifelong assets which cannot be taken away from them. This is

because the knowledge and skills acquired through training are internalised and become relevant

when required to perform jobs or functions.

Several other benefits can accrue to students who participate in industrial training. These include the

following:

 Opportunity for students to blend theoretical knowledge acquired in the classroom with

practical hands-on application of knowledge required to perform work in industry.

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 Exposure of students to the environment in which they will eventually work, thereby

enabling them to see how their future professions are organized in practice.

 Minimization of the bewilderment experienced by students, particularly those from non-

technological background, pursuing course in science, engineering and technology with

regard to different equipment, processes, tools etc, available in industry.

 Enabling SET students appreciate work methods and gain experience in handling equipment

and machinery which may not be available in their institutions

 Preparing students to contribute to the productivity of their employers and national

development immediately after graduation.

 Provision of an enabling environment where students can develop and enhance personal

attributes such as critical thinking, creativity, initiative, resourcefulness, leadership, time,

management, presentational skill, interpersonal skills, amongst others.

 Preparing students for employment and making the transition from school to the world of

work easier after graduation.

 Enhancing students’ contacts with potential employers while on training.

 Enabling students bridge the gap between the knowledge acquired in institutions and the

relevant production skills (RPSs) required in work organizations.

 Making SET students appreciate the role of their professions as the creators of change and

wealth and indispensable contributors to growing the economy and national development.

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  Enabling students appreciate the connection between their courses of study and other related

disciplines in the production of goods and services.

1.4. PLACE OF INTERNSHIP

This report is based on a six months industrial training done at Motion Paint and Decoration

Company at No 4, Omokhale Street, off Federal Girls Government College (FGGC) Road,

Osasogie, Benin City, Edo state.

The industrial training as organized by the federal government through students’ industrial work

experience scheme (SIWES) is aimed at exposing students to their field of study in order to acquire

some skills in the labour market and also put in practice, the practical aspect of their courses of

study. This justifying the degree in honour given to them at the end of their stay in school.

1.5. BRIEF HISTORY OF MOTION PAINT AND DECORATION COMPANY

Motion Paint and Decoration Company is a company incorporated in the year 2004 established

under the chairmanship of Ijeoma Christopher a follower of the Nigeria association of paint

manufacturers and Mr. Prince Nwaturuocha as the managing director here in Osasogie Edo State.

The company has its head office established first at number No 4 Omokhale street by FGGC road,

Osasogie, Edo State, due to the fact that their quality is high they need to expand by opening another

branch in rivers state in 2008, which is sited at km 20 Aba – Port Harcourt expressway beside Mife

construction company Oyigbo Port Harcourt Rivers State, after that they expand again in the year

2010 by opening another branch at km 10 Enugu - Port Harcourt expressway opposite Ezeonuigbo

by tower Abia State, Nigeria.

In other word, the company engage in the production and marketing of paints, painting products and

chemicals.

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The company was managed by a team of selected industrial based professionals who combines to

deliver a high quality premium paints that guarantee the efficient coating and design of buildings,

metals works and so on.

The company blends a wide range of paints which include:

1. Orbitex emulsion paint

2. Orbital gloss paint

3. Orbitex coated paint (texcoat)

4. Orbitex semi – gloss paint

5. Production of screeding materials

6. Production of high quality silk or satin paint

7. Agro – allied chemicals

8. Water treatment

1.6. AIMS AND OBJECTIVES OF MOTION PAINT AND DECORATION COMPANY

To promote high quality assurance or control and good working standards

To promote and harmonize research and development

To promote the exchange of information and knowledge

To promote safety standards of the workers in the company

To make sure there is conducive environment for both workers and customers.

To make sure there is an availability of raw materials.

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1.7. FUNCTION OF SOME CHEMICALS IN PAINT

The role some chemical play in a paint product:

Calcium carbonate (CaCO3): it is used as extender in paints in particular as fillers and due to its

special white colour as a coating pigment

Titanium dioxide (TiO2): it is the most important white pigment used and coating as it provides the

best opacity, whiteness brightness in nature

Polyvinyl acetate (PVAs): it serves as a film forming ingredient in water – based paint. the

monomer can be polymerized while dispersed in water to form a milky – white emulsion, the fluid

can be processed directly into latex paints, in which the PVAs forms a strong, flexible adherent film.

Petrol and kerosene in gloss paint: it serves as universal solvent that makes the gloss paint to be

smooth on the wall surface and can be washed when dirty without affecting the paint.

Ammonia in paint: ammonia is used as a drying agent (Preservation) to make it dry fast enough.

8
 1.8. ORGANOGRAM OF THE COMPANY

CHAIRMAN/CEO

MANAGING

DIRECTOR

PERSONEL PRODUCTION QUALITY CONTROL

MANAGER
MANAGER MANAGER

STORE SALES CASHIER MAINTENANCE PRODUCTION

KEEPER OFFICER OFFICER UNIT

Figure 1.1: Organogram of the company

9
 CHAPTER TWO

DETAILED ACTIVITIES AND PRODUCTION

2.1. DEFINITION OF PAINT

Paint is the general term for a family products used to protect, add color and design an object or

surface by covering it with pigment coating.

Paint is any liquid, liquefiable or mastic composition that after application to substrate in a thin

layer, convert to solid film. It is most commonly used to protect colour or texture to objects. Paint

can be made or purchased in many colors and in many different types such as water-colour,

synthetic etc., paint is typically stored, sold and applied as a liquid but most types dry into solid

2.2. THE HISTORY OF PAINTS

Ancient coloured walls at Egypt which were exposed for years to the elements, still possess their

brilliant colour, as vivid as when they were painted about 2000 years ago. The Egyptians mixed

their color with a gummy substance and applied them separately from each other without any

blending or mixture. They appear to have used six colours: white, black, blue, red, yellow and green.

10
They first covered the area entirely with white then traced the design in black, leaving out the light

of the ground colour, they used minimum for red and generally of dark tinge.

Paint was made with York of eggs and therefore, the substance would harden and adhere to the

surface it was applied to. Pigment was made from plants, sand and different soils. Most paints used

either water or oil as a base (the dilutant, solvent or vehicles for the pigment)

At 17th century house oil painting where a primer was used along with several undercoats and an

elaborate decorative overcoat, the pigment and oil mixture would have been ground into a paste with

a mortar and pestle. The process was done by hand by the painter and exposed them to lead

poisoning due to the white lead powder

In 1718 Marshall smith invented a machine or engine for the grinding of colours. It is not known

precisely how it operated, but it was a device that increase the efficiency of pigments dramatically.

Soon, a company called Emerton and Manby was advertising exceptionally low-priced paints that

has been grounded with labour – saving technology.

By the proper onset of the industries revolution, paints was being ground in steam – powered mills

and an alternative to lead based pigments was found in a white derivative of zinc oxide. Interior

house painting increasingly becoming the norm as the 19th century progressed, both for

decorative reasons and because the paints was effective in preventing the wall rotting from damp.

Linseed oil was also increasingly used as an inexpensive binder.

11
2.3. COMPONENT OF PAINTS

2.3.1. BINDER OR FILM FORMER

The binder is the film forming component of paint. it is the only component that must be present if

the binders are suitable for application. Many binders are too thick to be applied and must be

thinned. The type of thinner varies with the binder. The thinner is also called the vehicle, because it

makes it possible to transfer the binder to the surface with a brush, roller or sprayer. Component

listed below are included optionally, depending on the desired properties of the cured film. A clear

paint like vanish contains primarily the binder and the blender and the vehicle plus some driers. If

you add pigment to provide colour and opacity to vanish you create an enamel. Enamels therefore

contains three primary type of ingredient found in all paints 1 – binder, 2 – vehicle, 3 – pigments,

the binder imparts properties such as gloss, durability, flexibility and toughness. Binder include

synthetic or natural resins such as alkyds, acrylics, vinyl acrylics, vinyl acetate / ethylene (VAE),

polyurethanes, polyesters, melamine resins, epoxy or oils. Binder can be categorized according to

the mechanism for drying or curing. Although drying may refer to evaporation of the solvent or

thinner, it usually refers to oxidative cross – linking of the binders and is indistinguishable from

curing. Some paints form by solvent evaporation only, but most rely on cross – linking process.

Paints that dry by solvent evaporation and contain the solid binder dissolved in the solvent are

known as lacquers. A solid film forms when the solvent evaporates, and because they can re-

dissolve in the solvent, lacquers are unsuitable for applications where chemical resistance is

important.

2.3.2. DILUTENT OR SOLVENT

The main purpose of the dilutent is to dissolve the polymer and adjust the viscosity of the paint, it is

volatile and does not become part of the paint film. It also controls flow and application properties,

12
and in some cases can affect the stability of the paint while in liquid state. Its main function is as the

carrier for the non-volatile components. To spread heavier oils (for example linseed) as in oil –

based interior house paint, a thinner oil is required. These volatile substance imparts their properties

temporarily – once the solvent has evaporated, the remaining paint is fixed to the surface. This

component is optional. Some paint has no dilutent.

Water is the main diltuent for water – based paints, even the co – solvent types. Solvent – base also

called oil based paints can have various combinations of organic solvents as the diltuent, including

aliphatic,aromatics,alcohols, ketones and white spirit. Specific example are organic solvent such as

petroleum distillates, esters, glycol ethers and the like. Sometimes volatile low – molecular weight

synthetic resins also serve as dilutent.

2.3.3. PIGMENT AND FILLER

Pigments are granular solids incorporated in the paint to contribute colour. Fillers are granular solid

incorporate to impart toughness texture gives the paint special properties to reduce the cost of paint.

Alternatively, some paints contain dyes instead of or combination with pigment.

2.4. RAW MATERIALS USED IN PAINT PRODUCTION

A paint is composed of pigments solvents, resins and various additives. The pigment gives the paint

colour; solvents make it easier to apply; resins help it dry; and the additive serves as everything

from fillers to anti fungicidal agents,

1. Hundreds of different pigments both natural and synthetic exist.

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 i. Titanium dioxide (TiO2): Is a prime pigment which provides whiteness and colour, and are

the main source of hiding capability and is relatively expensive and one of the major

determinants in the quality and market cost of paint

ii. Colour pigment either inorganic and organic like iron oxide and cadmium sulfide for reds,

metallic salt for yellows and oranges,carbon black for black, and iron blue and chrome

yellows for blue and green are used to provides colour, and to make paint opaque thus

protecting the substrate from the harmful effects of ultraviolet light while also increasing a

paints hiding power.

iii. Solvents are various low viscosity,volatile liquids. They include petroleum mineral, spirit

and aromatic solvents such as benzol, alcohol, esters, ketones and acetone.

iv. Kerosene or fuel: Is a solvent and the liquid portion the gloss paint. It serves the purposes of

water in gloss paints.

v. Water (H2O): Is a solvent and the liquid portion paint (also referred to as the “carries”)

which provide desired consistency and make it possible to the surface being painted. Which

means is used in dissolving g the pigment before being added and is used in all paints

production except gloss paints.

2. The natural resins most commonly used are line-seed, coconut and soya bean oil, while

alkyds acrylics, epoxies and polyurethanes number among the most popular synthetic resins.

i. Polyvinyl acetate (PVA) or acrylic: Is a synthetic resin which provides adhesion, integrity

and toughness to the dry paint film by binding the pigment together. It is also called a binder.

ii. Mix-dryer: Is a liquid solution that comprises of cobalt for shining, manganese and alloy to

sustain the paint from clothing. As the name implies it is added to quicken, the drying of the

paint when applied.

14
 iii. Alkyd: Is a synthetic resins binder which provides adhesion, integrity and toughness to the

dried paint film by binding the pigments together. It is only used in gloss or oil paints.

Additive serves many purposes, an example of them are aluminum silicate etc.

i. Calcium carbonate (CaCO3), dolomite or calcite as the case may be in an additive that gives

the paint body and substance without changing its properties, and it also improves the

coverage of the paints.it is an essential additive that is used in the production of emulsion,

texcoat, and sometimes semi gloss paint. It also impacts properties like been sheen, scrub

resistance and exterior colour retention to the paint.

ii. Thickening agent e.g. hydroxyethyl cellulose: Is a thickener which provides adequate

viscosity (thickness) so that the paint may be applied properly, and impact how thick the

paint goes on and how well it flows out when applied. It also helps latex paint resist

spattering when applied by roller, and reduces spoilage.

Deformer are used to break bubble as they are formed in the paint.

i. Ammonia (NH3) serves as preservatives for the paint and fight the growth of living

organisms on the walls e.g. mushroom and spirogyra.

ii. Acticide: Is also a preservative that helps to keep the paint as much long as needed. It can

also have referred to as an antifungicidal agent.

iii. Marble dust is a fine quartz that is added to tex – coat or texture paints that makes it to have

toothed appearance on the wall when applied.

2.5. SOME KIND OF PAINT AND THEIR USES

There are many kinds of paint which include:

15
2.5.1. Water base paint i.e. emulsion or latex paint

This is an acrylic and water based copolymer emulsion paint for interior use but can also be used on

exterior work. It is a low cost, value engineered product that is targeted at mass housing projects. It

has good coverage and opacity depending on the quality of the paint. Quality latex paints that have

100% acrylic binder are especially durable and highly flexible. They tend to adhere extremely well

to a variety of exterior surfaces, which means they have greater resistance to troublesome paint

failures like blistering, flaking and peeling compared with other types of paint.

Figure 2. 1: Water based Paint

2.5.2. Gloss paint

This is alkyd resin enamel paint for used on a wide variety of application including wood, steel,

plaster, chipboard, hardboard etc. it is suitable for both interior and exterior use easy cleaning when

stained. Top quality oil based paints have excellent adhesion characteristics, which means they get a

tight grip on the surface being painted. And good adhesion is essential for durable painted job.

16
However, oil based coatings do tend to oxidize and get brittle over time which can lead to cracking

problems in exterior applications, yellowing and chipping problems in interior applications.

Figure 2. 2: Gloss Paint

2.5.3. Textured or tex-coat paint

This is a high quality textured acrylic copolymer emulsion paint reinforced with fine quartz and

suitable for interior and exterior use. Textured paint has a sheen and textured finish with 70%

washability, scrubbability and 100%opacity. It has a life span of over ten years on the wall. They are

paints with water soluble thinner and they include calcimines in which the thinner is glue. It has a

life span of 5-10 years on the walls.

17
 Figure 2. 3: Tex-coat Paint

2.5.4. Emulsion gloss or semi-gloss paint

This is high acrylic copolymer emulsion paint for interior and exterior use. Semi-gloss has a sheen

and smooth finish with 100% wash ability, scrubility and opacity. Semi-gloss has span of over 15

years on the wall and can be washed with soap or detergent without affecting the paint.

18
 Figure 2. 4: Emulsion gloss paint

2.6. DESCRIPTION OF OPERATIONAL SECTIONS AND UNITS IN MOTION PAINT

AND DECORATION COMPANY

The factory has various sections and units where processes and operations are carried out, however

all sections and units interacts with one another in the factory.

 Storage Unit: This is the largest unit in the factory (also referred to as warehouse) where

all materials are kept, for use and after use, majorly raw materials and finished products, are

stored in the unit as well as some working tools and packaging materials.

 Laboratory Section : The factory laboratory is a very sensitive section where samples of

raw materials and products are tested and certified before production and after production

19
 after which some are kept for future references, color charts are also kept in laboratory,

however laboratory scale machines and equipments are also in the laboratory for the

production of sample paints in order to identify and and meet up with the

procurements by the Standard Organization of Nigeria(SON) and the latest development

in the paints manufacturing industry.

 Production Unit: This is the unit where all the manufacturing processes is carried out

either mechanically or manually, there are two major types of operation In the production

unit, (i) Dry operation section (ii)Wet operation section

i. Dry Operation Section: In this section, paints such as Cement Texture (Cemtex) are

produced, meanwhile the raw materials are dry and the products are also dried powdered,

with the use of a special cemtex machine.

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 ii. Wet Operation Section: In this section, paints such as gloss, emulsion and Texcote are

produced using organic synthetic solvents and solute, as the raw materials and yielding a

liquefied product, however mixing machines are used in carrying out manufacturing process

in this section.

 Packaging/Labeling Section: This is the section that gives the finishing touches to the

products, meanwhile the activities carried out in this section includes, writing of

batch number, labeling and packaging of all finished products.

 Health, Safety and Environment Unit(HSEU) : Behind all the various sections and

units, there lies a group of personnel who are always on ground to ensure a hazard free

working environment, in which their responsibilities includes cleaning and tiding up

of the factory work tools as well as washing the mixing vessels and manufacturing

equipment, whether before or after use, and also setting up the equipment for use, they

also ensure that all wastes are disposed in accordance with the rules and regulations of

the Federal Environmental Protection Agency(FEPA) as well as the state, which is Edo

State Environmental Protection Agency(EDSEPA).

2.7. SOME EQUIPMENT AND THEIR USES IN THE PRODUCTION OF PAINTS

Some of the equipment used in paints factory for the processing of various types of paints are

pictorially presented as well as some other hand tools used for the completion of the production

process.

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2.7.1. PAINTS MIXING EQUIPMENTS

Various paints mixing equipment are mounted to process paints of different base and textures to a

suitable finished product.

i. Texcote Paints Mixing Equipment

it is specially designed to mix and blends various components, which gives a texcote

product, the equipment has two shafts, with one baffle to ensure a homogeneous mixing,

while belted to two electric motors in which one is to revolve the shaft rod as the

other is to revolve the baffles rod, it uses an hydraulic-elevator to lift the shafts and

baffles so that the mixing vessel (1200Lt capacity) can be remove at ease when several tasks

are to be performed.

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 Figure 2. 5: Texcote paints mixing equipmrnt

ii. Gloss Paints Mixing Equipment

The equipment is mounted to process oil based paints, it has two electric motors and two mixing

vessels of 240Lt capacity each

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 Figure 2. 6: Gloss Paints Mixing Equipment

Figure 2. 7: Gloss Paints Impeller blade and pebble balls

iii. Emulsion Paints Mixing Equipment:

The equipment are designed to mix and blend paint components using a shaft, the machines has an

hydraulic elevator, with an electric motor which revolves the shaft rod using a conveyor belt, the

mixing vessel is of 1200Lt capacity each

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Figure 2. 8: Emulsion paints mixing equipments (i)

Figure 2. 9: Emulsion paints mixing equipments (ii)

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 Figure 2. 10: Emulsion paints mixing equipments (iii)

Figure 2. 11: Emulsion paints mixing equipments and shafts

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2.7.2. MEASURING EQUIPMENTS

There are various measuring instruments and hand-tools used in the paints factory as required today

based on the demand for accuracy to minimize mistakes and errors as well as minimizing the waste

of raw materials and meeting up with the expected production capacity.

i. 240Kg Platform Weighing Scale

This is a heavy mass weighing scale of about 250kg capacity, it is used in the weighing of raw

materials and finished products for confirmation and certification of their mass before and after

production

Figure 2. 12: 240Kg Capacity Platform Weighing Scale

ii. Viscometer Clamp and Cup

This is an assembled instrument use to measure the Viscosity of a paint to check if it meets the

required model as stipulated by the Standard Organisation of Nigeria(SON), the cup used in

testing for the viscosity of the paint is known as ford viscosity cup, it is a viscosity measurement

device widely used in the paint industry, It is commonly a stainless steel cup with a tiny

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hole drilled in the center of the bottom of the cup, There are five cup specifications, labeled

ford cup #x, where x is the number from one through five, Large number cup sizes are used

when viscosity is high, while low number cup sizes are used when viscosity is low.

Figure 2. 13: Viscometer clamp with ford viscosity cup

To determine the viscosity of a paint, the cup is dipped and completely filled with time until the

liquid stream out of it breaks up, this is the corresponding “efflux time”, on paint standard

specifications, one denotes viscosity in the manner: efflux time, ford cup number

The Ford viscosity cup is a simple gravity device that permits the timed flow of a known volume of

liquid passing through an orifice located at the bottom, under ideal conditions, this rate of flow

would be proportional to the kinematic viscosity (expressed in stokes and centistokes) that is

dependent upon the specific gravity of the draining liquid. However, the conditions in a simple flow

cup are seldom ideal for making true measurements of viscosity, it is important when using a Ford

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Cup and when retesting liquids that the temperature of the cup and the liquid is maintained, as

ambient temperature makes a significant difference to viscosity and thus flow rate.

iii. High Precision 30Kg Electronic/Digital Weighing Scale: The laboratory make use of

the light weight scale in weighing, during operations related to sample scale Production,

weighing of chemical components used in the operation, as the scale is of low weighing

capacity(30Kg) and can also be operated in kilograms or grams.

Figure 2. 14: High Precision 30Kg Electronic/Digital Weighing Scale

iv. Mercury In Glass Thermometer: This tool is used sometimes to check the temperature

of some organic solvents used in manufacturing paints as well as the temperature of paints

while undergoing mixing process in the mixing vessel.

Figure 2. 15: Mercury in glass thermometer

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 CHAPTER THREE

PROCESS INVOLVED IN PAINT PRODUCTION

3.1. PAINT PRODUCTION STEPS

i. Making of paste

Pigment manufacturers send bags of fine grain pigment to paint plants. There the pigment is

premixed with resin (a wetting agent that assists in moistening the pigment, one or more solvents,

and additives to form a paste.

Figure 3. 1: Making of paste

ii. Dispersing the pigment

The paste mixture for most industrial and some consumer paints is now routed into a sand mill, a

large cylinder that agitates tiny particles of sand or silica to grand the pigment particles, making

them smaller and dispersing them throughout the mixture. The mixture is then filtered to remove

the sand particles.

Instead of being processed in sand mills, up to 90% of water-based latex paint designed for use by

individual home owners are instead processed in a high-speed dispersion tank. There the premixed

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paste is subjected to high – speed agitation by acircular toothed blade attached to a rotating shaft.

This process blends the pigment into the solvent.

Figure 3. 2: Dispersal Mixer

iii. THINNING THE PASTE

Whether created by a sand mill or dispersion mixer tank, the paste must now be thinned to produce

the final product. Transferred to large kettles, it is agitated with the proper amount of so went for

the type of paint desired.

iv. CANNING THE PAINT.

The finished paint is pump into the canning room. For the standard 8pint (3.73 litre) paint can be

available to consumers, but empty cans are first rolled horizontally onto labels and they are set

upright so that paint can be pumped into them. A machine places lids onto the filled cans, and a

second machine presses on the lids to seal them.

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 Figure 3. 3: Canning of paint

3.2. PRODUCTION OF 200 LITRES OF CREAM EMULSION PAINT

Step 1: making of paste

Four kilogram of titanium dioxide is dissolved with small quantity of water in the paste bowl. 0.4kg

of yellow pigment is also added into the bowl and stirred till it dissolved to liquid and desire colour

gotten

Step II

Hundreds litres of water is measured into the rapid mixer (i.e. 10 litres of water for 20 litres of

paint). The paste is then poured into the mixer after which 32kg of calcium carbonate is added too

(i.e. 16kg of CaCO3 for 20 litres of paint). After few minutes of mixing by the rapid mixer 50kg of

acrylic is measured out and added into the mixer or more depending on the desired quality of paint

wanted. At this stage now the defoamer is added to break the bubbles, followed by dissolving one

kilogram of thickener with small water and poured into the mixer to thicken the paint. Preservatives

like ammonia and actcide are also added.

Step III

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After about 10 – 15 minutes of final mixing by the rapid mixer, the paint is then set for canning.

3.3. PRODUCTION OF 40 LITRES OF GREEN GLOSS PAINT

Step 1: making the paste

Five kilogram of titanium dioxide is dissolved with small quantity of kerosene or fuel in bowl.

0.5kg of green pigment is also added stirred inside the bowl till all dissolves

Step II

Twenty litres of kerosene or fuel is poured into the mixer (I.e. 1.5 kg of alkyd for 4 litres of gloss

paint {1 gallon}). After some minutes of proper mixing by the rapid mixer two kg of mixdryer is

also added or even more depending on the quality of paint wanted.

Step iii

At this point the paint is ready for canning after about 10 – 15 minutes of mixing by the rapid

mixer.

3.4. PRODUCTION OF 100 LITRES OF BROWN SEMI GLOSS PAINT

STEP I: MAKING THE PASTE

Two kilogram of titanium dioxide is dissolved with small quantity of water in a paste of bowl.

0.4kg of yellow pigment and 0.1kg of red pigment is also added and stirred well inside the bowl till

all dissolve and the needed colour is gotten

STEP II

Twenty-five litres of water is added into the mixer (i.e. 5 litres of water for 20 liters of paint), the

paste is poured into the mixer, followed by 50kg of calcium carbonate (i.e. 10kg for 20 litres). Due

33
to the type of paint being produced with emulsion gloss or semi-gloss high quantity of acrylic is

used more than calcium carbonate, so 40kg of acrylic is used or more followed by the defoamer and

preservatives like ammonia and acticide. After 0.5kilogram of thickener is dissolved with small

quantity of water and added to thicken the paint.

Step III

After about like 15 minutes of mixing by the machine, the paint is then ready for canning.

3.5. PRODUCTION OF 300 LITERS OF WHITE TEX – COAT PAINT

STEP I: MAKING OF PASTE

Since we are producing a white paint, only 7.5 of titanium dioxide is dissolved with small quantity

of water in the paste bowl to make the required paste for this production.

STEP II

Sixty litres of water is measured into the rapid mixer (i.e. 4 litres of water for 20 litres of tex-coat

paint). The paste is poured into the rapid mixer followed by 180 kilogram of calcium carbonate (I e

12kg of calcium carbonate for 20 litres of tex – coat paint). 180 of marble dust is also added with

45kg of acrylic. After some minutes of mixing. The defoamer is poured into the mixer to break the

bubbles, followed by the preservatives (i.e. ammonia and acticide).

At this point 1.5 kilogram of thickener is dissolved with small water and added to thicken the paint.

STEP III: CANNING

After about 7 – 12 minutes of mixture, the paint is then ready for canning.

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 CHAPTER FOUR

QUANITY CONTROL / ASSURANCE MEASURES IN PAINT

PRODUCTION

Quality is an important factor when it comes to any product or services. With the high market

competition, quality has become the market differentiator for almost all product and services.

Therefore, all manufacturers and service provider out there constantly look for enhancing their

product or the service quality.

In order to maintain or enhance the quality of the offerings, manufacturers use two techniques,

quality control and quality assurance. These two practices make sure that the end product or the

service meets the quality requirement and standards defined for the product or the services. There

are many methods followed by organization to achieve and maintain required quality. Some

organizations believe in the concepts of Total Quality Management (TQM) and some others believe

in internal and external standard.

The standard usually defines the processes and procedures for organizational activities and assist to

maintain the quality in every aspect of organizational functioning. When it comes to standards for

quality, there are many. ISO (International Standards organization) is one of the prominent bodies

for defining quality standards for different industries.

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Paints manufacturers utilize an extensive array of quality control measures. The ingredient and the

manufacturing process undergo stringent tests, and the finished product is checked to insure that is

of high quality. A finished paint is inspected for its density, fineness of grind, dispersion and

viscosity. Paint is applied to a surface and studied for bleed resistance, rate of drying and texture.

In term of the paints aesthetic components, colour is checked by an experienced observer and by

spectral analysis to see if it matches a standard desired colour. Resistance of the colour to fading

caused by the element is determined by exposing a portion of painted surface to an arc light and

comparing the amount of fading to painted surface that was not so exposed. The paint hiding power

is measured by painting it over a black surface and a white surface. The ratio of coverage on the

black surface to coverage on the white surface is then determined, with 98 being high quality paint.

Gloss paint is measured by determining amount of reflected light given off a painted surface.

Test to measure the paint more functional qualities include one of the mar resistance, which entail

scratching or abrading a dried coat of paint. Adhesion is tested by making a crosshatch, calibrated

to 0.7inch (2 millimeters), on a dried paint surface. A piece of tape is applied to the crosshatch, then

pulled off; good paint remains on the surface. Scrubbability is tested by a machine that rubs a soapy

brush over the paint’s surface. A system also exits to rate settling. An excellent paint can sit for six

months with no settling and rate a ten. Poor paint, however will settle into immiscible lump of

pigment on the bottom of the can and rate a zero. Weathering is rested by exposing the paint to

outdoor conditions. Artificial weakening exposes a painted surface to sun, water, extreme

temperature, humidity or sulfuric gases. Fire retardency is checked by burning the paint and

determining its weight loss. If the amount of weight lost is more than 10 percent, the paint is not

considered fire resistant.

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When it comes to our focus, we understand that the quality control is a product oriented process.

When it comes to quality assurance, it is a process – oriented practice. When quality control makes

sure the end product meets the quality requirements, quality assurance makes sure that the process

of manufacturing the product does adhere to standards.

Therefore, quality assurance can be identified as a proactive process, while quality control can be

noted as a reactive process.

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 CHAPTER FIVE

CONCLUSION AND RECOMMENDATIONS

5.1. CONCLUSION

It is important to note that the e quality of paint is analyzed after production to ensure that they

meet the required standard set by the regulatory body. The quality standards one however

maintained by the formulation given, as well as the test conducted by the quality control laboratory

for every batch of product, to ensure that on the final production any deviation from the set

standards is minimal completely eliminated. In addition, theses must be liason between the quality

control laboratory and the production department of the company, for the products to meet set

standard or even the company meeting their personal goals.

5.2. RECOMMENDATION

The idea of industrial training as organized by the federal government and the industrial work

experience scheme (SIWES) is quite an encouraging one as it exposed student to the labour market

as well as to the practical aspect of their course of study. Infect, I am very happy with the federal

government, SIWES and ITF for their joint effort in seeing that this programme was established and

carried out.

To be sincere, I learnt so many things relayed to my course of study during the six-month industrial

training (IT) exercise and therefore encourage the continuity of this work experience scheme.

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 REFERENCES

Bently, J. (Author) and turner, G.P.A (Author) (199&) introduction to paint chemistry and principle

of paint technology. ISBN 0412723204

Flick, Ernest w. handbook of paint raw materials, 2nd edition. Noyes Data Corp, 1989

Martens, Charles R. Emulsion and water soluble a paints and coatings. Reinhold Publishing

Company 1964

Stephanie papa (October 13, 2011) “oldest human paint making studio discovered in cave” Live

science.

Turner, G.P.A. introduction to paint chemistry and principle of paint technology, 3rd edition,

chapman & hall, 1988

Woodbridge, Paul R (Edition) (1991). Principle of paint formulation. ISBN 0412029510.

http://resources.schoolscience.co.uk/index.asp

http://www.paintmaking.com/index.html

http://www.goldenpaints.com/index.php

http://www.thepaintedsurface.com/index.php

http://en.wikipedia.org/wiki/Viscosity

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http://www.zorotools.com/

http://www.homeinstitute.com/

http://www.thomasnet.com/

http://colerepair.com/

http://www.steelconstruction.info/

http://www.diynetwork.com/painting/index.html

http://www.aaechemie.com/index.html

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