SDDDZ

Contents
Introduction..................................................................................................................................................................................... 2
Background................................................................................................................................................................................... 2
Departments................................................................................................................................................................................ 2
Research and Development (R&D) department.....................................................................................................................3
Production department...........................................................................................................................................................3
Quality control (QC) department.............................................................................................................................................3
Packaging and Warehousing department...............................................................................................................................3
Sales and marketing department............................................................................................................................................4
Supply chain and procurement department...........................................................................................................................4
Environmental health and safety department........................................................................................................................4
Maintenance and engineering department............................................................................................................................4
Human resource department..................................................................................................................................................4
Administration and finance department.................................................................................................................................5
Manufacturing system.................................................................................................................................................................5
Raw material............................................................................................................................................................................ 5
Types of paints............................................................................................................................................................................. 5
The Process.................................................................................................................................................................................. 7
PLANT LAYOUT............................................................................................................................................................................... 10
What is plant layout?..................................................................................................................................................................10
Principles of plant layout...............................................................................................................................................................10
Types of Plant Layout.................................................................................................................................................................11
Plant layout for paint factory......................................................................................................................................................13
MACHINERIES AND EQUIPMENT....................................................................................................................................................15
Process of Paint Manufacturing.............................................................................................................................................15
Selection of raw materials.....................................................................................................................................................15
Mixing and blending..............................................................................................................................................................15
Grinding and milling...............................................................................................................................................................15
Quality control and testing....................................................................................................................................................15
Packaging and shipping..........................................................................................................................................................15
Production process paint.......................................................................................................................................................15
Laboratory.................................................................................................................................................................................. 16
Weighing the raw materials...................................................................................................................................................16
Dispersion................................................................................................................................................................................... 16
Pre-mixing.............................................................................................................................................................................. 16
Grinding the pigments...........................................................................................................................................................16
Fineness inspection................................................................................................................................................................16
Color inspection.......................................................................................................................................................................... 17
Stability inspection................................................................................................................................................................ 18
Filling...................................................................................................................................................................................... 18
Paint Production Line................................................................................................................................................................. 19
Raw Materials and Their Preparation.........................................................................................................................................19
List of Raw Materials Used in the Paint Manufacturing..............................................................................................................20
Solvents.................................................................................................................................................................................. 20
Pigments................................................................................................................................................................................ 20
Binders................................................................................................................................................................................... 20
Additives................................................................................................................................................................................ 20
Industry Homogenizer................................................................................................................................................................20
LABORATORY.............................................................................................................................................................................. 21
Product Application....................................................................................................................................................................21
Shorter batch time................................................................................................................................................................. 22
Lower Cost.............................................................................................................................................................................. 22
Working Principle...................................................................................................................................................................22
Homogenizer head.................................................................................................................................................................22
Some Cases................................................................................................................................................................................. 23
PILOT PLANT............................................................................................................................................................................... 24
Product Parameter.....................................................................................................................................................................25
Fluid Machinery.......................................................................................................................................................................... 25
Disperser................................................................................................................................................................................ 25
Basket Mill (Mounted on Kettle).................................................................................................................................................26
Disc Type Horizontal Beads Mill..................................................................................................................................................26
Hydraulic Tri-roller Mill...............................................................................................................................................................27
Vacuum Emulsifying Mixing Unit................................................................................................................................................28
Mixer Mounted on Kettle...........................................................................................................................................................28
Filter Unit.................................................................................................................................................................................... 29
Semi-automatic Filling Machine (Weighing Type)......................................................................................................................29
High Viscosity Semi-automatic Filling Machine..........................................................................................................................30
Automatic Liquid Filling Machine (Volume Type).......................................................................................................................30
Storage....................................................................................................................................................................................... 31
Temperature and Humidity........................................................................................................................................................31
Low Temperatures...................................................................................................................................................................... 31
High Temperatures..................................................................................................................................................................... 32
Industrial Zoning Standards...........................................................................................................................................................32
Industrial Zoning......................................................................................................................................................................... 32
1. Amenities Zones:............................................................................................................................................................33
2. Special Infrastructure Zones:.........................................................................................................................................33
3. Logistics Zones:..............................................................................................................................................................34
4. Utilities Zones:................................................................................................................................................................34
5. Residential Zones:..........................................................................................................................................................34
6. Green Zones:.................................................................................................................................................................. 34
Other Associated Regulations.....................................................................................................................................................35
1). Floor Area Ratio (FAR).....................................................................................................................................................35
Impact of FAR in Industry Design................................................................................................................................................35
Why it varies from City to City....................................................................................................................................................36
Factors that Influence FAR..........................................................................................................................................................36
2. Built-up Area Ratio (BAR)..................................................................................................................................................36
Impact of BAR in Industry Design..........................................................................................................................................37
3. Work at Height Regulations (WAHR).................................................................................................................................38
Importance of Setback requirements....................................................................................................................................41
Site selection.............................................................................................................................................................................. 42
Environmental Protection and Industrial Location...............................................................................................................43
Industrial pollution is one of the major causes of air pollution,...........................................................................................43
Transportation Infrastructure................................................................................................................................................43
Site Design Standards.................................................................................................................................................................44
Building Location.................................................................................................................................................................... 44
Circulations............................................................................................................................................................................ 45
Parking................................................................................................................................................................................... 46
Landscaping............................................................................................................................................................................ 47
Site Lighting................................................................................................................................................................................ 48
Static Lighting Vs Flexible Lighting.............................................................................................................................................49
Safety measures......................................................................................................................................................................... 50
Security....................................................................................................................................................................................... 51
INDUSTRIAL BUILDING DESIGN.....................................................................................................................................................52
Architectural............................................................................................................................................................................... 52
Form and Detail..................................................................................................................................................................... 52
Color and Materials...............................................................................................................................................................52
Structural.................................................................................................................................................................................... 54
Framing system...................................................................................................................................................................... 54
Foundation type.....................................................................................................................................................................57
Roofing system........................................................................................................................................................................... 58
Flooring system and finishes......................................................................................................................................................59
MEP (Mechanical, Electrical, and Plumbing) Design for a Paint Factory.....................................................................................60
Introduction
Background
Contemporary paints and coatings encompass a vast array of compounds meticulously engineered to meet the diverse
demands of countless applications. From the familiar latex paints adorning homes to the translucent coatings safeguarding food
containers, to the intricate finishes adorning automobiles, the realm of paint is expansive and varied, tailored to fulfill specific
needs.
Paint, originally comprising pigments suspended in liquid mediums, traces its origins back approximately 30,000 years when
early humans adorned cave walls with rudimentary colors, leaving behind visual narratives of their existence. However, it
wasn't until the Industrial Revolution that the paint and coatings industry emerged as a significant component of the economy.
The first recorded paint mill in America was established in Boston in 1700, while advancements such as the patenting of "ready
mixed" paints by D.R. Averill in 1867 marked significant milestones in the industry's development.
The mid to late 1800s witnessed the proliferation of paint factories across populated areas, facilitated by mechanization, which
broadened access to manufacturing processes. However, the decentralized structure of small manufacturers prevailed until the
mid-1900s due to the high transportation costs associated with prepared paint. The advent of assembly line manufacturing
during the early 1900s further propelled the demand for paints and coatings, integral for enhancing the aesthetic appeal,
protection, and longevity of manufactured goods.
Prior to World War II, as the understanding of the environmental and health impacts of paint components grew, manufacturers
began responding by reformulating their products to mitigate risks. The gradual phase-out of lead pigments commenced before
the war, culminating in voluntary industry standards in the 1950s to limit lead content in house paints. By 1978, the Consumer
Product Safety Commission banned the use of lead in consumer paint, marking a pivotal moment in paint safety regulations.
In the modern era, paints and coatings often operate behind the scenes, yet they play indispensable roles in delivering high-
quality products to consumers. Whether preserving food freshness, protecting durable goods, enhancing housing aesthetics, or
ensuring the longevity of furniture, the value of paints and coatings is immeasurable. The industry's total value of product
shipments in 2020 amounted to approximately $26.1 billion, underscoring its enduring significance in various sectors of the
economy.
In essence, the evolution of paints and coatings mirrors humanity's journey from primitive cave paintings to sophisticated
protective barriers, embodying technological advancements, environmental consciousness, and regulatory standards. As the
demands of modern life continue to evolve, so too will the innovation and adaptability of paints and coatings, ensuring their
continued relevance in safeguarding and enhancing our surroundings.
Departments
A paint manufacturer has a number of departments. Each department is located in a separate building on the same
factory site. These are:
 Research and Development (R&D)
 Production
 Quality control (QC)
 Packaging and Warehousing
 Sales and Marketing
 Supply chain and procurement
 Environmental health and safety (EHS)
 Maintenance and engineering
 Human resource
 Administration and Finance
Research and Development (R&D) department

The Research and Development (R&D) department in a paint manufacturing plant plays a pivotal role in driving
innovation and advancing paint technology. R&D pioneers’ innovation by exploring new materials, techniques, and
processes, aiming to redefine conventional paint technology and meet consumer expectations. Their responsibilities
include formulating new paints, enhancing existing products, and developing environmentally friendly alternatives.
With expertise in materials science, polymer chemistry, and surface coatings, R&D professionals meticulously
analyze and optimize formulations to meet specific market demands. They are committed to reducing the
environmental footprint of paint production through sustainable practices and eco-conscious solutions, ensuring
precision and efficiency in their work.
Production department
The production department oversees the actual manufacturing process of paints, including mixing raw materials,
blending, milling, and dispersing pigments and additives.
 Mixing Raw Materials: The production process begins with the precise measurement and mixing of the raw
materials needed for the paint formulation. These raw materials typically consist of resins, solvents,
pigments, additives, and other components. Precise measurement and thorough mixing are required to
ensure uniformity and consistency in the paint mixture.
 Blending: Once the raw materials are accurately measured, they are blended together in mixing vessels or
tanks. Blending ensures that all components are thoroughly combined and distributed evenly throughout
the mixture. This step is crucial for achieving the desired properties and characteristics of the paint, such as
color, texture, and viscosity.
 Milling: Milling is a process used to break down particles and achieve the desired particle size distribution
in the paint formulation. This step is particularly important for dispersing pigments and other solid
additives evenly throughout the paint matrix. Milling may involve the use of specialized equipment such as
bead mills, roller mills, or attritors to achieve the desired particle size and distribution.
 Dispersing Pigments and Additives: Dispersing pigments and additives evenly throughout the paint matrix
is essential for achieving uniform color, texture, and performance characteristics. The production
department employs various techniques and equipment to disperse pigments and additives effectively,
such as high-speed dispersers, homogenizers, or shear mixers. This ensures that the paint has consistent
color intensity and properties across different batches.
Quality control (QC) department
QC personnel in a paint factory monitor and test both incoming raw materials and finished paint products to
guarantee they meet predetermined quality criteria. This encompasses assessing parameters like color consistency,
viscosity, drying time, durability, and compliance with regulatory standards. They utilize various testing methods to
ensure that the paints maintain consistent quality throughout production and adhere to safety and environmental
regulations.
Packaging and Warehousing department
The Packaging Department manages the packaging materials, labeling, and storage processes within a paint
manufacturing company. It oversees the handling of packaging materials, application of labels to paint containers,
and storage of packaged products until distribution. Proper packaging is essential for ensuring the safety of paint
products during transportation and storage, protecting them from external factors like moisture and contaminants.
Additionally, secure packaging maintains product integrity and compliance with regulatory standards. Ultimately,
the Packaging Department plays a crucial role in upholding product quality, customer satisfaction, and brand
reputation through effective packaging practices.
Sales and marketing department
The Sales and Marketing Department assumes the pivotal role of promoting and selling paint products within a
company. It encompasses a range of activities aimed at enhancing product visibility, attracting potential customers,
and fostering long-term relationships. Market research forms a cornerstone of this department's operations,
allowing for a deeper understanding of consumer needs, preferences, and market trends. Advertising initiatives are
devised and executed to effectively communicate product benefits and differentiate offerings in a competitive
landscape. Moreover, customer engagement strategies are employed to cultivate brand loyalty and satisfaction,
thereby driving sales growth and market penetration.
Supply chain and procurement department

Supply chain and procurement management is a critical function within a company, responsible for overseeing the
flow of goods and services from suppliers to customers. This department coordinates various activities such as
sourcing raw materials, managing supplier relationships, negotiating contracts, and optimizing logistics operations.
By ensuring the timely availability of materials and resources, supply chain and procurement efforts contribute to
the seamless operation of the business. Additionally, effective management in this area can lead to cost savings,
improved efficiency, and enhanced overall performance. Ultimately, this department plays a vital role in
maintaining a competitive edge and meeting customer demands in the marketplace.
Environmental health and safety department

The Environmental Health and Safety (EHS) department is entrusted with safeguarding the well-being of
employees, protecting the environment, and ensuring compliance with regulatory standards. This department
implements policies and procedures aimed at identifying, assessing, and mitigating potential hazards in the
workplace. Responsibilities include conducting risk assessments, developing safety protocols, providing employee
training, and maintaining emergency response plans. Additionally, the EHS department monitors environmental
impact, implements pollution prevention measures, and manages waste disposal practices to minimize adverse
effects on ecosystems and communities. By prioritizing health, safety, and environmental stewardship, this
department promotes a culture of responsibility and sustainability within the organization.
Maintenance and engineering department

The Maintenance and Engineering department plays a crucial role in ensuring the reliability, efficiency, and safety
of equipment and facilities within a company. This department is responsible for overseeing the upkeep, repair,
and optimization of machinery, infrastructure, and other assets essential to the production process. Maintenance
technicians conduct routine inspections, preventive maintenance, and troubleshooting to identify and address
potential issues before they escalate. Engineers within this department design, implement, and improve systems
and processes to enhance productivity and reduce downtime. By maintaining equipment in optimal condition and
implementing innovative solutions, the Maintenance and Engineering department contributes to operational
continuity, cost-effectiveness, and overall business performance.
Human resource department

The Human Resources (HR) department serves as the backbone of an organization's workforce management and
development. It is responsible for a wide range of functions related to personnel, including recruitment, hiring,
onboarding, training, performance management, employee relations, benefits administration, and compliance with
labor laws and regulations. HR professionals work to create a positive and supportive work environment, address
employee concerns, promote diversity and inclusion, and foster professional growth and development
opportunities. Additionally, HR plays a strategic role in aligning the organization's human capital with its overall
goals and objectives, ensuring that the company has the right talent in place to drive success and innovation.
Administration and finance department

The Human Resources (HR) department serves as the backbone of an organization's workforce management and
development. It is responsible for a wide range of functions related to personnel, including recruitment, hiring,
onboarding, training, performance management, employee relations, benefits administration, and compliance with
labor laws and regulations. HR professionals work to create a positive and supportive work environment, address
employee concerns, promote diversity and inclusion, and foster professional growth and development
opportunities. Additionally, HR plays a strategic role in aligning the organization's human capital with its overall
goals and objectives, ensuring that the company has the right talent in place to drive success and innovation.
Manufacturing system
Product and product variants
Paints are a type of coating that is used as both a colorful decoration and a protective layer. Coatings are any kind
of covering that is applied to an object's surface for either functional or decorative reasons. In the realm of art,
paint is used to create images, commonly referred to as paintings. Paints are commonly used for finishing in
construction industry.
Raw material
 Pigments: These are finely ground colored powders that give paint its hue. Pigments can be organic or
inorganic, and they provide the color and hiding power to the paint.
 Binders (Resins): Binders, also known as resins or polymers, are the components that hold the pigment
particles together and adhere them to the painted surface. Common binders for enamel paints include alkyd
resins, acrylic resins, and epoxy resins.
 Solvents: Solvents are used to dissolve the binder and adjust the viscosity of the paint. They evaporate during
the drying process, leaving behind the solid paint film. Common solvents used in enamel paint production
include mineral spirits, toluene, xylene, and acetone.
 Additives: Various additives may be included to modify the properties of the paint, such as drying agents to
accelerate drying time, thickeners to adjust viscosity, anti-settling agents to prevent pigment settling, and
stabilizers to enhance shelf life.
 Fillers: Fillers are inert materials added to enamel paints to improve their durability, texture, and opacity.
Common fillers include calcium carbonate, talc, silica, and kaolin clay.
Types of paints
I. Oil-based paints
Oil paints are usually applied as a primer, undercoat and a finish coat. They are often referred to as “solvent
based” or “alkyd” paints. Oil based paints contain a much higher level of Volatile Organic Compounds
(VOCs), which makes the paint's odor very noticeable. In the past oil paints were heavily relied on because
of its durability and longevity on surfaces. Oil paints are best suited for wooden and metallic surfaces for
home projects due to their durability and strong adhesion.
The raw material need for producing this type of paints are:
 Pigments: Both natural and synthetic
 Solvents: natural linseed oil or synthetic alkyd oil
 Resins
 Additives: Fillers and Anti-fungicidal agents
II. Enamel paint
Enamel paint is paint that air-dries to a hard, usually glossy, finish, used for coating surfaces that are
outdoors or otherwise subject to hard ware or variations in temperature; it should not be confused with
decorated objects in "painted enamel", where vitreous enamel is applied with brushes and fired in a kiln.
The name is something of a misnomer, as in reality, most commercially available enamel paints are
significantly softer than either vitreous enamel or stoved synthetic resins, and are totally different in
composition.
 Pigments
 Resins: Alkyd resins-based
 Solvents: Mineral spirits, turpentine
 Drying Agents
 Additives: UV stabilizers ,
 Minerals: Silica, borax, feldspar, and metal oxides.
III. Emulsion paint: is a water-based paint made with a mixture of synthetic resins, additives, pigments, and
water. It is the most commonly used type of wall paint by a house painter due to its affordability, easy
application, and durability. It also dries quickly compared to oil-based paints.
 Acrylic resin binder
 Pigments
 Additives: anti-fungicides or mildew ides
 titanium dioxide
IV. Varnish
Varnish is a clear transparent hard protective coating or film. It is not to be confused with wood stain. It
usually has a yellowish shade due to the manufacturing process and materials used, but it may also be
pigmented as desired. It is sold commercially in various shades.
 Drying Oils: linseed oil, Tung oil, and walnut oil.
 Resins: Both synthetic and natural resins are used. Polyurethanes, polyesters, vinyl
acetate/ethylene (VAE), silanes, and epoxy resins.
 Solvents: toluene, xylene, or acetone
 Pigments
 Fillers: Diatomaceous earth, talc, and clay
V. Anti-Corrosive Paint
Made from anti-corrosive elements like linseed oil, zinc chrome and fine sand, Anti-Corrosive Paints are
ideal for metallic surfaces. As its name suggests, it helps prevent corrosion on various surfaces, mainly
metallic in nature.
 Pigments
 Binders
 Solvents: Mineral spirits, alcohol
 Additives: zinc metallic, aluminum pigments, or zinc phosphate
VI. Granite paint
Granite paint is a type of faux finish that mimics the look of natural granite. It’s commonly used to update
and decorate walls and furniture. You can find specialty granite flakes at home improvement stores, which
are added to a base paint color. The paint is then applied to surfaces using traditional painting methods1.
Keep in mind that while it looks like granite, it isn’t as durable as real granite. Therefore, it’s not
recommended for high-traffic areas in your home, such as stairways or hallways2. If you’re considering
painting granite surfaces, make sure to follow the necessary prep work and steps for a lasting finish
Raw materials
 water
 silicone oil as deformer
 purpose water-washed kaolin
 meshes of heavy calcium carbonate
 hydroxyethyl cellulose
 polyacrylic acid ammonium salt as dispersant,
 alkyl phenol polyoxyethylene ether
 pure Acrylic elastic emulsion amp-95
 5% concentration protective glue.
The Process
Producing a paint of very high quality is a labor-intensive and specialized process. Most paint type have the same
production process; they varies by their raw material need.
Those steps are:
A. Laboratory: Before production starts each separate paint has a unique
formula developed for it in the laboratory. During this development
stage the paint’s quality aspects are comprehensively tested. The
laboratory is also responsible for inspecting the raw materials before
they go into the product and monitoring the quality during the
production process. In addition to the above activities, particular
attention is also given to research into new raw materials and paint
systems.
B. Weighing the raw materials
In the production of painting depends on the need of raw material
varies depend on the type of the painting.
At the start of the production process the dry raw materials are
weighed here accurately to the gram and prepared for transport to the
next department, the pre-mixing department.
C. Dispersion: Pigments are insoluble in the binder. They therefore have

to be regularly dispersed in the binder, that is to say finely distributed.
This dispersal occurs in two steps, first through pre-mixing with a
mixer and then the final fineness is determined with a triple roll mill.
D. Pre-mixing: The pigments are supplied in dry powder form, with the
pigment components held together in clusters. During the pre-
mixing these are turned to smaller clusters and homogenously
distributed throughout the binder. The tinting strength of the paint
is now relatively low, but this will increase as the pigment is ground
finer in the next production phase.
E. Grinding the pigments: In the triple roll mill the pigment

clusters are ground further to the desired fineness.
During this process the pigment particles must not get
damaged as this may result in a change of color. The
three rollers rotate in opposite directions with different
speeds. The first roller turns relatively slowly, the second 3
times as fast and the third 9 or 12 times as fast,
depending on the type of mill. The difference in speed
helps to grind the pigment lumps and the paint goes from
one roller to the other. The paint is finally removed using a scraper.
F. Inspection: After a serious of production the paint will be inspect different kind of physical characteristics
of the paints before filing and packaging.
 color. Both are applied thick as well as thin so that both the mass tone and the undertone of the
color can be seen. There must not be a difference between the new color and the standard color.
 Stability inspection: In order to ensure that only quality products are sold, each batch is left to
stand for a certain time in order to check the stability.
After this period another laboratory check is carried
out, and after approval the paint is filled into
containers.
 Fineness inspection: The distance between the rollers
determines the fineness of the grind. This process is
run through for a maximum of five times. The finer
the grind, the greater the tinting strength of the paint.
G. Filling: Tubes are filled from the underside, with the top
already in place. Plastic tubes are closed by melting the
material, while the aluminum tubes are folded step-by-step
and squeezed shut. Bottles are filled, closed and then
labelled. The final step is to check that the packaging
contains the right amount of paint.
The process flow
A process flow is a sequential series of steps that are performed to
achieve a production process.
The production process of paint is a meticulously orchestrated series of steps that begins with laboratory
development and quality testing. Here, chemists and technicians work diligently to formulate unique formulas for
each paint type, ensuring they meet specific requirements for color, texture, durability, and drying time. Raw
materials undergo rigorous inspection to ensure they meet the required standards before being utilized in the
production process. Once formulas are finalized, the next step involves the precise weighing of dry raw materials,
including pigments, binders, solvents, additives, and fillers. Accurate measurement ensures consistency in the
composition of paint batches, which is crucial for maintaining quality throughout the manufacturing process.
Following the weighing of raw materials, the dispersion and pre-mixing stages are carried out to homogeneously
distribute pigments throughout the binder. Pigments, supplied in dry powder form, are broken down into smaller
particles during pre-mixing, resulting in a uniform dispersion within the paint base. Subsequently, the pigments
undergo further refinement in a triple roll mill, where they are ground to the desired fineness without damaging the
particles. This grinding process is essential for achieving optimal color intensity and uniformity in the final product.
Throughout these stages, strict quality inspections are conducted to assess the paint's physical characteristics,
including fineness, color accuracy, and stability.
Once the paint passes inspection, it moves on to the filling stage, where it is packaged into containers for distribution
to customers. Tubes are sealed through melting or folding, while bottles are filled, sealed, and labeled according to
product specifications. The final step involves verifying the correct amount of paint in each container to meet
regulatory standards. This comprehensive production process ensures that the end product meets stringent quality
criteria and satisfies customer expectations for performance and consistency. By adhering to strict protocols and
continuous
Innovation, paint manufacturers can deliver products that meet the highest standards of quality and reliability in the
market.
PLANT LAYOUT
What is plant layout?
Plant layout encompasses the strategic arrangement of various components within a factory setting to optimize production
efficiency, ensuring maximum output with desired quality while minimizing costs. It involves the meticulous placement of
machinery, personnel, storage areas, material handling equipment, and ancillary services to utilize available floor space
effectively. This comprehensive plan aims to facilitate the manufacturing process by creating the most efficient and economical
configuration of resources. By strategically locating machines and facilities, plant layout ensures seamless workflow, minimizes
material handling distances, and enhances overall productivity. Additionally, an effective layout considers factors such as safety
regulations, ergonomic principles, and workflow optimization to create a conducive working environment that fosters efficiency
and innovation. In essence, plant layout serves as a blueprint for the systematic utilization of factory space and resources to
achieve optimal production outcomes.
Principles of plant layout

When designing a plant layout, several key principles should be considered to ensure efficiency, safety, and optimal utilization
of resources. Let’s delve into these principles:
I. Principle of Minimum Movement: The Principle of Minimum Movement in plant layout design emphasizes organizing
materials and labor within a facility to minimize their travel distances during production. By strategically positioning
workstations, machinery, and storage areas closer together, unnecessary transportation and material handling costs
and time can be saved. This principle aims to optimize resource utilization, enhance productivity, and reduce
operational expenses by streamlining workflow and minimizing movement within the facility.
II. Principle of Space Utilization: The Principle of Space Utilization in plant layout design underscores the efficient use of
all available space within a facility, emphasizing both horizontal and vertical dimensions. This principal advocates for
maximizing the utilization of not only the floor area but also the vertical space, such as ceiling height.
 Horizontal space utilization: Ensuring that the floor area is efficiently utilized by arranging workstations,
machinery, storage areas, and other facilities in a manner that minimizes wasted space. This may involve
organizing equipment and processes in a compact and logical manner to minimize unnecessary movement and
maximize workflow efficiency.
 Vertical space utilization: Making efficient use of vertical space by utilizing shelves, racks, mezzanines, and
other storage solutions to store materials, products, and equipment vertically. By utilizing the vertical
dimension, companies can increase storage capacity without expanding the footprint of the facility
horizontally. This can be particularly beneficial in facilities with limited floor space.
III. Principle of Flexibility: The Principle of Flexibility in plant layout design emphasizes creating layouts that can easily
adapt to changes necessitated by expansion, technological advancements, or shifts in production requirements. This
principle acknowledges the dynamic nature of manufacturing environments and the need for facilities to remain agile
and responsive to evolving business needs. The key aspects of the principle of flexibility are:
 Modular Design: Arrange the layout in modular units to allow for easy adjustments without major redesigns.
 Scalability: Ensure the layout can handle both small and large changes in production capacity or processes.
 Clearances and Access: Maintain sufficient space and access routes for smooth movement of equipment and materials,
facilitating quick reconfiguration.
 Future-Proofing: Incorporate features that anticipate future needs and trends, minimizing the need for costly
renovations later on.
IV. Principle of Interdependence: The principle of interdependence suggests that operations and processes that rely on
each other should be situated close together to minimize the distance products need to travel. This proximity offers
benefits like lower transportation costs, increased efficiency through better coordination, shorter lead times, reduced
inventory levels, and improved quality control. In essence, it's about optimizing spatial planning to enhance production
processes and overall operational performance.
V. Principle of Overall Integration: It advocates for consolidating all plant facilities and services into a unified operating
unit. This consolidation aims to streamline operations, reduce redundancy, and optimize resource utilization, ultimately
minimizing production costs. By fostering better communication, coordination, and efficiency across the organization,
this approach enhances productivity and helps achieve long-term sustainability and competitiveness.
VI. Principle of Safety: This principle emphasizes the importance of integrating safety considerations into the layout design
to ensure the comfort and well-being of workers. It involves incorporating features such as clear pathways, adequate
lighting, ergonomic workstations, and proper ventilation to create a safe working environment. By prioritizing safety in
the layout design, companies can reduce the risk of accidents and injuries, promote employee health and satisfaction,
and comply with regulatory standards.
VII. Principle of Smooth Flow: The Principle of Smooth Flow focuses on designing a layout that minimizes work bottlenecks
and enables the uninterrupted flow of materials, information, and activities throughout the plant. This involves
arranging workstations, equipment, and processes in a logical sequence to avoid congestion and delays. By optimizing
the flow of work, companies can enhance productivity, reduce lead times, and improve overall operational efficiency.
VIII. Principle of Economy: The Principle of Economy underscores the importance of designing a layout that achieves cost-
effectiveness in terms of investment in fixed assets. This involves optimizing space utilization, minimizing unnecessary
movement of materials or resources, and avoiding overinvestment in equipment or infrastructure. By maximizing
efficiency and minimizing waste, companies can achieve a higher return on investment and improve profitability.
IX. Principle of Supervision: This principle focuses on designing a layout that facilitates effective supervision and
management of workers. It involves arranging workstations and processes in a way that allows supervisors to oversee
operations easily, monitor performance, and provide guidance or support as needed. By enhancing supervision,
companies can ensure adherence to quality standards, promote accountability, and maintain productivity levels.
X. Principle of Satisfaction: The Principle of Satisfaction emphasizes the importance of designing a layout that enhances
employee morale and satisfaction. This involves creating a work environment that promotes collaboration, autonomy,
and recognition, as well as providing amenities such as break areas, restrooms, and comfortable workspaces. By
prioritizing employee satisfaction, companies can boost morale, reduce turnover, and improve overall productivity and
performance.
Types of Plant Layout
The process layout arranges workflow around the production process. All workers performing similar tasks are grouped
together. There are four main types of plant layouts:
 Process layout
 Production layout
 Fixed-position layout
 Combination
a) Process layout: In this type of plant type similar machines and similar operation is held in one place. The machines
are arranged according to their function.
Advantages of process layout

 Better utilization of available equipment
 Worker are dealing with only one type of machines , so product will be better.
 Workers in one section are not affected by the operation carried out in other section.
Disadvantage of process layout
 For the same amount of production , the process layout needs more space.
 Automatic material handling is difficult
 Production control becomes difficult
 Raw material has to travel a longer distance for being processed to finished goods, this increases
material handling and associated costs.
 It needs more inspection and efficient co-ordination.
b) Production layout: It also known as line layout , various operation on raw material are performed in a sequence
and machines are placed accordingly the production flow. It applies mass production where a huge amount of the
same product and continuous flow of the process is need.
The machines will arrange according to the sequence of operation.

 Less space required for the same volume of production
 Material handling is lesser
 Co-ordination will be better , production planning , and control will be easier.
 Fewer skilled workers maybe do the work
Disadvantage of process layout
 Specified in product determines the layout , a change in product will made a major change in layout.
Thus, flexibility in the layout is reduced
 Rate of production is depended on the output rate of the slowest machine. This leads to excessive idle
time of another machine if the production line is not balanced.
 It is difficult to increase production beyond the capacities of the production line.
c) Combination layout: It combines the advantage of both process layout and product layout. It is possible where the
item is made in different types and size.

 It combine the advantage of both process and production layout
 It can be useful when a number of items are produced in the same sequence but in small numbers. No
item justified for individual production line.
d) Fix position layout: in other type of layouts the product moves past stationary production equipment but in fixed
potion layout the product kept stationery and equipment move around it. Its common applicable in ship and
aircraft manufacturing.
 It is possible to assign one more skilled workers from the start of a project to finish in order to ensure
continuity of work.
 Involves the least movement of materials , manufacturing of large size product is possible .
 A number of quite projects can be taken with same layout
Disadvantages of process layout
 It involves a low content of work in progress
 It involves high equipment handling costs.
Paint factories typically use a process layout type. In a process layout, similar machines and equipment are grouped together
based on the type of process they perform. This layout is commonly used in industries where products undergo multiple stages
of processing, such as mixing, blending, and packaging, which is typical in paint manufacturing. Process layouts allow for
efficient flow of materials and resources through the production process, facilitating easier supervision and control over each
stage of production.
Plant layout for paint factory
Most paint factories uses process plant layout and production layout. Most of the machinery are stationary and the product are
not fixed so the factories doesn’t need fixed plant layout.
Process plant layout
MACHINERIES AND EQUIPMENT
Process of Paint Manufacturing
To prepare these raw materials for use in paint manufacturing, they must undergo several processing steps. This typically
involves grinding and mixing the pigments and other ingredients to create a homogeneous mixture. The resulting paint base is
then packaged and shipped to paint manufacturers, where it is further processed and combined with additional ingredients to
create the final paint product. The paint manufacturing process typically involves the following steps:
Selection of raw materials
The first step in the paint manufacturing process is the selection of raw materials. These include pigments, binders, solvents,
and additives that will be used to create the desired paint color and properties. The selection of raw materials is crucial to the
quality of the final paint product, and manufacturers carefully choose each component to ensure that it meets their
specifications.
Mixing and blending

Once the raw materials have been selected, they are carefully mixed and blended in the proper proportions to create the base
paint mixture. This is typically done using large industrial mixing equipment, such as blenders or agitators, to ensure thorough
and consistent mixing.
Grinding and milling

After the base paint mixture has been created, it must be ground and milled to achieve the desired consistency and
smoothness. This is typically done using a mill, which can be either a horizontal or vertical roller mill. The paint is fed into the
mill, where it is ground and milled until it reaches the desired consistency.
Quality control and testing

Before the paint is packaged and shipped to customers, it must undergo thorough quality control and testing. This involves
evaluating the paint's physical and chemical properties, such as its colour, viscosity, and drying time, to ensure that it meets the
manufacturer's specifications and customer requirements.
Packaging and shipping

The last step in the paint manufacturing process is packaging and shipping the finished product to customers. Paint is typically
packaged in containers such as cans or drums and shipped to retailers or directly to consumers.
Overall, the paint manufacturing process is a complex and highly controlled one that involves a wide range of steps and
materials to produce a high-quality product. By carefully selecting and blending raw materials, grinding, and milling the paint to
the desired consistency, and conducting thorough quality control and testing, manufacturers can produce a wide range of
durable and attractive paint coatings for a variety of applications.
Production process paint

Producing an artists' paint of very high quality is a labor-intensive and specialized process. The production staff of
Royal Talen’s receive internal training for this by laboratory specialists and refine their knowledge of the trade under
the supervision of the experienced paint makers. By combining the modern developments in the area of paint
technology optimally with the best from its past, the quality of the Royal Talen’s products is now recognized
throughout the world.
Laboratory
Before production starts each separate paint has a unique formula developed for it in the laboratory. During this
development stage the paint's quality aspects are comprehensively tested. The laboratory is also responsible for
inspecting the raw materials before they go into the product and monitoring the quality during the production
process. In addition to the above activities, particular attention is also given to research into new raw materials and
paint systems.
Weighing the raw materials

The central warehouse stores all the dry raw materials. This includes pigments and extenders, as well as binders such
as dextrine and Gum arabic which is later made liquid through dilution. At the start of the production process the dry
raw materials are weighed here accurately to the gram and prepared for transport to the next department, the pre-
mixing department. The pre-mixing department stores the liquid binders and additives. The correct amount is
tapped off, after which the weighed dry raw materials are added. As small amounts of dry raw materials are left
behind in the sacks during this process, the paint has to be checked at each subsequent production step against
standards for the relevant product according to colour and viscosity, and is adjusted if necessary.
Dispersion
Pigments are insoluble in the binder. They therefore have to be regularly dispersed in the binder, that is to say finely
distributed. This dispersal occurs in two steps: first through pre-mixing with a mixer and then the final fineness is
determined with a triple roll mill.
Pre-mixing
The pigments are supplied in dry powder form, with the pigment components held together in clusters. During the
pre-mixing these are turned to smaller clusters and homogenously distributed throughout the binder. The tinting
strength of the paint is now relatively low, but this will increase as the pigment is ground finer in the next production
phase.
Grinding the pigments

In the triple roll mill the pigment clusters are ground further to the desired fineness. During this process the pigment
particles must not get damaged as this may result in a change of color. The three rollers rotate in opposite directions
with different speeds. The first roller turns relatively slowly, the second 3 times as fast and the third 9 or 12 times as
fast, depending on the type of mill. The difference in speed helps to grind the pigment lumps and the paint goes
from one roller to the other. The paint is finally removed using a scraper.
Fineness inspection
The distance between the rollers determines the fineness of the grind. This process is run through for a maximum of
five times. The finer the grind, the greater the tinting strength of the paint. The rollers are hollow and are cooled on
the inside with water, as the pigments would otherwise burn through the heat of the friction. Depending on the
nature of the pigment and the purpose of the paint or ink, the pigments are ground to between 2 and 55 microns (1
micron = 1/1000 mm). After the last grinding the paint finally has the required viscosity.
After the grinding the fineness is checked using the Hegman bar. The depth of the groove in the bar gradually
increases, indicated in microns. The paint is thinned to a certain viscosity and then applied to the groove and levelled
off. At the point where the pigment particles are larger than the thickness of the paint layer they stick up above the
surface of the paint film. At this point, visible to the human eye under skimming light, the fineness is read off.
Color inspection
The new color is now compared against the standard color. Both are applied thick as well as thin so that both the
mass tone and the undertone of the color can be seen. There must not be a difference between the new color and
the standard color.
Stability inspection
In order to ensure that only quality products are sold, each batch is left
to stand for a certain time in order to check the stability. After this
period another laboratory check is carried out, and after approval the
paint is filled into containers.
Filling
Tubes are filled from the underside, with the top already in place. Plastic
tubes are closed by melting the material, while the aluminum tubes are
folded step-by-step and squeezed shut. Bottles are filled, closed and then labelled. The final step is to check that the
packaging contains the right amount of paint.
Paint Production Line

Raw Materials and Their Preparation
Paint is typically made from a combination of raw materials, including solvents, pigments, binders, and additives. These raw
materials are carefully selected and combined in precise proportions to create the desired properties and characteristics in the
finished paint.
The specific raw materials used in paint manufacturing will vary depending on the type of paint being produced. For example,
the raw materials used in water-based latex paint production will be different from those used in oil-based alkyd paint.
List of Raw Materials Used in the Paint Manufacturing

There are many different raw materials that are combined and used in the preparation of paint Some common raw materials
used in paint manufacturing include:
Solvents
Solvents are used to dissolve the other ingredients in the paint and control the consistency of the finished product.
Common solvents used in paint include water, alcohol, and mineral spirits.
Pigments
Pigments are the colorants that give the paint its color. They are typically finely ground minerals or chemicals that are
insoluble in the paint's solvent. Common pigments used in paint include titanium dioxide, zinc oxide, and iron oxide.
Binders
Binders are the glue that holds the pigments together and adheres the paint to the surface it is applied. Common
binders used in paint include latex, acrylics, and alkyds.
Additives
Additives are substances added to the paint to improve its performance or alter its properties. Common additives used
in paint include preservatives to prevent mold growth, flow agents to improve the paint's application properties, and
UV absorbers to protect against fading from sunlight.
Industry Homogenizer
Application of Industry Homogenizer
 SPC is a single machine equipment with lifting and lowing

 SPA is more suitable for engineering production
 Product description
 Simple structure and reliable effect
 Easy to clean and maintain
 The equipment is equipped with a bottom mounted internal or external circulation high shear homogenizer
 The emulsification tank is equipped with a bidirectional stirring award with scraping walls as standard
 Optional: 316 stainless steel material, various operating methods, CIP cleaning system, and tank structure
LABORATORY
Product Application
 Laboratory emulsification
 Small-scale emulsification production
 Product Advantages
 Programmable parameters
 It can deal many materials in various tests and productions.
Shorter batch time
It can quickly establish a dispersed emulsification system and quickly mix a large amount of material.
Lower Cost
Shorten cleaning time and reduce maintenance requirements, optimize and streamline costs to achieve high production.
Working Principle
The production raw materials are directly pumped into the homogenization head through vacuum, emulsified, and then enter
the main tank through a circulating pipeline, and wait to enter the homogenization head again.
The specially designed scraping wall mixing ensures the mixing effect and high heat exchange efficiency.
Homogenizer head
Design Volume Max. Work Volume Min. Work Volume

Model Dimens （mm）
（L）（L）（L）
SPA-650 650 520 110 1250*1250*2960
SPA-1300 1300 1000 200 1500*1500*3610
SPA-2000 2000 1500 350 1720*1720*3940
SPA-3000 3000 2500 500 1970*1970*4570
SPA-4000 4000 3000 650 2150*2150*4700
SPA-5000 5000 4000 800 2270*2270*4700
SPA-6000 6000 5000 1000 2270*2270*5220

Show
Some Cases
PILOT PLANT
1. Better emulsification result

Lotion is more stable, and the
droplet size is less than 5um
2. Suitable for high viscosity
materials up to 80000mpas in
viscosity
3. High precision
4. PID temperature control,
rapid heating
5. Safety: There is an insulation
layer outside the heating
inter-layer to prevent
operators from getting
burned.
6. Convenience: The structure is
easy to clean and maintain
7. Support customized functions
Vacuum/sterile/explosion-
proof/voltage
Product Parameter
Max.
Design Useful Min.
Model Dimensions (L*W*H/mm)
volume(L) volume Useful volume(L)
(L)
Main tank Water/oil tank
ZJR-30 30 25 10 1400*600*1900(2400) 1000*510*1350
ZJR-50 50 40 15 1400*600*1950(2500) 1000*550*1400
ZJR-100 100 80 30 1750*650*2150(2850) 1500*700*1400
ZJR-150 150 120 45 1900*780*2380(3000) 1500*780*1700
ZJR-250 250 200 75 2600*1900*2500(3500)
ZJR-350 350 280 100 3000*2750*2750(3850)
ZJR-650 650 500 200 3650*3400*3300(4560)
ZJR-850 850 700 250 3750*3550*3350(4800)
ZJR-1300 1300 1000 400 4900*3300*3000(4600)
ZJR-2500 2500 2000 750 4800*4400*3300(4800)
Fluid Machinery
Disperser
Vacuum Disperser with Scraper
The Vacuum Disperser with Scraper is a comprehensive product with function of dispersing,
scraping, and vacuumizing, with the core technology comes from Germany. During dispersing
process, scraper can rotate along the tank wall and generates a radial mixing flow. In addition,
the PTFE scraper can scrape the materials off the tank wall efficiently. It is good for the
materials with mid-and-high viscosity and thixotropic property. The finished products can be
discharged completely and the tank are easy to clean. With vacuum closed design, together
with vacuum pump or the pump group. The vacuum degree can go up to -
0.098mpa（20mba）, It is apply to the dispersing and mixing materials under special working
condition like vacuum degassing, vacuum materials feeding, inert gases protection etc.
 Materials Viscosity Height: 2-5 meters (6-16 feet)

 ≤100,000 cps Width: 1-2 meters (3-6 feet)
 Production Capacity Depth: 1-2 meters (3-6 feet)
 50-5,000L
Application Industry
Prefect meet the requirement of dispersing and mixing materials in industries such as biology, pharmaceuticals, food, paint, ink,
adhesive, pigment, pesticide and etc.
Applicable Materials
Well used in all kinds of slurries with viscosity less than 100,000cps, and solid content less than 60%, such as emulsion paint,
industrial paint, water-based ink, pesticide suspension, adhesive and etc. anaerobic adhesive and etc.
Basket Mill (Mounted on Kettle)
Basket Mill (Mounted on Kettle) is fixed on various containers,

widely applied in complete production line. After grinding, the raw
material will be transported to the next procedure through pipeline,
which makes it easy to become automatic, programmable, and
digital operation. It is the ideal grinding equipment in the automatic
production line.
 Materials Viscosity Height: 1.5-3 meters (5-10 feet)

 ≤5000 cps Width: 1-2 meters (3-6 feet)
 Production Capacity Depth: 1-2 meters (3-6 feet)
 200-3000L
Suitable for dispersing, grinding materials in industries such as biology, pharmacy, cosmetic, food, paint, ink, color paste,
dyestuff, fertilizer etc.. (For more application industry, please click “free consultation”
Materials shall be with viscosity less than 5000cps, with comparatively high requirements of final grinding result or with many
varieties such as emulsion paint, industrial paint, color paste, water-borne ink, fertilizer suspension, enamel etc.
Disc Type Horizontal Beads Mill
The Disc Type Horizontal Beads Mill is a closed continuous production machine for grinding liquid materials. It is one of the
most popular wet grinding machines in the market with good performance and mature structure. And it is characterized in
simple operation, good reliability and full specifications. Its sealing structure adopts double end mechanical seal with self-
lubricating system, sealing liquid is optional, more reliable and durable. The machine is also with temperature, pressure
monitor and protection to ensure the quality of the finished product. Using cerium stabilized zirconium bead (80% Zirconia
content), suitable for grinding paste with fineness requirements of 10-20 micron. It is widely used in coating, paint, ink,
pesticide and other industries.
 Materials Viscosity
 ≤20,000 cps
 Production Capacity and 10-4000L/h
Coating, paint, ink, pesticide and other industries
Paste with viscosity below 20,000 cps and grinding fineness can be down to 10micron, such as primer, intermediate coating,
pesticide suspension agent etc.
Hydraulic Tri-roller Mill
Hydraulic Tri-roller Mill is suitable for grinding and dispersing ointment or high
viscosity slurry with comparatively high requirement of fineness. It achieves
required grinding effect by the friction and crashing among the three tilt rollers
rotating at different speeds. It is equipped with emergency brake button to
prevent equipment damage caused by foreign matter dropped into. The roller is
a casting of special hard alloy (and ceramic materials are optional). The hydraulic
system controls and regulates the clearance between the rollers to achieve the
desired final fineness and production output, stable and highly efficient.
 ≤3,000,000 cps
 Production Capacity
 100-1000kg/h
Suitable for dispersing and grinding materials in industries such as ink, color paste, biology, pharmacy, cosmetic, paint,
adhesive, photovoltaic materials etc. (For more application industry, please click “Free Consultation” )
Materials shall be with viscosity less than 3,000,000cps, with comparatively high requirements of final grinding result such
as offset ink, chocolate, lithium slurry, electronic glue, silver aluminum paste etc..
Vacuum Emulsifying Mixing Unit
Vacuum Emulsifying Mixing Unit is consisted of homogenizing emulsifying pot (lifting

cover, tilting pot body), water pot, oil pot, scraper dual mixing, vacuum system,
electric heating or steam heating temperature control system, electric control, etc. It is
the equipment for top grade medicinal ointment, cream, emulsion.
 Height: 1.5-3 meters (5-10 feet) Production Capacity

 Width: 1-2 meters (3-6 feet) 5-2000L
 Depth: 1-2 meters (3-6 feet)
Mixer Mounted on Kettle
Mixer Mounted on Kettle is functioning in stirring and mixing of liquid-liquid and

liquid-powder for the mass production product, and it can be supplemented by
dispersing, emulsifying, heating and cooling functions to meet the needs of
different production process. The machine can be used continuously for long
period, stable operation and low noise, easy operation, strong adaptation; it is
ideal equipment for multi-function as mixing and dispersing.
 Height: 3-6 meters (10-20 feet) Production Capacity

 Width: 1-2 meters (3-6 feet) Capacity: 50-10,000L
Filter Unit
Filter cart consists of a stainless steel bag type filter, a pneumatic

diaphragm pump, air filter and oil lubricator, single air control valve,
all the components are on the cart. It can be removed to any place
of the production line. There are multi-method of filter group in
option, normally, it is a group consists of a bag-type filter and a
cartridge filter. Delivery pump sucks the raw materials from finished
vessel to the filter group, go through the bag filter for coarse
filtration first and then go toe the cartridge filter for fine filtration to
obtain required finished products.
 Material Viscosity
 ≤50,000 cps
 Filtering Fineness
 0.1-50um
Semi-automatic Filling Machine (Weighing Type)
Semi-automatic Filling Machine(Weighing Type ) adopts

gravimetric method to measure, by weighing sensor output signal
to control the charging valve opening, so as to realize the
purpose of automatic filling. By equipped with a pump in the
front end of the feeding port, or pressuring the material tanks to
sent material from tank to the filling machine. The filter device
can be added before filling to guarantee the quality of products.
The equipment has advantages of high filling efficiency and small
filling error. SIEHE Semi-automatic Filling Machine (Weighing
Type ) is widely used in industries such as coating, printing ink,
paint, asphalt, glue, lubricant, petrochemical, fineness chemical
etc.. It is not only suitable for the filling of liquid, but also for
filling of ointment product.
 ≤50,000 cps
 500-50,000ml
High Viscosity Semi-automatic Filling Machine
High Viscosity Semi-automatic Filling Machine adopts

gravimetric method to measure, by screw extruder or high
viscosity convey pump (such as screw pump, rotor pump) for
feeding, conveying device with the function of frequency
speed control can realize quick or slow feeding. Weighing
sensor output signal control screw and the discharge of the
pump (fast, slow, or stop feeding) to achieve automatic
filling. The filter device can be added before filling to
guarantee the quality of products. The machine is the
dedicated filling machine SIEHE Industry developed for processing high viscosity product.
Materials Viscosity
 ≤500,000 cps
 5-50kg
Automatic Liquid Filling Machine (Volume Type)
Automatic Liquid Filling Machine (Volume Type) consists of the following parts: automatic arrangement of dividing
barrel and lift barrel system, double head volume type filling system, convey system, automatic lift and gland cover
system, automatic code/labeling system, the finished product output system, packaging platform, control system etc..
Parts contact with material is SUS304 stainless steel, the conveying system roller is made of stainless steel, roller chain
plate for engineering plastics, aluminum frame. The automatic arrange dividing barrel and lift barrel system is
customized automatic separation equipment for overlap exposure plastic containers. It is dedicated equipment that
conveys the overlap exposure plastic containers to the separation machine, by machine grab and separate, and convey
them to the next station by pipeline. Filling system consists of four parts: hopper, piston metering pump, filling mouth,
rack and pneumatic control system; The filling nozzle height can install by loosen the cylinder block of hex bolt,
adjusted to the required position and tighten; Filling adopt low filling type filling, when filling, filling mouth put into the
bottom of the barrel, filling and slowly rising at the same time, maintain proper distance between the filling mouth with
the liquid surface, which can effectively prevent
material splash. Automatic cover & gland system
consists of cover storage shelf, cover suction machine,
cover holding cylinder, cover clamping cylinder, cover
pressing cylinder. It is machine made for overlap
exposure plastic container lid cover to finish automatic
separation, lift, and gland. It single separate the overlap
exposure container cover, by fetching manipulator, and
placed in a sealed container needed, again through the
photoelectric detection, special die pressure, to push
back the cover and barrel close together.
 Height: 1-2 meters (3-6 feet)

 Width: 1-2 meters (3-6 feet)
Storage
Ideally, latex paint materials should be stored and applied in ambient air temperatures about 50°F (10°C)
and below 80° F (27°C), with a relative humidity of 50% or lower. Stacking of 5 gallon buckets should not
exceed 3 buckets high.
Other materials, such as substrates, wallboard, siding, etc., should be stored according to manufacturers’
instructions, away from moisture and extreme temperatures. Containers should be sealed to prevent
contamination and degradation.
Proper storage can dramatically reduce prep time for materials. When materials are moisture-free and within the
recommended temperature range, they are ready for paint application.
Because of their tendency to absorb moisture, gypsum products should be stored in a dry environment.
Exterior siding and trim materials specified for painting should be stored in dry environments. Surfaces exposed to rain, fog, or
high humidity conditions should be allowed to dry thoroughly and to reach the optimum temperature range prior to painting.
Temperature and Humidity

Temperature and humidity can have a significant impact not only on material drying and curing, but also on the general
application and touch-up performance of primers and paints.
1. For proper paint application you must monitor and regulate:

2. Materials Surface Temperature
3. Ambient Air Temperature
4. Product Storage Temperature
Temperature fluctuation may affect the degree of coalescence (film formation) of paint. Fluctuations can cause color variations
even when material is sourced from the same container.
To ensure color and consistency match, touch-up paint should be applied in the same conditions that existed when the paint
was first applied to the substrate.
Low Temperatures
The consistency of paint material is affected by temperature. At 50°F (10°C) or colder, paint material thickens, making it difficult
to brush, roll, or spray properly. Applying paint to extremely cold surfaces may affect how well the material “hangs” and
adheres to the substrate.
For low temperature application, exterior products have been formulated to cure at temperatures as low as 35°F (1.6°C).
Compared to conventional exterior products, these products offer faster curing schedules and improved early moisture
resistance. While these products can cure at lower temperatures, it is important to note that the rate of drying slows as
temperature drops and relative humidity increases.
High Temperatures
Without proper ventilation, condensation may occur on materials that have been stored in cooler areas than the environment
in which paint is applied. Abrupt temperature shifts may cause uneven paint application as the materials warm up. This is often
the case when materials are transported from cold storage into forced heat painting areas.
Dramatic temperature shifts may also cause mud cracking of paint, mudded seams, and cracking of applied texture materials.
At temperatures of 85°F (29°C) or higher, paint material things, creating application problems. Applying paint to extremely hot
surfaces may cause paint to dry too rapidly, often causing uneven painted surfaces.
Industrial Zoning Standards

Industrial design zoning standards play a crucial role in shaping the physical layout and functionality of industrial areas. These
standards are established to ensure safety, efficiency, and compatibility within industrial zones. Let’s explore some key aspects:
1. National Industrial Zoning Committee (NIZC)
 After World War II, industrial expansion faced challenges due to a shortage of suitable industrial land.
 The NIZC, formed by six national organizations, issued the Principles of Industrial Zoning pamphlet.
 One key principle emphasizes reclassifying industries based on modern manufacturing processes and construction
policies.
2. Zoning Ordinances and Classification
 Traditional zoning ordinances classify industries by name (e.g., “light” or “heavy” industrial districts).
 However, rapid changes in industrial processes render such classifications obsolete.
 External effects of industrial operations, rather than industry names, determine desirability for inclusion in specific
areas1.
3. Specific Standards
 Minimum Area, Setbacks, and Maximum Height: Refer to the 2021 International Zoning Code (IZC) for regulations2.
 Administration of the Ordinance: Consider side yards, street property lines, and landscaping requirements1.
4. Local Guidelines
 Each locality may have additional guidelines specific to industrial and commercial development.
 These guidelines address functionality, safety, environmental impact, and overall amenity.
Industrial Zoning
Industrial parks benefit from organized zoning, which involves categorizing land use for various activities like industrial,
residential, commercial, administrative, and recreational purposes. This zoning promotes on-site efficiencies in utility
infrastructure and transportation networks, enhancing waste management, water recycling, and circulation patterns for both
vehicles and pedestrians. Industrial zones for targeted sectors - these include industrial plots, industrial factory shells, and
multi-story industrial units for non-polluting or medium-polluting industries.
There are diverse zones within an industrial park. Each zone serves a distinct purpose, contributing to the overall functionality
and efficiency of the park. Here’s an expanded version:
Industrial Zones:
Industrial Plots: These designated areas provide space for setting up
factories and manufacturing units. They cater to both non-polluting and
medium-polluting industries.
 Industrial Factory Shells: Ready-to-use factory structures

that offer convenience to businesses looking to establish
their operations swiftly.
 Multi-Story Industrial Units: Vertical spaces designed for
industrial activities, optimizing land use and
accommodating various production processes.
1. Amenities Zones:
Information Centers: Hubs where visitors and stakeholders can access
essential details about the park, its facilities, and services.
 Training Centers: Spaces for skill development,

workshops, and capacity-building programs.
 R&D Facilities: Research and development centers
fostering innovation and technological advancements.
Clinics: Medical facilities ensuring the well-being of workers and visitors.
 Administrative Buildings: Offices for managing park

operations.
 Shopping Centers: Retail spaces for convenience and
leisure.
 Fire Stations: Emergency response units safeguarding
against fire incidents.
 Weigh Stations: Locations for weighing and monitoring
cargo vehicles.
2. Special Infrastructure Zones:

 Certification Laboratories: Facilities for quality testing and
certification of products.
 Quarantine Services: Areas ensuring compliance with
health and safety regulations.
 Market Intelligence Unit: Collects and analyzes market
data to inform business decisions.
3. Logistics Zones:
 Loading and Unloading Yards: Efficient spaces for handling goods
during transportation.
 Parking Lots: Ample parking areas for vehicles.
 Packaging Facilities: Centers for packaging products before
distribution.
 Transportation Hubs: Connects the park to broader
transportation networks.
 Cargo-Handling Centers: Streamlined spaces for managing cargo flow.
 Raw Material Collection and Storage Depots: Essential for uninterrupted production.
 Goods Storage Warehouses: Secure storage for finished products.
4. Utilities Zones:
 Solid Waste Collection Centers: Responsible waste management
hubs.
 Electrical Sub-Stations: Power distribution points.
 CETPs (Common Effluent Treatment Plants): Treats industrial
wastewater collectively.
5. Residential Zones:
 Multi-Format Worker Housing: Accommodations for employees
working within the park.
 Guesthouses and Hotels: Lodging options for visitors and business
travelers.
6. Green Zones:
 Green Belts and Buffer Zones: Lush areas surrounding the park, enhancing aesthetics and ecological
balance.
 Lawns and Parks: Recreational spaces for relaxation.
 Water Features: Ponds, lakes, or fountains adding serenity.
 Internal Walkways Between Zones: Pedestrian pathways connecting different areas within the park.
Other Associated Regulations
1). Floor Area Ratio (FAR)
 FAR, also known as floor space index (FSI), is a widely used term in real estate and urban planning.
 It quantifies the relationship between a building’s total usable area (often referred to as gross floor area)
and the total land area upon which the building stands.
gross floor area
 Mathematically, FAR is expressed as: FAR =
area oof the plot
 The FAR of a particular region is determined by the local Municipal Corporation or relevant authorities.
 It plays a crucial role in zoning regulations and city planning.
 A higher FAR allows for denser development, while a lower FAR results in more open space and lower
building density.
 Developers and architects must adhere to the specified FAR limits when designing buildings to ensure
sustainable land use and efficient utilization of available space.
FAR values can vary significantly based on the specific location and local regulations. It’s essential to consult the relevant
authorities and guidelines when planning any construction project.
Impact of FAR in Industry Design
1. Space Utilization and Density
 FAR directly influences the amount of usable space within a building. A higher FAR allows for more floor
area, which can be advantageous for industries requiring extensive machinery, storage, or production lines.
 However, a balance must be struck. While a high FAR maximizes space utilization, it can lead to
overcrowding, reduced ventilation, and cramped working conditions. Industries need to consider the
optimal balance between space efficiency and employee comfort.
2. Building Height and Vertical Expansion
 FAR often correlates with building height. A higher FAR typically permits taller structures.
 For industries, this means the possibility of vertical expansion. Multi-story industrial buildings can
accommodate various functions on different levels, such as manufacturing, offices, and warehousing.
 Vertical expansion can optimize land use, especially in urban areas where available land is limited.
3. Zoning and Land Use Regulations
 Zoning laws dictate FAR limits based on the intended land use (e.g., industrial, commercial, residential).
 Industries must adhere to these regulations when designing their facilities. Exceeding the specified FAR
could result in legal issues or non-compliance.
 FAR also impacts setbacks (distances from property lines), which affect building placement and access.
4. Infrastructure and Services

 A higher FAR necessitates robust infrastructure, including utilities (water, electricity, sewage) and
transportation access.
 Industries must plan for efficient service connections to support their operations.
5. Aesthetics and Environmental Impact
 FAR affects the visual impact of industrial buildings. High-rise factories may alter the skyline and
neighborhood aesthetics.
 Sustainable design considerations become crucial. Balancing FAR with green spaces, landscaping, and
energy-efficient features is essential.
6. Economic Implications
 FAR influences property values. Higher FAR often leads to more valuable real estate.
 Industries must weigh the cost of land against potential revenue from increased floor area.
FAR significantly shapes industrial design by determining usable space, building height, compliance with regulations, and overall
functionality. Architects and industrial planners must navigate these factors to create efficient, safe, and productive spaces.
Why it varies from City to City
The most important purpose of floor area ratio (FAR) is to ensure that the construction of a project doesn't violate a city's safe
load factor. Each city has limited space and capacity, which need to be used in a safe manner.
This is referred to as the safe load factor. Depending upon the density of a city's population, geographical features, growth
patterns and construction activities, the FAR varies from city to city.
Besides, regulations implemented by local governing authorities as well as urban planning policies also have an important role
in determining the FAR of a city or the FAR of each region in a city.
Factors that Influence FAR
What are the key factors that influence the floor area ratio? First and foremost, it is the area. It's quite possible that a city can
have different FARs based on the area. The municipal corporation fixes the FAR for the respective zones.
For instance, within a city, the old and established areas may have a different FAR from the new ones. Other criteria include the
size of the property, the location of the building, its size, location, infrastructure including roads in the vicinity, etc.
2. Built-up Area Ratio (BAR)

 BAR, also known as building coverage ratio, is a critical parameter in urban planning and architectural
design.
 It quantifies the relationship between a building’s total floor area (often referred to as gross floor area)
and the total land area upon which the building is constructed.
gross floor area
 Mathematically, BAR is expressed as: BAR =
Land Area
 Unlike Floor Area Ratio (FAR), which considers all floor areas without regard to their spatial distribution,
BAR specifically measures the building’s footprint on the lot.
 It helps regulate the extent of land coverage by buildings, ensuring a balance between development and
open space.
 Lower BAR values promote more open land and green spaces, while higher BAR values indicate denser
construction.
BAR, along with FAR, plays a crucial role in shaping urban landscapes and ensuring sustainable development. Architects and
planners must consider both ratios when designing buildings to create harmonious and functional environments.
Impact of BAR in Industry Design

Space Utilization and Footprint
 BAR specifically measures the building footprint on the lot. It considers the spatial distribution of the
building’s base area.
 For industrial design, this means understanding how much ground area the building occupies. A higher BAR
implies a larger footprint, potentially allowing for more machinery, storage, or production space.
 However, industries must balance this with other factors like setbacks and open spaces.
Building Height and Density
 While BAR focuses on the base area, it indirectly influences building height. A larger footprint may allow for
taller structures.
 Industries can use vertical space efficiently, especially when land availability is limited.
 However, excessive height can impact aesthetics and practicality.
Compliance with Zoning Regulations
 Zoning laws often set maximum BAR values to control land coverage. Industries must adhere to these
limits.
 BAR ensures that buildings don’t encroach too much on open spaces or neighboring properties.
 Compliance ensures safety, fire access, and overall harmony in industrial zones.
Functional Layout and Efficiency
 A well-designed industrial facility considers the optimal arrangement of production areas, storage, offices,
and utilities.
 BAR affects the layout—whether it’s a sprawling single-story factory or a multi-level complex.
 Efficient space utilization impacts productivity and workflow.
Environmental Impact
 A higher BAR may reduce green spaces and landscaping. Industries should mitigate this by incorporating
green roofs, courtyards, or outdoor areas.
 Sustainable design principles can offset the impact of higher BAR values.
Economic Considerations
 BAR affects property values. A prime industrial location with high BAR may command higher prices.
 Industries must evaluate the cost-benefit trade-offs when choosing their footprint.
BAR plays a pivotal role in shaping industrial design by defining the physical footprint, density, and adherence to regulations.
Architects and planners must strike a balance between functional needs, aesthetics, and environmental responsibility.
3. Work at Height Regulations (WAHR)

 The Work at Height Regulations 2005 (WAHR) are crucial guidelines aimed at preventing injuries and
fatalities resulting from falls at work.
 These regulations apply to various industries, including construction, maintenance, and industrial settings.
 Here are key points related to WAHR:
 Defining “Work at Height”
 According to Regulation 2, a place is considered “at height” if there is a risk of a person falling from it, even
if it’s at or below ground level.
 The definition includes not only physical height but also situations where someone could be injured due to
a fall.
 For instance, a worker on a ladder, scaffold, or elevated platform is considered to be working at height.
B. Scope of the Regulations
 WAHR applies to all work at height where there is a risk of a fall liable to cause personal injury.
 The regulations cover employers, the self-employed, and anyone who controls the work of others (such as
facilities managers or building owners).
 They consolidate previous legislation related to working at height and implement European Council
Directive 2001/45/EC (Temporary Work at Height Directive).
C. Detailed Requirements
Ensure Safe Access
 Employers must ensure that workers can safely access and exit areas where they work at height. This
includes providing secure ladders, scaffolds, or other access equipment.
 Safe access is crucial to prevent falls during entry and exit. Suitable and Stable Equipment
 Employers must provide equipment that is suitable, stable, and strong enough for the specific job.
 Regular maintenance and inspections are essential to ensure equipment remains safe for use.
 Precautions for Fragile Surfaces
 When working on or near fragile surfaces (such as fragile roofs), additional precautions are necessary.
 Measures may include using crawl boards, safety nets, or platforms designed to distribute weight evenly.
Protection from Falling Objects
 Employers must provide protection to prevent objects from falling onto workers below.
 Measures include using toe boards, debris nets, or securing tools and materials.
Emergency Evacuation and Rescue Procedures
 Employers should consider emergency evacuation and rescue procedures for workers at height.
 Having clear protocols ensures timely response in case of accidents or emergencies.
D. Why these regulations are so important?
1.Preventing Fatalities and Injuries
 Falls from height remain a significant cause of workplace fatalities and major injuries.
 WAHR aims to prevent such incidents by setting clear guidelines and safety standards.
 Compliance with these regulations ensures safer working conditions for employees and contractors.
2.Clear Guidelines for Employers and Workers
 WAHR provides specific rules and requirements for working at height.

 Employers can use these guidelines to create safe work environments, train employees, and implement
necessary precautions.
 Workers benefit from knowing what is expected of them and how to protect themselves.
3.Risk Assessment and Mitigation
 WAHR emphasizes the importance of risk assessment before any work at height.
 Employers must evaluate potential hazards, plan safe access, and select appropriate equipment.
 By identifying risks early, accidents can be prevented.
4.Safe Access and Equipment
 The regulations ensure that workers have safe access to areas where they work at height.
 Suitable and stable equipment is essential to prevent falls.
 Regular maintenance and inspections are crucial to keep equipment safe.
5.Protection from Falling Objects
 WAHR requires measures to prevent objects from falling onto workers below.
 Toe boards, debris nets, and secure storage of tools and materials protect workers from falling objects.
6.Emergency Preparedness
 Having clear emergency evacuation and rescue procedures is vital.

 In case of accidents or emergencies, timely response can save lives.
7.Legal Compliance and Accountability

 Employers who comply with WAHR demonstrate their commitment to safety.
 Non-compliance can result in legal consequences, fines, and damage to reputation.
8.Industry Best Practices
 WAHR sets a benchmark for best practices in working at height.

 Employers can learn from these guidelines and adopt safety measures beyond legal requirements.
4. Set back
Front Setbacks
 Front setbacks refer to the minimum distance between the front property line (boundary facing the street)
and the front facade of a building.
 These setbacks serve several purposes:
1. Aesthetics: They create a visually pleasing streetscape by preventing buildings from being too close to
the road.
2. Safety: Adequate front setbacks allow for pedestrian pathways, landscaping, and visibility.
3. Privacy: They maintain a reasonable distance between neighboring properties.
Side Setbacks
 Side setbacks are the minimum distances between the side property lines and the building’s walls.
 Their importance includes:
4. Fire Safety: Sufficient space between buildings reduces the risk of fire spreading from one structure to
another.
5. Light and Ventilation: Side setbacks ensure that neighboring buildings receive adequate natural light
and ventilation.
6. Privacy: They prevent buildings from encroaching too closely on adjacent properties.
Rear Setbacks
 Rear setbacks define the minimum distance between the rear property line and the back of a building.
 Reasons for rear setbacks:
7. Privacy: They maintain privacy for neighboring properties.
8. Access and Utilities: Sufficient space allows for utility access, drainage, and maintenance.
9. Green Space: Rear setbacks contribute to open space and landscaping.
Zoning Regulations and Variations

 Setback requirements vary based on local zoning laws, building codes, and the type of land use
(residential, commercial, industrial).
 Some areas may allow flexibility through conditional use permits or variances.
Design Considerations
o Architects and industrial designers must incorporate setbacks into their plans.
o Balancing setbacks with functional needs (such as parking, loading docks, and outdoor storage) is essential.
Importance of Setback requirements

1. Safety and Fire Prevention
o Setbacks ensure that buildings are adequately spaced apart. This reduces the risk of fire spreading from
one structure to another.
o Sufficient distance between buildings allows emergency responders to access the area and manage
incidents effectively.
2. Light and Ventilation
o Setbacks prevent overcrowding and allow for natural light and ventilation.
o Adequate spacing ensures that neighboring buildings receive sunlight and fresh air, promoting a
healthier environment.
3. Privacy and Aesthetics
o Front setbacks create a pleasing streetscape by maintaining a reasonable distance between buildings
and the street.
o Side and rear setbacks preserve privacy for neighboring properties.
o Well-designed setbacks contribute to the overall aesthetics of an industrial area.
4. Utilities and Infrastructure
o Setbacks provide space for utility connections (water, electricity, sewage).
o They allow for drainage systems, maintenance access, and infrastructure development.
5. Compliance with Regulations
o Zoning laws and building codes specify setback requirements.
o Adhering to these regulations ensures legal compliance and avoids penalties.

6. Balancing Functionality and Space
o Architects and designers must balance setbacks with functional needs.
o Setbacks impact parking areas, loading docks, outdoor storage, and circulation paths.
Site selection
Industrial site selection is a strategic decision that usually involves several different but equally important criteria connected to
technical, economic, social, environmental, and sometimes political issues.
Therefore decision-making for industrial site selection requires appropriate tools and knowledge to enable data collecting,
analysis, and site management to address this complex, multifaceted scenario.
In this blog, I will introduce IPG’s approach for making strategic decisions on choosing the perfect industrial location. Let’s get
right onto business.
What Makes a Good Industrial Site?
Just as good location and neighborhood are everything for personal real estate, the same goes for finding the
right manufacturing site for industrial needs. Now, how to choose the best location for your business?
Well, I advise you to think through some considerations and opt for an industrial location that will be able to give you the best
geographic position to succeed.
Considerations for site selection criteria for industrial buildings:
 Think about from where and how are you going to

source raw materials and workforce
 How the next industrial site fits into your distribution

model and needs
 How the location of your industrial site will impact

your supply chain and the neighborhood in general
Industrial Site Classification – Know Your Niche
It is normal that different industries require different factors. For example, secondary industries are those that take the raw
materials produced by the primary sector and process them into manufactured goods and products.
Examples include heavy manufacturing, light manufacturing, food processing, oil refining, and energy production.
The tertiary sector is also a service sector but involves the selling of services and skills, such as health service, transportation,
education, entertainment, tourism, finance, sales, retail, etc.
The quaternary sector is made of those industries providing informational services. This can be information and communication
technologies, consultancy, advising, scientific research, etc.
What must a factory consider when deciding on a new location?
While accessibility to materials used in the manufacturing process is of vital interest to the manufacturing plant, sometimes
markets may be half a world away from the source of material supply.
If the materials used in the manufacturing process are way too large, heavy, or low in value, it might be advantageous to locate
the industry as near as possible to the source of the material. This can also reduce the excessive costs for transporting your
items.
Environmental Protection and Industrial Location
The protection of our natural habitat is another, very important manufacturing site selection criteria. How to choose a location
for business if not in alliance with environmental requirements. Here you have to consider these factors:
 Wetland studies
 Threatened and endangered species review
 Geotechnical review
 Cultural resources review
Industrial pollution is one of the major causes of air pollution,

Which further creates an imbalance in the ecosystem.
At the same time, industrial processes have negative environmental impacts,

causing climate change, loss of natural resources, air and water pollution, and
extinction of some species.
Poorly chosen and uplifted industrial site selection is a threat to the global
environment as well as economic and social welfare.
Transportation Infrastructure
Transportation is one of the largest costs in the industrial sector, taking from 45 percent to 70 percent of the gain. Most of that
is the cost of shipping goods from the warehouse to customers (namely to households) rather than getting goods from a port to
the warehouse.
This is why it’s so important to position your business and industrial site as close to a large population center of customers as
possible.
You need to get materials in and product out, so the transportation options at your site also have important consideration such
as:
 How close you’ll need to be to major interstates and highways
 Does your site needs to be rail-served (and if so, whether rail infrastructure exists or can it be developed at
your potential industrial site)
 Do you have the transportation infrastructure you need? And if not, how much will you need to invest to build it?
Industrial location for manufacturing plants tends to be sited where a variety of readily accessible transport choices are
generally available.
Transport facilities thus are the important links that bridge material supply and reach the market. Railroads, highways, ports,
and airports close at hand are important considerations for the location of industries.
Choose the Right Industrial Site with IPG
The process of choosing a location for a warehouse, fulfillment center, or manufacturing site has gotten significantly more
complex in recent years amid the rapid rise of e-commerce and strong competition for labor.
Finding the right industrial site takes time and consideration, but knowing the right questions to ask is a helpful place to start.
If you’d like a little extra guidance, get in touch and we’ll connect you with an expert who can help.
IPG offers site selection service and advising for users that look for warehouses and other industrial real estates and their
perfect locations.
Site Design Standards
Building Location
When considering the building location for an industrial facility, several factors come into play.
1. Zoning and Land Use
 Zoning Regulations: Understand the local zoning codes and

regulations. These dictate the permissible land uses, building
types, setbacks, and other requirements.
 Industrial Zones: Look for areas specifically designated for
industrial use. These zones often have infrastructure and utilities
suitable for industrial operations.
2. Accessibility and Proximity
 Transportation: Evaluate proximity to major transportation routes (highways, railways, ports, airports).
Easy access to these facilitates the movement of raw materials, finished products, and employees.
 Suppliers and Customers: Consider the convenience of reaching suppliers and serving customers. Being
close to suppliers can reduce transportation costs.
3. Topography and Site Conditions
 Terrain: Assess the topography of the site. Flat or gently sloping land is preferable for construction.
 Soil Conditions: Conduct soil tests to understand soil stability, drainage, and load-bearing capacity.
 Flood Zones: Avoid flood-prone areas.
4. Utilities and Services
 Water Supply: Ensure access to reliable water supply for industrial processes.
 Electricity: Availability of sufficient electrical power is crucial.
 Natural Gas: If needed, proximity to natural gas lines.
 Sewer System: Connection to a sewer system for wastewater disposal.
 Telecommunications: High-speed internet and communication networks.
5. Environmental Considerations
 Environmental Impact: Assess potential impacts on the environment (air quality, noise, etc.). Avoid
sensitive areas (wetlands, habitats).
 Green Space: Balance industrial development with green spaces and landscaping.
 Brownfield vs. Greenfield: Decide between redeveloping existing sites (brownfield) or starting fresh on
undeveloped land (greenfield).
6. Security and Safety
 Security Measures: Choose a location that allows for security measures (fencing, surveillance).
 Emergency Services: Proximity to fire stations, hospitals, and police stations.
 Natural Hazards: Consider risks related to earthquakes, hurricanes, or other natural disasters.
7. Neighborhood Compatibility
 Adjacent Land Uses: Evaluate neighboring properties. Avoid conflicts with incompatible land uses (e.g.,
heavy industry next to residential areas).
 Aesthetics: Strive for a location that aligns with the overall aesthetic of the area.
Circulations
Circulation within an industrial site involves planning and designing pathways for various types of movement. Let’s see some
key considerations.
1. Vehicle Circulation
 Roadways: Design wide, well-paved roads to accommodate trucks, forklifts, and other heavy vehicles.
Ensure turning radii allow easy maneuvering.
 Truck Routes: Separate truck routes from pedestrian walkways to enhance safety.
 Loading Docks: Position loading docks strategically for efficient loading and unloading.
2. Pedestrian Circulation
 Walkways: Create clear pedestrian pathways between buildings, parking areas, and entrances.
 Safety: Ensure pedestrian safety by using crosswalks, signage, and proper lighting.
 Emergency Exits: Clearly mark emergency exits and provide accessible routes.
3. Material Flow
 Raw Materials: Plan routes for raw material delivery to production areas.
 Finished Goods: Design pathways for finished goods to move from production to storage or shipping.
 Internal Logistics: Consider conveyors, automated guided vehicles (AGVs), or other systems for material
transport.
4. Parking Areas
 Employee Parking: Allocate sufficient space for employee parking near entrances.
 Truck Parking: Designate areas for truck parking, especially near loading docks.
 Visitor Parking: Provide convenient visitor parking close to the main entrance.
5. Signage and Wayfinding
 Directional Signs: Install signs indicating routes, parking areas, and building entrances.
 Color Coding: Use color-coded markings on the ground to guide vehicles and pedestrians.
 Clear Navigation: Ensure visitors and employees can easily find their way around the site.
6. Emergency Access
 Fire Lanes: Designate fire lanes for emergency vehicles.

 Access to Hydrants: Ensure hydrants are accessible for firefighting.
 Medical Access: Plan routes for medical response teams.
Efficient circulation enhances productivity, safety, and overall functionality within an industrial site. Consulting with architects,
civil engineers, and traffic experts can help optimize circulation design.
Parking
1. Employee Parking
 Quantity: Allocate sufficient parking spaces for employees based on the facility’s size and workforce.
Consider peak shifts.
 Proximity: Place employee parking close to entrances for convenience.
 ADA Compliance: Designate accessible parking spots for employees with disabilities, adhering to
the Americans with Disabilities Act (ADA) requirements.
2. Truck Parking
 Loading Docks: Position truck parking areas near loading docks for efficient loading and unloading.
 Turning Radius: Ensure adequate space for trucks to maneuver.
 Idle Areas: Designate spots for trucks waiting to load or unload.
3. Visitor Parking
o Visibility: Clearly mark visitor parking areas near the main entrance.
o Limited Duration: Limit visitor parking to a specific duration (e.g., 2 hours).
o Security: Ensure visitor parking is well-lit and monitored.
4. Reserved Spaces
 Management and Executives: Reserve spaces for management, executives, and key personnel.
 Carpool Spaces: Encourage carpooling by designating carpool parking spots.
 Electric Vehicle (EV) Charging Stations: If applicable, provide EV charging stations.
5. Signage and Markings
 Signs: Install clear signs indicating parking areas, reserved spaces, and any restrictions.
 Painted Lines: Use painted lines to demarcate individual parking spaces.
 Color Coding: Differentiate employee, visitor, and reserved spaces using color-coded markings.
6. Security Measures
 Lighting: Ensure well-lit parking areas to enhance safety.

 Surveillance: Consider security cameras for monitoring.
 Access Control: Restrict access to authorized personnel.
Landscaping
Landscaping plays a vital role in enhancing the aesthetics, functionality, and environmental impact of an industrial site.
1. Green Spaces and Plantings
 Trees and Shrubs: Plant trees and shrubs strategically to provide shade, reduce heat, and improve air
quality.
 Grass and Groundcover: Use grass or other groundcover to prevent soil erosion and create visually
appealing areas.
 Native Plants: Opt for native species that require less water and maintenance.
2. Storm water Management

 Retention Ponds: Design retention ponds or swales to manage storm water runoff. These also enhance
biodiversity.
 Permeable Surfaces: Use permeable materials (such as permeable pavers) to allow rainwater infiltration.
3. Screening and Buffering
 Visual Screening: Use landscaping to screen unsightly areas (e.g., dumpsters, utility structures).
 Noise Buffer: Trees and shrubs can absorb sound, creating a buffer between the industrial site and
neighboring properties.
4. Safety and Security
 Clear Sightlines: Trim vegetation to maintain clear sightlines for security cameras and personnel.
 Lighting Enhancement: Use landscaping to direct site lighting effectively.
5. Aesthetics and Branding
 Corporate Image: Landscaping reflects the company’s image. Consider aligning it with your brand identity.
 Entrance Landscaping: Create an inviting entrance with well-maintained greenery.
6. Maintenance Considerations
 Low-Maintenance Plants: Choose plants that thrive in the local climate and require minimal care.
 Irrigation System: Install an efficient irrigation system to keep plants healthy.
Thoughtful landscaping not only beautifies the site but also contributes to employee well-being, environmental sustainability,
and overall site functionality.
Site Lighting
Site lighting is crucial in various contexts, especially in industrial settings. Their importance is explained as follows.
1. Safety and Visibility
 Vision Dominance: Our sense of sight provides about 83% of the information we receive. Proper lighting
ensures that workers can see hazards, machinery, and obstacles clearly.
 Accidents Prevention: Adequate lighting reduces the chances of accidents by making potential dangers
more visible. This is particularly critical during early mornings, evenings, and night shifts.
2. Accuracy and Efficiency

 Task Performance: Well-lit environments make tasks easier to perform. Workers can accurately handle
tools, read instructions, and assess their surroundings.
 Productivity: Good lighting enhances productivity. When workers can see clearly, they work more
efficiently and make fewer errors.
3. Health and Well-Being
 Eye Comfort: Inadequate lighting can lead to eye strain, headaches, and discomfort.
 Fatigue Reduction: Proper illumination reduces fatigue, especially during long shifts.
4. Legal Responsibilities
 Employers have a legal duty to provide safe lighting for employees, contractors, and visitors.
 Health and Safety Executive (HSE) guidelines emphasize suitable lighting that allows hazard detection,
proper vision, and color discrimination.
5. Cost Considerations
 Poor lighting can result in costly consequences

 Time Off: Accidents or health issues due to inadequate lighting lead to time off work.
 Absenteeism: Employees may take more sick days.
 Reduced Productivity: Diminished work output due to discomfort or inefficiency.
Static Lighting Vs Flexible Lighting
1. Static Lighting
 Purpose: Static lighting provides consistent and unchanging illumination.

 Application
 Scaffolding: Static lighting is suitable for illuminating scaffolding, ensuring safety during construction.
 Shadow Areas: It works well in areas where shadows can obscure hazards (such as machinery and
equipment).
 Examples: Fixed lights mounted on support poles, scaffolding, or tower cranes fall under static lighting.
2. Flexible Lighting:
 Purpose: Flexible lighting allows for local arrangement and adapts to work progress.
 Application
 Connectable Systems: Festoon kits are an example of flexible lighting. They can be used in multiple
runs, disconnected when not in use, and easily reconnected when needed.
 Up lights: Up lights can be moved to specific areas where illumination is required.
 Advantages
 Versatility: Flexibility enables lighting adjustments based on changing work conditions.
 Ease of Handling: Up lights with shoulder straps simplify transportation across the site.
A well-balanced combination of static and flexible lighting ensures safety, productivity, and efficient use of illumination in
industrial environments.
Safety measures
1. Natural Light and Artificial Lighting
 Arrange the site so that natural light is available whenever possible.
 When natural light is inadequate or unavailable, provide artificial lighting.
 Ensure artificial lighting does not alter the apparent color or visibility of safety signs or other safety-related
items (e.g., fire extinguishers).
2. Shadow Areas
 Shadows can obscure hazards both at the workplace (e.g., cutting discs, drill bits) and on the site (e.g.,
stairwells).
 If needed, provide extra lighting to illuminate shadow areas.
3. Emergency Lighting
 In areas where failure of primary artificial lighting poses a risk (e.g., someone working on a tower scaffold in a
basement), provide emergency lighting.
 Emergency lighting should come on automatically when primary lighting fails. If not possible, torches or similar
lights can serve as suitable alternatives.
4. Emergency Routes
 Emergency routes (corridors, passageways) must be well-lit while workers are on the site.
 If emergency routes need artificial light, provide emergency lighting that activates if primary lighting fails (e.g.,
battery-powered or generator-powered lighting).
 Emergency lighting doesn’t need to match normal lighting levels; it should be sufficient for escape.
Proper site lighting enhances safety, visibility, and overall work efficiency. Consult relevant guidelines and experts to ensure
compliance with safety standards.
Security
Security is a critical aspect of industrial site design. Let’s explore some key security considerations:
1. Perimeter Security
 Fencing: Install sturdy fencing around the site to prevent unauthorized access.
 Access Points: Control access through designated gates or entrances.
 Surveillance: Use cameras to monitor the perimeter.
2. Lighting
 Illumination: Ensure well-lit areas to deter intruders and enhance safety.
 Motion Sensors: Consider motion-activated lights for added security.
3. Access Control
 Badge Systems: Implement access cards or badges for employees and authorized personnel.
 Visitor Management: Register and track visitors at entry points.
4. CCTV Surveillance
 Camera Placement: Install cameras at critical locations (entrances, loading docks, parking lots).
 Monitoring: Regularly review surveillance footage.
5. Alarm Systems
 Intrusion Alarms: Set up alarms for unauthorized entry.
 Fire Alarms: Ensure proper fire detection and evacuation systems.
6. Personnel Training
 Security Awareness: Train employees on security protocols.
 Emergency Response: Educate staff on emergency procedures.

INDUSTRIAL BUILDING DESIGN
Architectural
Form and Detail

Form of industrial plants for a plant building, the need for natural lighting,
ventilation and other factors will be a criteria for choice of its Form. Besides, the
selected Form will provide easy expansion and unobstructed walls.
Therefore, for the proposed factory located in tropical country like Ethiopia,
where the use of internal stack effects, cross ventilation, natural lighting is
desirable for comfort, the rectangular (prism) Formed industrial plant is ideal.
This Form will permit natural ventilation and lighting coupled with artificial means and it also provides easy expansion and
unobstructed walls the other anticipated problems like; noise, glare, heat gain etc. can be solved by design and use of ideal
building materials.
However, other building Forms can be utilized where there are some restrictions like;
 Land limitations.
 Property lines being at curious angles.
 Where production process will cause dirt, noise or vibration, odor etc.
 Where production is susceptible to fire or explosion.
Color and Materials

Coloring
Use of complementary harmonious colors has an effect on performance, efficiency and productivity. It also promotes safety by
identifying dangerous areas and escape routes. Colored lighting can also be used to emphasis working and circulation zones and
for identifying services and machinery.
The basic functions of color are to aid vision, psychological effects, aesthetic effects, and to develop a pleasant and orderly
appearance.
The proposals for color application are as follows:
(a) Brightness contrasts shall be greater within the confines of the work in hand.
(b) Brightness contrast shall be less between work in hand and its background.
(c) That is contrast farther away shall be permitted to interfere with the first two relationship mother words, effective
illumination upon the object in work is required, slightly less upon the background against which the object is seen, and
successive small contrast against the floor, walls or other surfaces within view.
FLOORS: This should be light in color in order to minimize brightness contrast.
The specification of lighter colors is based on the fact that less light falls open the
floor than upon the machine. The color of the floor will approach neutral as a
concession to maintenance and as a common denominator between other
colors.
WALLS: Slight brightness contrast is required between the walls, the machine and their color value depends on their distance,
height, orientation and illumination. Upper part of walls shall be in white and lower parts in colors that will the above effect.
CEILINGS: These should be handled with care because they are situated above the horizontal field of vision and usually reflects
all possible light from sky or interior sources. In most cases they should be white and maintained by repainting at reasonable
intervals.
MACHINES: I. Mechanical Equipment – Neutral
II. Maintenance Equipment - Yellow
III. First aid Equipment - Green Cross on white background
Materials
WALLS: Sand Crete bocks are utilized at the offices, restaurants (Jnr), Maintenance block, Security department etc. and
Aluminum Cladding materials on sand Crete blocks at the warehouses, production halls etc.
ROOFING: Aluminum roofing sheet over simple wooden and steel roofing structures.
FLOORS: Reinforced concrete mezzanine and upper floors and reinforced concretes ground floor for production spaces and
normal mass concrete ground floor and reinforced concrete upper floors for Administrative, Sales, Personnel and
Maintenance Units.
Structural
Framing system
The most elementary system used for an industrial building consists of two columns and a beam. This configuration can be
modified in numerous ways using various types of connections between the beams and columns and for the column base. The
types of structures most commonly used in industrial buildings are portal frames with hinged column bases. Portal frames
provide sufficient in-plane stability, and thus only require bracings for out-of-plane stability
The portal frame structure comes in several shapes, including single-span, double-span, high-low-span, and multi-span, with
options such as a single ridge, multiple ridges, single slope, double slope, multiple slopes, and a flat slope.
Single-span rigid frames are commonly used in buildings that don’t need much lateral space and have spans ranging from 25 to
40 meters. The beams and columns of these frames are usually made of welded or rolled H-shaped sections and are positioned
and adjusted in height based on the span and the bending distance diagram.
The multi-span rigid frame is ideal for large buildings, with a similar cross-section to the single-span rigid frame but with a
center column that typically has an equal cross-section. Currently, the maximum span of a portal frame has reached 72 meters.
The spacing between portal frames, that is, the longitudinal distance between the axis of the column network, should be 6
meters, but can also be 7.5 meters or 9 meters, with a maximum of 12 meters. For smaller spans, 4.5 meters can be used.
The composition of Portal Steel Framing

 Primary framing includes transverse rigid frames (including middle and end rigid frames)
The primary force skeleton of portal frame steel buildings comprises steel columns, roof beams, and bracing systems. This is
considered to be the primary framing.
 Secondary framing: roof purlin
The roof purlins and wall girts also support the roof and walls and lateral support for the main structural beams and columns,
forming the secondary framing.
 Envelope structure: roof and wall panels
The roof and wall panels act as the envelope and closure for the structure, enhancing its overall stiffness.
The structural system of the portal steel frame buildings:

1. Transverse load-bearing structure:
The transverse load-bearing structure comprises steel roof beams, columns, and foundations. This structure supports and
transfers both vertical and horizontal loads.
2. Longitudinal Frame Structure:
The longitudinal frame structure comprises longitudinal columns, crane beams, wall bracing, rigid tie beams, and a foundation.
Its purpose is to maintain the building’s stability and rigidity along its length and to support and withstand various forces, such
as longitudinal wind loads, horizontal crane loads, thermal stresses, and seismic effects on the gable and roof.
Bracing
A bracing system helps keep the column or beams steady while they're being built. It also helps spread out the weight and
keeps the beams from bending sideways when they're carrying heavy stuff.
Angle Bracing Rod Bracing
Beam column connection
Vertical connection Horizontal connection
Foundation type
Pile foundation For paint industrial buildings, pile foundations are often used because they provide strong support for heavy
structures and equipment. These foundations can handle the weight and loads typically found in industrial settings, ensuring
stability and safety for the building and its operations. Specially for poor bearing quality of soil
Strip foundation A strip foundation, also known as a continuous footing, is a type of shallow foundation that consists of a
continuous strip of concrete along the length of the load-bearing walls of a building. It distributes the building's load over a
larger area of soil, preventing excessive settlement and ensuring stability. Specially for good bearing quality of soil
Connection
Hinged column base
During installation, steel columns with hinged feet are secured using cables and wedge-shaped blocks. Adjacent columns are
promptly connected for stability. After correction, secondary grouting is done, with micro-tensile grouting material applied at
the foundation's upper part. The grouting layer should be 50-100mm thick.
Before installation, shear grooves are cleaned and checked for dimensions. No foreign matter should be present. Anchor bolt
pads and steel column foot plates are welded with fillet welding, ensuring the height is at least half the pad's height.
Adequate space is reserved during design for tightening anchor bolt nuts easily.
Rigid column base
Anchor bolts for rigidly connected columns should be at least 6 in number and firmly connect to steel columns. During
installation, the rigid feet provide stability, and secondary grouting follows correction. The grouting layer is typically 50m to
10m thick. Shear keys aren't usually needed for these bases. Two nuts, one for the backing plate and one for the steel column
bottom plate, are welded securely in place.
Roofing system
Roof structure
1) Roof panels withstand wind loads.
2) Purlins support roof panels.
3) Rigid frame beams carry weight.
Roof bracing arraignment
Bracing is spaced at 30m-40m intervals, not exceeding 60m. Horizontal roof and wall bracing between the same columns
maintain system geometry and enhance overall stiffness. When roof bracing is between second columns, rigid tie bars are
added between the first columns.
Purlin Type: C type purlin
H type purlin
C-type purlins are lighter and have a "C" shape, while Z-shaped purlins are stronger, with an "Z" shape.
Z-shaped purlins are welded and offer greater strength for heavier loads.
Flooring system and finishes
For a paint factory, the best flooring option would be the Vacuum de-watered Concrete floor. This type of floor is strong and
durable, which is important for a factory where heavy equipment and machinery are used. It's also resistant to water and
chemicals, which is essential in a paint factory where spills can happen. Additionally, the smooth surface of the vacuum de-
watered concrete floor makes it easy to clean, helping to maintain a hygienic environment for manufacturing paint. Overall, it's
the best choice because it's strong, durable, resistant to chemicals, and easy to clean, making it suitable for a paint factory's
specific needs.
Description
A vacuum-de-watered floor, or VDF, is a common choice for industries. Here's how it's made:
 Concrete is poured over a base and reinforced.
 Excess water is removed with a vacuum, making the concrete stronger.
 The surface is smoothed with a power trowel.
Advantages:
 It's cheaper and easy to install.
 It lasts long with little maintenance.
Disadvantages:
 Water and contaminants can weaken it.
 Joints may break, letting in substances.
 Dust can accumulate, damaging equipment.
 Cleaning can be difficult due to imperfections.
MEP (Mechanical, Electrical, and Plumbing) Design for a Paint Factory
Key considerations
Mechanical
HVAC & Process:
 Heating, Ventilation, and Air Conditioning (HVAC):
 Maintain a comfortable temperature range for personnel.
 Control humidity to prevent paint drying issues.
 Provide adequate ventilation to remove volatile organic compounds
(VOCs) and dust generated during production. This may involve
explosion-proof exhaust systems for flammable materials.
Process Equipment:
 Selection of mixing tanks, grinding mills, bead mills, and dispersion equipment based on paint type and production
capacity.
 Design of pipelines for transferring raw materials, finished products, and solvents. Consider material compatibility and
proper insulation for temperature control.
 Heating and cooling systems for process equipment to maintain desired product viscosity.
 Dust collection systems to capture and remove paint particles during production.
Electrical
Power Distribution:
 Provide a reliable and safe power supply for equipment operation,
lighting, and ventilation systems. Consider potential for high-demand
areas like grinding mills.
 Implement proper grounding and earthling to prevent electrical hazards,
especially with flammable materials.
Lighting:
 Provide adequate lighting for all work areas, considering explosion-proof fixtures where necessary.
 Implement task lighting for specific processes requiring close visual inspection.
Controls and Automation:

 Design a control system to automate paint production processes, ensuring consistent
quality and efficient operation.
 Consider integrating monitoring systems for temperature, pressure, and flow rates in
critical equipment.
Plumbing
Water Supply:
 Provide potable water for sanitation and equipment cleaning.
 Separate system for industrial water used for cooling or specific processes, if needed.
Process Piping:
 Design dedicated piping systems for solvents, resins, and other liquid raw materials, considering material compatibility
and proper labeling.
Wastewater Disposal:
 Treat and dispose of wastewater generated during production according to local environmental regulations. This might
involve a system for separating paint residues and solvents before discharge.
References
 Digitalizing the Paints and Coatings Development Process
 https://havitsteelstructure.com/specification-of-portal-street-freem-buildings/
 https://library.automationdirect.com/what-is-needed-for-industrial-control-panels/
 https://www.researchgate.net/publication/
281175022_VACUUM_DEWATERIMG_NEW_WAY_FOR_CONCRETE_FLOORING_BY_TREMIX_METHOD?
enrichId=rgreq-3d7d73a3e2936076fbecef553864273f-
XXX&enrichSource=Y292ZXJQYWdlOzI4MTE3NTAyMjtBUzoyNjU0OTg3MjYyMzYxNjBAMTQ0MDMxMTIzNzE0Ng
%3D%3D&el=1_x_2&_esc=publicationCoverPdf
 MEP Coordination in Building and Industrial Projects
 Best Practice in Steel Construction - Industrial Buildings
 PAINT FACTORY MAKURDI OROKPO HYCENT GEORGE ARC/2009/085
 https://www.paint.org/about/industry/history/
 https://www.koolearn.com/shiti/tk-st-12001.html
 https://www.nerolac.com/blog/types-of-paint
 https://threesixtysafety.com/the-height-of-safety-navigating-osha-regulations-for-working-at-heights/
 http://s-t-a.org/Files%20Public%20Area/HS/Brief%20guide%20to%20working%20at%20heights%20regulations
%202005.pdf
 https://fontanarchitecture.com/floor-area-ratio-zoning-far/
 https://www.acquisition.gov/far/part-2

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Contents

Research and Development (R&D) department

Supply chain and procurement department

Environmental health and safety department

Maintenance and engineering department

Human resource department

Administration and finance department

C. Dispersion: Pigments are insoluble in the binder. They therefore have

E. Grinding the pigments: In the triple roll mill the pigment

What is plant layout?

Principles of plant layout

Types of Plant Layout

Advantages of process layout

Disadvantage of process layout

Advantages of process layout

Disadvantage of process layout

Advantages of process layout

Plant layout for paint factory

Selection of raw materials

Mixing and blending

Grinding and milling

Quality control and testing

Packaging and shipping

Production process paint

Weighing the raw materials

Grinding the pigments

Paint Production Line

List of Raw Materials Used in the Paint Manufacturing

 SPC is a single machine equipment with lifting and lowing

Design Volume Max. Work Volume Min. Work Volume

SPA-650 650 520 110 1250*1250*2960

SPA-1300 1300 1000 200 1500*1500*3610

SPA-2000 2000 1500 350 1720*1720*3940

SPA-3000 3000 2500 500 1970*1970*4570

SPA-4000 4000 3000 650 2150*2150*4700

SPA-5000 5000 4000 800 2270*2270*4700

SPA-6000 6000 5000 1000 2270*2270*5220

1. Better emulsification result

 Materials Viscosity Height: 2-5 meters (6-16 feet)

Basket Mill (Mounted on Kettle)

Basket Mill (Mounted on Kettle) is fixed on various containers,

 Materials Viscosity Height: 1.5-3 meters (5-10 feet)

Disc Type Horizontal Beads Mill

Coating, paint, ink, pesticide and other industries

Hydraulic Tri-roller Mill

Vacuum Emulsifying Mixing Unit is consisted of homogenizing emulsifying pot (lifting

 Height: 1.5-3 meters (5-10 feet) Production Capacity

Mixer Mounted on Kettle

Mixer Mounted on Kettle is functioning in stirring and mixing of liquid-liquid and

 Height: 3-6 meters (10-20 feet) Production Capacity

Filter cart consists of a stainless steel bag type filter, a pneumatic

Semi-automatic Filling Machine (Weighing Type)

Semi-automatic Filling Machine(Weighing Type ) adopts

High Viscosity Semi-automatic Filling Machine adopts

Automatic Liquid Filling Machine (Volume Type)

 Height: 1-2 meters (3-6 feet)

Temperature and Humidity

1. For proper paint application you must monitor and regulate:

Industrial Zoning Standards

1. National Industrial Zoning Committee (NIZC)

2. Zoning Ordinances and Classification

 Industrial Factory Shells: Ready-to-use factory structures

 Training Centers: Spaces for skill development,

Clinics: Medical facilities ensuring the well-being of workers and visitors.

SPA-650 650 520 110 125012502960

SPA-1300 1300 1000 200 150015003610

SPA-2000 2000 1500 350 172017203940

SPA-3000 3000 2500 500 197019704570

SPA-4000 4000 3000 650 215021504700

SPA-5000 5000 4000 800 227022704700

SPA-6000 6000 5000 1000 227022705220