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Paint manufacturing process

Marda paint and marble factory

What Is Paint Made of?

1. All paints generally have four main ingredients
 Pigments
 binders,( resins)
 solvents (liquids) and
 additives

 pigments : it provide color and hide

 Pigments are finely ground particles that are dispensed into paint and provide color and hiding
properties. There are two primary types of pigment - prime pigments and extender pigments.

 Prime pigments are those that contribute to both wet and dry hide in paint. Titanium dioxide
(TiO2 ) is the most costly pigment and it contributes directly to a paint's wet hide, while providing
whiteness Colorants are prime pigments that provide the actual color within the can.

 There are two main types : 1’organic

2,inorganic
 Organic colorants: provide the brighter colors, and examples of these pigments
include hansa yellow and phthalo blue. These are not very durable for exterior paint
application.
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 Inorganic colorants: are the duller, earthy colors and are more durable for exterior
paint application. Examples of these kinds of pigments include red oxide, yellow ochre
and umber.

NB:Extender pigments are lower cost pigments that give extra

weight or bulk to the paint. These types of pigments contribute only to a
paints dry hide, but are necessary in order to control gloss. Some extender
pigments also provide additional film performance in the areas of scrub or
abrasion resistance. Commonly used extenders include clay, silica,
diatomaceous silica, calcium carbonate, talc and zinc oxide
 Clay: Used mainly in interior paints, clay provides hiding power.
 Silica: Provides enhanced durability in exterior paints as well as scrub and abrasion resistance.
 Diatomaceous silica: Consisting of fossilized organisms, this form of silica is used to control sheen
levels.
 Calcium Carbonate: Used in both interior and exterior paints, calcium carbonate, also called
chalk, is a general purpose, low cost, low hide pigment.
 Talc: Also called magnesium silicate, talc is a soft, general purpose extender pigment.
 Zinc oxide: Used primarily in primers and exterior paints, zinc oxide provides mildew resistance,
corrosion inhibition and stain blocking

 binders: it work to "bind" the pigment together and create the

paint film
 Provide Performance and Support for Dry Paint Film
 Binders are ingredients that provide a binding effect that holds the pigments
together to create a dry film on the surface. A paints binder is the key
ingredient that directly relates to a paints performance, including adhesion,,
washability, scrub resistance, fade resistance or gloss retention .

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 Alkyd (oil) based binders are made from various oil derivatives such as linseed oil, tung
oil, and soya oil. Traditional alkyd paints dry to a very hard finish and provide superior
adhesion and flow and leveling; however, they will yellow in light colors and are prone
to oxidation and chalking when used on exterior surfaces. As technology and VOC
restrictions have changed over the years, fewer paints today are made with traditional
alkyd binders. A newer technology based on modified oil binders is available; alkyd
emulsion.. This type of hybrid binder gives you oil-like performance with the ease of
soap and water clean-up. Alkyd-emulsion paints dry harder, flow more smoothly than
typical latex paints; however, they may still yellow in lighter colors. If used on exterior
surfaces subjected to UV exposure, alkyd-emulsion paints may eventually oxidize, and
chalk over time.

Latex Paint and Ingredients

Latex binders are used in water-based paints. There are various types of latex binders
available, such as 100% acrylic, styrene acrylic or vinyl acrylic, each providing specific

performance characteristics .
Acrylic Paint and Ingredients
100% Acrylic binders: often used in exterior paints as the benefits include
adhesion (both wet and dry), fade resistance, alkali and efflorescence
resistance. 100% acrylic binders are typically regarded as the best overall
performing.
Adhesion under wet conditions allow for greater performance in blister, cracking and
peeling resistance.
UV fade resistance allows the painted surface to retain its color and sheen longer.
Alkali resistance means the paint is less likely to “burn" over fresh concrete or
masonry.
Vinyl acrylic, also called PVA, binders: often used in interior paints as the benefits
include scrub resistance and washability.
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Styrenated acrylic binders: often used in masonry primer/sealers and top coats due to

its resistance to alkali burn and efflorescence ,

 solvent: are the liquids that suspend the ingredients and
allow you to place the paint on the surface

--- Provides a vehicle for the pigment and binder to get from the can
onto the surface

Solvents, or liquids, are the vehicle for allowing paint to get from the can to the
surfaces and these types of liquids differ depending on the type of paint. Combining
the pigments and binders, considered solids, with the liquids, creates the paint
coating you see in the paint can

Oil-based and alkyd paints: the liquid is typically paint thinner or other type of
solvent.

Latex paints: the liquid is primarily water.

Higher-quality paints allow for more solids, typically 35-40%, depending on

gloss level. Solids by volume indicate how much paint will remain on the surface
after the liquids have evaporated. The overall paint performance is directly
attributable to the make-up of the solids. Just because a paint has high solids by
volume does not always translate to a high quality product..

 additives: additives are ingredients that provide specific

paint properties such as mildew resistance
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-- Provides additional property enhancements

Thickening agents: provides “viscosity" or additional thickness so the paint can be applied
properly; also allows for better “flow and leveling" and resists a splatter effect when rolling
out the paint
Surfactants or soaps: provides paint stability so the paint won't separate; also keeps the
pigments dispersed in the liquid to allow for better hiding power and additional assurance
for color accuracy
Biocides: in latex paints, there are two types of biocides used – a preservative to keep
bacteria from growing; and a mildewcide to discourage mildew growth
Defoamers: provides a way to break bubbles as they are formed during the paint
manufacturing process, when paint is shaken at the tint center and when paint is applied
onto a surface
Co-solvents: provides additional liquids to the water and can assist the binders in forming a
good film when applied in cold temperatures and assists brushing properties so paint has
time to be applied before drying

Notes All four ingredients combine to provide paint

that meets your specific design needs. .
All four ingredients are key to creating the foundation for a
top-quality paint.

2. The Manufacturing Process

Making the paste:
1 .Pigment manufacturers send bags of fine grain pigments to paint plants. There, the pigment is
premixed with resin (a wetting agent that assists in moistening the pigment), one or more solvents,
and additives to form a paste.
 Dispersing the pigment
2,The paste mixture for most industrial and some consumer paints is now routed into a sand
mill, a large cylinder that agitates tiny particles of sand or silica to grind the pigment
particles, making them smaller and dispersing them throughout the mixture. The mixture is
then filtered to remove the sand particles.
3, Instead of being processed in sand mills, up to 90 percent of the water-based latex paints
designed for use by individual homeowners are instead processed in a high-speed dispersion tank.
There, the premixed paste is subjected to high-speed agitation by a circular, toothed blade attached
to a rotating shaft. This process blends the pigment into the solvent.
 Thinning the paste
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4 ,Whether created by a sand mill or a dispersion tank, the paste must now be thinned to produce
the final product. Transferred to large kettles, it is agitated with the proper amount of solvent for
the type of paint desired.

 Canning the paint

5 ,The finished paint product is then pumped into the canning room. For the standard 8 pint (3.78
liter) paint can available to consumers, empty cans are first rolled horizontally onto labels, then
set upright so that the paint can be pumped into them. A machine places lids onto the filled cans,
and a second machine presses on the lids to seal them. From wire that is fed into it from coils, a
bailometer cuts and shapes the handles before hooking them into holes precut in the cans. A
certain number of cans (usually four) are then boxed and stacked before being sent to the
warehouse.

Quality Control
Paint manufacturers utilize an extensive array of quality control measures. The ingredients and the
manufacturing process undergo stringent tests, and the finished product is checked to insure that it
is of high quality. A finished paint is inspected for its density, fineness of grind, dispersion, and
viscosity. Paint is then applied to a surface and studied for bleed resistance, rate of drying, and
texture.

In terms of the paint's aesthetic components, color is checked by an experienced observer and by
spectral analysis to see if it matches a standard desired color. Resistance of the color to fading
caused by the elements is determined by exposing a portion of a painted surface to an arc light and
comparing the amount of fading to a painted surface that was not so exposed. The paint's hiding
power is measured by painting it over a black surface and a white surface. The ratio of coverage on
the black surface to coverage on the white surface is then determined, with .98 being high-quality
paint. Gloss is measured by determining the amount of reflected light given off a painted surface.

Tests to measure the paint's more functional qualities include one for mar resistance, which entails
scratching or abrading a dried coat of paint. Adhesion is tested by making a crosshatch, calibrated to
.07 inch (2 millimeters), on a dried paint surface. A piece of tape is applied to the crosshatch, then
pulled off; good paint will remain on the surface. Scrubbability is tested by a machine that rubs a
soapy brush over the paint's surface. A system also exists to rate settling. An excellent paint can sit
for six months with no settling and rate a ten. Poor paint, however, will settle into an immiscible
lump of pigment on the bottom of the can and rate a zero. Weathering is tested by exposing the
paint to outdoor conditions. Artificial weathering exposes a painted surface to sun, water, extreme
temperature, humidity, or sulfuric gases. Fire retardancy is checked by burning the paint and
determining its weight loss. If the amount lost is more than 10 percent, the paint is not considered
fire-resistant.

 Byproducts/Waste
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A recent regulation (California Rule 66) concerning the emission of volatile organic compounds
(VOCs) affects the paint industry, especially manufacturers of industrial oil-based paints. It is
estimated that all coatings, including stains and varnishes, are responsible for 1.8 percent of the 2.3
million metric tons of VOCs released per year. The new regulation permits each liter of paint to
contain no more than 250 grams (8.75 ounces) of solvent. Paint manufacturers can replace the
solvents with pigment, fillers, or other solids inherent to the basic paint formula. This method
produces thicker paints that are harder to apply, and it is not yet known if such paints are long
lasting. Other solutions include using paint powder coatings that use no solvents, applying paint in
closed systems from which VOCs can be retrieved, using water as a solvent, or using acrylics that dry
under ultraviolet light or heat. A consumer with some unused paint on hand can return it to the
point of purchase for proper treatment.

A large paint manufacturer will have an in-house wastewater treatment facility that treats all liquids
generated on-site, even storm water run-off. The facility is monitored 24 hours a day, and the
Environmental Protection Agency (EPA) does a periodic records and systems check of all paint
facilities. The liquid portion of the waste is treated on-site to the standards of the local publicly
owned wastewater treatment facility; it can be used to make low-quality paint. Latex sludge can be
retrieved and used as fillers in other industrial products. Waste solvents can be recovered and used
as fuels for other industries. A clean paint container can be reused or sent to the local landfill.

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