Macro Polymer

8/3/2019 Macro Polymer

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TRAINING REPORT ON MACRO POLYMER PLANT

AT

G.V.M.M, ODHAV, AHMEDABAD

BY

RONAK A. SHAH

B.E CHEMICAL

LUKHDHIRJI ENGINEERING COLLEGE, MORBI,

GUJARAT.


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Acknowledgement

It gives me great pleasure to submit this in plant training report on completion of my

industrial training during 6.06.2011 to 24.06.2011 at the MACRO POLYMER PLANT,

ODHAV G.V.M.M, AHEMEDABAD.

It was a great experience for me at this esteemed organization, which I will cherish

forever.

I express my sincere thanks to Mr. Mayank Parikh[DIRECTOR] for giving me the

opportunity to pursue my industrial training at the MACRO POLYMER PLANT.

I am highly indebted to Mr. Pankaj Parmar[MANAGER] for guiding me throughout my

training report.

Id also like to express my gratitude to all the staff of MACRO POLYMER PLANT for

their support and cooperation.

Thank you all once again.

RONAK A. SHAH

B.E. CHEMICAL

L.E. COLLEGE, MORBI


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INDEX

SERNO

TOPIC NAME PAGENO

1 INTRODUCTION2 OVERVIEW

3 HIGHLIGHTS

4 DETAIL DESCRIPTION

5 APPLICATION

6 FORMULATION

7 TYPES OF PAINTS

8 OTHER PRODUCTS


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INTRODUCTION

We MACRO POLYMERS is a private limited & an ISO 9001:2008 certified company

located at ODHAV & MORAIYA at Gujarat in Western India.

The company is built on a foundation of technocrats who have experience

of five decades in the manufacture of Synthetic Resin for Paints,

Printing Inks and Adhesive Industries.

Our Chairman Mr. Shirish Parikh started factory in 1962.

In 1995 we turned into Private Limited Company.

Since the inception of the company in 1995 with an installed capacity

of just 500 tones per year, and now we are achieving 15,000 tones per annum.

The credit of the companys rapid progress is largely attributed to the

most valued customers for patronizing the products of the company,

hard work done by all the employees and an unprecedented support extended

by all the stack holders and well wishers.

Currently we are one of the leading manufacturer of resins in India and


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exporting to Middle East, Africa, Asian and south east Asian Countries.

We are known for our consistent quality and uninterrupted supply position.

We can provide performance guarantee for the material supplied by us.

We have manufacturing capacity so as to give full container load with

one single batch.

We are committed to deliver customers consistent quality products and

an assurance of the quality for the entire range of the products.

This assurance begins from the purchase of the raw materials,

its analytical testing and approval before consumption, stringent

control of processing parameters, intermediate quality monitoring

and approval of the finished products before dispatch.

The norms of Quality Assurance Department are being strictly followed,

without any compromise and deviation from the standards.

We laid down stringent specification and procedures for the purchase of

raw materials, processing parameters and specification of the finished goods testing in detail.


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OVERVIEW

Manufacturer of Alkyd Resins, Butylated Melamine Formaldehyde Resin,

Butylated Urea Formaldehyde Resins, Maleic Modified Rosin Ester, Acrylic Resins,

Epoxy Resin, Epoxy Hardner & Ketone Resin.

We Macro Polymers is a private limited & an ISO 9001:2000 certified company

located at Odhav &Moraiya at Gujarat in Western India.

The company is built on a foundation of technocrates who have experience of five

decades in the manufacturer of Synthetic Resin for Paint, Printing Inks and

Adhesive Industries...


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Research & Development Centre

We have good facilities to develop and standardize resin and varnishes to suit

customers requirements and specifications.

Our R&D Centre is recognized by Department of Scientific & Industrial

Technology, Ministry of Science & Technology, Government of India.

Our Chairman Mr. Shirish M. Parikh is a qualified Chemical Engineer from

UDCT Bombay University and has master degree in Chemical

Engineering from U.S.A.


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Our Director Mr. Mayank S. Parikh is also a Chemical

Engineer from L.D. Engineering College of Engineering Ahmedabad.

Our Chairman has worked in Production and in research & development

facilities abroad and in India in renowned paint and synthetic resins

manufacturing companies.


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HIGHLIGHTS

Product:

Butylated MF Resin

Butylated UF Resin

Production of UF Resin:

Production of MF Resin:

Applications:

PU Automotive Paint and Automotive Refinishing Paint

Paint for specific use

Wood coating Amino-alkyd baking coating, alkyd air drying paint

Alkyd air drying paint

Nitrocellulose lacquer, polyurethane paint

Alkyd for polyurethane paint

Polyester Resin for coil coating


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Formulations:

Air Drying Paint

NC Paints

Stoving Paint

Wood Coating

Types of Paints:

Stoving enamel/varnish

Air Drying enamel/varnish

NC lacquer/Sanding sealer/paint

Stoving finishes

Air Drying finishes

Melamine wood finishes

PU wood finishes

Polyurathane (PU) finishes


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DETAIL DESCRIPTION

PRODUCTION OF UREA FORMALDEHYDE RESIN:

Structure:

Properties:

Urea-formaldehyde resin's attributes include hightensile strength,

flexural modulus and heat distortion temperature, low water absorption,

mould shrinkage, high surface hardness, elongation at break,

and volume resistance.
http://en.wikipedia.org/wiki/Tensile_strengthhttp://en.wikipedia.org/wiki/Tensile_strength


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Chemical structure:

The chemical structure of UF resins can be described as polymethylene.

This description leaves the details of the structure undetermined which can

vary linearly and branched. These are grouped by their average molar mass

and the content of different functional groups. Changing synthesis conditions

of the resins give good designing possibilities for the structure

and resin properties.

Raw material:

Butanol

Formaline

Urea

Seperat solution [Toluene]

Tri Ethanol Amine [T.E.A]

Recover Butanol [RCB]

Process description:

In this manufacturing process, add butanol and formaline in the close vessel for

agitation. This vessel should be rounded at the bottom.

An impeller is mounted on an overhung shaft, which is supported from above.

The shaft is driven by motor, is directly to the shaft.

After addition of material add 10%of caustic solution and set pH.

pH should always be an equal to 6.


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If it is greater than, add formic acid and if it is less than, add 10% caustic and set

pH.

This solution is completely miscible then add urea and start to heat this vessel

from the boiler.

Heating is started in the vessel, When the temperature of vessel will reach to

70C-80C .

We can get this temperature then close heating and under stirring this mixture up

to 90 min but do not change of temperature.

After completion of this again start to heating and wait for getting reflux.

We can get reflux after 30-45min. then add toluene, recover butanol and also

catalyst.

Here toluene is used as a seperat solution.

Catalyst is the mixture of phthalic powder, oxalic acid, butanol.

Addition of RCB is connected to the removal of water.

We can get this water as a byproduct which as a steam is condenced in the

vertical condenser and separate in the separator.

Approx. addition of 940 ltr. RCB, add catalyst.

At that time temperature will be increase.

In all this process, we can get two by product water and RCB.

After that, the product goes through the packing by filtration.

Types:

UF-8

UF-8LFF

UF-8NFF


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Urea Formaldehyde Resin:

Ser

no

Product

Code

Type Solvent% Non

Volatiles

(2)

Viscosity

in poises

at 25* C

Acid

Value

KOH/gm

Mineral

Spirit

Tolerance

ml/10gm

resin

1 UF-8 ButylatedUF

Butanol 60 10-20 P 3 10-20

Notes : Very fast, low temperature acid curing screen and wood lacquers.

2 UF-8

LFF

Butylated

UF

Butanol 60 10-20 P 3 30-50

Notes : Low Free Formaldehyde content (0.5% max.) used for acid curing wood

coatings.

3 UF-8

NFF

Butylated

UF

Butanol 60 Brook Field

RVT/S-3,

RPM-20

3Max

Notes : To be used for wood coating in acid cure application partially no free

formaldehyde, low odor.
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PRODUCTION OF MELAMINE FORMALDEHYDE RESIN:

Structure:

Raw Material:

Butenol

Formeline

Methanol

Toluene

Urea

RCB


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Process description:

In this manufacturing process, add butenol and catalyst in the

close vessel for mixing and also add formeline.

Then by stirring process add 10% costic and set pH value 7 and

add methanol. Again check the pH value and if it is less than 7 then again add

10% costic and if it is more than 7 then add formic acid.

After pH value is set add melamine and urea.

Then close the vessel and give heat till 70C.

After gett ing 70C temp. stop heating and keep it under

stirring for 90 min.

After 90 min. start heating.

After 30 min. at about 96C-97C we will get re flux.

After getting reflux add RCB. When water came out then add RCB and catalyst.

Take reading at 1hr interval and taking reading from reflux for

15hr check tolerance by using o-xylene and MTO.

Then set the viscosity at 10 poise.

Lastly pack the product by filtration process.

TYPES:

MF-268

MF-970

MF-910


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Melamine formaldehyde resin:

Ser

no

Product

Code

Type Solvent% Non

Volatiles

(2)

Viscosity

in poises

at 30* C

Acid

Value

KOH/gm

Mineral

Spirit

Tolerance

resin

1 MF-268 Butylated

MF

Butanol 60 10-15 2.5 30-50

Notes : High gloss stoving enamels with alkyds, epoxy and acrylic

systems.

2 MF-970 ButylatedMF

Butanol 68 8-12 3 Infinite

Notes : Wide compatibility, low temperature curing flexible lacquers for

metalized plastic articles. Useful for MTO based finishes and anti

wrinkling agent for Rosinated alkyd based stoving finishes.

3 MF-910 Butylated

MF

Butanol 60 10-15 2.5 30-50

Notes : Highly efficient, fast curing colour retentive stoving enamels

resistant to overbaking.
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Application

1. PU Automotive Paint and Automotoive Refinishing Paint

Polyester Resin

Acrylic polyol

Thermoplastic Acrylic

2. Paint for specific use

Anticorrosion for container

Electroplating article

Resin for dipping and air drying for long/large article

Glass painting, solid varnishes

Aluminium paint for motor of agricultural automobile

Heat resistant paint

Paint for aluminium single pack system

Glazing for paper

Special Resin for hammer tone coating

Special Resin for traffic paint Special Resin for leather coating

F class insulating varnish

Fast drying electrical insulation

General use electrical insulation

Coil coating application

Water clear stoving varnish

Glass sleeve coating Resin

Auto refinishing chain stopped air drying paint

Machinery paints for faster and better drying

Machinery parts touchup or fast drying paint which dries as fast as stoving

paints


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3. Wood coating

One component patty/sealer

Alkyd Resin for melamine finish UF Resin for melamine wood finishes

Resin for clear or matte paints

Resin for PU bright finish

Resin for nitrocellulose lacquer

Polyester Resin for lamination coating

4. Amino-alkyd baking coating, alkyd air drying paint

Automotive finish

Miscellaneous car and high grade industrial baking coating

Universal type

Solid finishing cost

Hammer tone paint

Low temp. quick drying baking coating

Wet on wet coatings application

5. Alkyd air drying paint

Air drying paint

Air drying modified paint

6. Nitrocellulose lacquer, polyurethane paint

Resin for grind Nitrocellulose coloured paint

Leather varnish


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7. Alkyd for polyurethane paint

C - 1032 economy, universally

F - 4035 excellent leveling and weathering resistance

C - 1030 excellent yellowing resistance

8. Polyester Resin for coil coating

P-11

UF-8


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Formulations

1. Air Drying Paint

White decorative enamel for interior & exterior use

Tinted decorative enamel

Yellow decorative enamel for interior use

Knifing paste filler

Air drying varnish

2. NC Paints

Nitrocellulose primer

Nitrocellulose lacquer

General purpose white stoving enamel

Polishing lacquer for furniture

Polishing lacquer for furniture3. Stoving Paint

Silver gray automotive baking finish

White stoving enamel for hot spraying

Blue automotive stoving enamel

Stoving primer

White stoving primer

Gray stoving primer

Polyurethane spraying sealer

Black spraying enamel for tracks & bases

General purpose white stoving enamel

Polishing lacquer for furniture

White stoving enamel (poor shelf life)

White stoving enamel for boilers, electrical heaters.

Stoving enamels for steel furniture

Varnish resistant to boiling alkalis


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4. Wood coating

General purpose white stoving enamelPolishing lacquer for furniture

Types of paints

1. Stoving enamel/varnish

TSA-1001

C-1052 (IPA+TMP)

D-2040 HV

D-2040L

C-1032

C-1030

MF-970

MF-268

UF-8

2. Air drying enamel/varnish

TPA-2001M HV

TPA-2001

S-5060 (IPA)

STRY-25

Acry-30

ACRY-25

F-4035

L-6060

S-5060

L-6050 R

S-5050


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D-2060

F-4043

F-4038

D-2050 R

D-2050

3. NC lacquer/sanding sealer/paint

TPA-2001

CA-3045

CA-3035

D-2040L

D-2040M

C-1032

C-1030

4. Stoving finishes

TSA-1001

C-1032 (IPA+TMP)

C-1052 (IPA+TMP)

C-1030

D-2040L

D-2040 HV MF-268

MF-910

C-1032

D-2040M

UF-8


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5. Air drying finished

TPA-2001

TPA-2001 M HV

ACRY-25 Acry-30

STRY-25

S-5060 (IPA)

D-2050

D-2050 R

D-2060

S-5050

L-6050 R

S-5060

L-6060 F-4035

F-4038

F-4043

6. Melamine wood finish

C-1030

C-1032

S-5030

UF-8

UF-8LFF

7. PU wood finish

TSA-1003

8. Polyurethane (PU) finishes

TSA-1003

Polyol-32

Polyol-280


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OTHER PRODUCTS

Maleic Modified Rosin Ester

SernoProduct CodeType % Solid Acid value

KOH/gm

Capillary Melting

point in deg. C

1 MR Gly Maleic modified

rosin glycerine

ester

solid 25 100-110

Notes : NC compatible hence used in NC formulation. Not compatible with MTO.

2 MR Penta Maleic modifiedrosin Penta

ester

solid 25 100

Notes : MTO Compatible used with Long / medium Alkyd
http://www.synresin.com/pro_melic_gly.htmlhttp://www.synresin.com/pro_melic_gly.htmlhttp://www.synresin.com/pro_melic_penta_nf.htmlhttp://www.synresin.com/pro_melic_penta_nf.htmlhttp://www.synresin.com/pro_melic_penta_nf.htmlhttp://www.synresin.com/pro_melic_gly.html


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Alkyd Resins

Serno Product

Code

Oil Type & Length %

Solid

(2)

Solvent Acid Value

KOH/gm

Viscosity in

seconds at

30 C

in FC4*

Colour on

Gardner Scale

50% solution of

resin(max)

1 C-1030 Saturated Fatty Acid

type Non oxidising

short oil length

70 Xylene 5-15 225-300

seconds in

FC4

1

Notes : Non yellowing white baking enamels and 2k as plasticizer for NC lacquers and for Acid Curing /Wood Coating.

2 C-1031 Saturated Fatty

Acid type Non

oxidising short oil

length

70 Xylene 5-15 175-225

seconds in

FC4

1

Notes : White baking enamels and 2k as plasticizer for NC lacquers and for Acid Curing / Wood

Coating.

3 C-1032 Coconut oil Acid

Non oxidising short

oil length

70 Xylene 5-15 225-300

seconds in

FC4

2

Notes : White baking enamels for refrigerators, washing machines, water filter and hospital appliances

and as plasticizer for NC lacquers wood coating.

4 D-2040M Dehydrated Castoroil, type semi

oxidising short oil

70 Xylene 5-15 80

100Sec

8

Notes : Fast drying general purpose baking enamels for industrial equipments, machineries, household

appliances and printing inks. Very useful for cold catalysed lacquers with UF Resin used in textile

printing screen. Residual hydroxyl of DCO usefull as co-reactant in polyurethane finishes.
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Ketone Resin

Serno Product

Code

%

Solid

Hydroxyl

value

KOH/gm

Melting

Point

Capillary

Viscosity

at 30*C

Solubility Compitibility

1 KF-10 100 250 Min 85-105 35-50 in

60%

Toluene

Alchols ester

ketones & glycol

ethers

cholrinated

hydrocarbons

Ester & alchol soluble

Nitrocellulose short oil

alkyds aminos phenolics

polyurethanes PVB resins

natural & synthetic rubber

& commonly used

plasticizer

Notes : For all types of NC lacquers, printing inks for paper, ball pen inks and in casting resins. In surface

coatings, it improves gloss & adhesion, plastisols, nail lacquers Etc.

Epoxy Resin

Serno Product

Code

Type %

Solid

(2)

Solvent Colour

Gardner

Viscosity

poises at

25*C

Epoxide

Value

Epoxide

Equivelant

1 Epoxy-

450

Bisphenol

Epoxy

Resin

75 Xylene 2 65-100 as

is

3 450-500

Characteristics : For Two pack Epoxy Paints.
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Polyamide Hardner

Serno Product

Code

Type %

Solid

Solvent Colour

Gardner

Viscosity poises at 25*C Amine

Value

1 SP-115 Polyamide

Resin

100 Solvent

Less

10 as such in Brook Field LVT/S-4,

RPM-6 at 40C: 450

-650 Poise

210-230

Characteristics : Hardner for Epoxy, Good chemical resistance for faster curing.

2 SP-125 Polyamide

Resin

100 Solvent

Less


RPM-6 at 25C: 400-550 Poise

2290-320

Characteristics : Coating for Paint and Adhesive.

3 SP-140 PolyamideResin

100 SolventLess

10 such in Brook Field LVT/S-4,RPM-6 at 25C: 130-170 Poise

350-400

Characteristics : Floor Coating for Construction and Solvent Less Coatings.

4 SP-160 Polyamide

Resin

100 Solvent

Less


RPM-6 at 25C: 3-6 Poise

350-400

Characteristics : Floor Coating for Construction and Solvent Less Coatings.
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Phenolic Resin

Serno Product

Code

Colour on gardner

scale

%

Solid

Acid

value

Capillary Melting point in deg.

C

1 P-260 50% Solution of Resin:

12Max

100 25 100-110

Notes : Paints, Printing Inks, Insulating Varnishes, oil Varnishes etc.


13Max

100 25 135-145

Notes : Lithographic and Gravure Printing Inks


12Max

100 20 (Ball & Ring) 125-135



12Max

100 25 150-160

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Poluester Resin

Serno Product

Code

Solid (+

2%)

Solvent Acid value

mgKOH/gm

Viscosity Colour on

Gardner Scale

1 P-10 55 Styrene 15 25-35 Sec in FC4 Cup at

25'C

1

2 P-11 65 3.4:1 CIX, 2

Butoxy ethanol

10 90 110 Sec in FC4 Cup

at 30'C

3

3 P-12 60 Mix Xylene 10 75 95 Sec in FC4 Cup at

30'C

3

4 P-13 65-70 Styrene 22 5 8 Poise as such in BF

RVT/S-3, RPM-12 at 25C

7
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