1

Introduction

Asian Paints Bangladesh Ltd (APBL) started its journey in Bangladesh in the year 2002 as a
joint venture with Confidence Cement, a leading & reputed producer of cement in
Bangladesh to produce top class range of paints for the discerning consumers of
Bangladesh. Beginning with selling imported paint, we quickly ramped up through our own
plant in Gazipur on the outskirts of Dhaka with a capacity to manufacture over 12,000 KL
of paints annually. Now the company is engaged in manufacturing & marketing a wide
variety of products with its expertise and cutting edge technology to satisfy all the painting
needs of consumers in Bangladesh.

Today APBL has come a long way from its humble beginnings, becoming the 2nd largest
paint company in Bangladesh. With a Presence across all 64 districts, a 500 plus supportive
dealer network, we are well placed to meet the painting demand of all category of
consumers across Bangladesh. We service our customers through a network of strategically
located depots in Dhaka, Chittagong, Sylhet, Khulna, Comilla and Bogra.

The Company aims to provide the best products to consumers in most prominent segments.
Apart from a wide range of decorative paints, there are a no. of popular industrial products
which have strengthened their presence in the Bangladesh paint market. Asian Paints have
also brought excitement in the Bangladesh market through introduction of a no. of
innovative concepts and initiatives, which have set benchmarks of progress in the market
today. Some of these would include work on a better retail ambience in paint shops
(Through attractive shop makeover in certain outlets with usage of interesting layouts and
tools to help consumers understand products and colour more effectively), popularizing the
concept of signature walls (through a successful launch of Royale Play Special Effect
Paints) and consistent work on applicator education and skill enhancement. The world class
brands widely accepted in Bangladesh today include Royale Play, Royale Luxury Silk
Emulsion, Apex Ultima, Apcolite and Decora. Today there are more than 200 Colour
Worlds (outlets with automatic colour dispensing machine for delivering a wide range of
shades within minutes) in the country which has ensured even better servicing of customer
needs.

An initiative towards capacity expansion of the factory is on its way, and this would ensure
doubling of current capacity by early 2013.

It is also a matter of pride that Asian Paints have been awarded "Superbrand" status since
2009 in Bangladesh - and is seen as one of the most respected corporate entities in the
country.
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Profile
Profile

Asian Paints (Bangladesh) Ltd.

Products & Services: Houseing and Real Estate Services

HO- House 428/A (3rd,4th & 5th Floor) Road 30,

Address: New DOHS Mohakhali Dhaka – 1206.
Factory- Plot#317 &757, Gazipur.

City: Dhaka

Country: Bangladesh

Phone: 880-2-9204482-3

E-mail: www.asianpaints.com/bd

Vision
Asian Paints aims to become one of the top five Decorative coatings companies world-wide
by leveraging its expertise in the higher growth emerging markets. Simultaneously, the
company intends to build long term value in the Industrial coatings business through
alliances with established global partners.

Their Main Objectives Is On The Following Areas

•Company is using PC,V-sats based line and internal mesh to become most networked
corporation in India.
•Company is trying to cut down the inventory and improve the working capital cycle for a
continuous production.
•Asian paint is highly accepted in the urban sector and now the company is trying to access
the rural market with low price product like Utsav targeting very customer of all income
level
.•To enhance their marketing in rural sector a huge amount investment is made in ad
campaign and demonstration cum sales technique is going on

.•To increase its sales in the urban sector Asian paints today have 30 colour world located in
different cities of India where any body can have the real taste of the colour
•Online marketing has become an integrated part of the company and company is trying
install a strong integrated for online marketing
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•Asian paints international unit, which have a dedicated marketing team is also targeting for
a rapid growth in over seal market
•Asian paint is concentrating on the development of technological improvement in their
Industrial Coating so that to make the product more stronger positon in the market.

The Departments Of Asian Paints (Bangladesh) Ltd.

 Production
 Quality Control and Research & Development
 Admin
 QEHS
 Distribution
 Information Technology
 Maintainance
 Store
 VAT

Product
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Corporate profile

Introducing The Asian Paints Group

Asian Paints is India's largest paint company and Asia's third largest paint company, with a
turnover of Rs 141.83 billion. The group has an enviable reputation in the corporate world
for professionalism, fast track growth, and building shareholder equity. Asian Paints
operates in 19 countries and has 26 paint manufacturing facilities in the world servicing
consumers in over 65 countries. Besides Asian Paints, the group operates around the world
through its subsidiaries Berger International Limited, Apco Coatings, SCIB Paints,
Taubmans and Kadisco.

Asian Paints was included in Forbes Asia's 'Fab 50' list of Companies in Asia Pacific in
2011, 2012, 2013 and 2014. Forbes Global magazine USA ranked Asian Paints among the
'200 Best Small Companies in the World' for 2002 and 2003 and presented the 'Best under a
Billion' award, to the company. Asian Paints is the only paint company in the world to
receive this recognition. Forbes has also ranked Asian Paints among the 'Best under a
Billion companies in Asia' in 2005, 2006 and 2007.

The company has come a long way since its small beginnings in 1942. Four friends who
were willing to take on the world's biggest, most famous paint companies operating in India
at that time set it up as a partnership firm. Over the course of 25 years Asian Paints became
a corporate force and India's leading paints company. Driven by its strong consumer-focus
and innovative spirit, the company has been the market leader in paints since 1967. Today it
is double the size of any other paint company in India. Asian Paints manufactures a wide
range of paints for Decorative and Industrial use.

In Decorative paints, Asian Paints is present in all the four segments v.i.z Interior Wall
Finishes, Exterior Wall Finishes, Enamels and Wood Finishes. It also introduced many
innovative concepts in the Indian paint industry like Colour Worlds (Dealer Tinting
Systems), Home Solutions (painting solutions Service), Kids World (painting solutions for
kid's room), Colour Next (Prediction of Colour Trends through in-depth research) and
Royale Play Special Effect Paints, just to name a few.

Asian Paints has always been ahead when it comes to providing consumer experience. It has
set up a Signature Store in Mumbai, Delhi and Kolkata in India, where consumers are
educated on colours and how it can change their homes.

Vertical integration has seen it diversify into products such as Phthalic Anhydride and
Pentaerythritol, which are used in the paint manufacturing process. Asian Paints also
operates through 'PPG Asian Paints Pvt Ltd' (50:50 JV between Asian Paints and PPG Inc,
USA, one of the largest automotive coatings manufacturer in the world) to service the
increasing requirements of the Indian automotive coatings market. Asian Paints has formed
another 50:50 JV with PPG named 'Asian Paints PPG Pvt Ltd' to service the protective,
industrial powder, industrial containers and light industrial coatings markets.
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International Presence

Today the Asian Paints group operates in 19 countries across the world and is the largest
paint company in eleven countries. The group operates in five regions across the world viz.
South Asia, South East Asia, South Pacific, Middle East and Caribbean region through the
five corporate brands viz. Asian Paints, Berger International, SCIB Paints, Apco Coatings,
Taubmans and Kadisco. The Group operates as:

 Asian Paints in South Asia (India, Bangladesh, Nepal and Sri Lanka)
 SCIB Paints in Egypt
 Berger in Asia (Singapore & Indonesia), Middle East (UAE, Bahrain and Oman),
Caribbean (Jamaica, Barbados, Trinidad & Tobago)
 Apco Coatings South Pacific (Fiji, Tonga, Solomon Islands and Vanuatu)
 Kadisco in Ethiopia
 Taubmans in South Pacific (Fiji and Samoa)

The company has a dedicated Group R&D Centre in India for paints and has been one of the
pioneering companies in India for effectively harnessing Information Technology solutions
to maximize efficiency in operations.

Home Improvement

Asian Paints with its intent to enter the Home Improvement and Décor space in India had
acquired 51% stake in Sleek group, a kitchen solutions provider in August 2013. Sleek is a
major player in the organized modern kitchen space and is engaged in the business of
manufacturing, selling and distribution of modular kitchens as well as kitchen components
including wire baskets, cabinets, appliances, accessories etc. In June 2014, Asian Paints
acquired the entire front and sales business including Brands, Network and Sales
Infrastructure of Ess Ess Bathroom products Pvt Ltd. Ess Ess is a prominent player in the
bath and wash segment in India and has high quality products in this segment. Asian Paints
believes that both these acquisitions has a strategic fit both with its current business as well
as other lines of Home Improvement businesses that may get added in the future

Awards

•Awarded the "Sword of Honor" by the British Safety Council for all the paint plants in
India. This award is considered as the pinnacle of achievement in safety across the world.
•Forbes Global magazine, USA ranked Asian Paints amongst the 200 'Best Small
Companies of the world' in 2002 and 2003 and amongst the top 200'Under a Billion Firms' of
Asia in 2005.
•Ranked 24th amongst the top paint companies in the world by Coatings World -
Top Companies Report 2006.

•The Asset - one of Asia's leading financial magazine ranked Asian Paints amongst the leading
Indian companies in Corporate Governance in 2002 and2005.

•Received the Ernst & Young "Entrepreneur of the Year - Manufacturing “award in 2003.
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Environment And Safety

➢Asian Paints approaches the environment issue from the perspective of waste
minimization and conservation of resources.

➢It attempt is to reuse, recycle and eliminate waste, which results in less and less waste
being generated. Accordingly, the material losses in manufacturing have been reduced
substantially over the last few years.

➢It has ISO 14001 certification for environment management standards.

➢It has achieved 'zero industrial discharge' capability. This has been achieved by the
installation of upgraded effluent treatment facilities and installation of reverse osmosis
plants in conjunction with appropriate recycling and reuse schemes. Our emulsion
manufacturing facility also achieved 'zero waste' status. It has adopted the principles of
"green productivity". It has adopted the principles of "green productivity".

➢Some of its innovative schemes which enhance green productivity are dealer tinting
systems which has resulted in large batch sizes ; bulk storage facility for monomers which
reduces wastage; Use of natural gas which is a cleaner fuel ; solvent recovery plants have
been set up which has resulted in zero reduction of solvent disposal ; Improved in cinerating
systems and reverse osmosis.

➢The "Sword of Honour", instituted by the BSC, is recognized the world over as the
pinnacle of achievement in safety management systems.

Quality Policy
•We shall provide products and services that meet stated standards on time, every time.
•We accept Zero Defect as a quality absolute, and shall design and operate our quality
system accordingly.

•We will organize our work practices to do a job right the first time, every time.

•We are committed to continuous improvement in quality in all business processes and shall
track such improvement through measurable indicators.
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Paint Technology & Its Application

Paints
Paint is generally homogenous mechanical mixture of pigments, binder, additives and
solvent which after application to a surface in a thin layer is converted to an opaque
coherent solid film that provides protective purpose as well as aesthetic view.

Pigments :
In the coloring of paint a pigment is a dry colorant, usually an insoluble powder.Pigments
that are dispersed in paints, work by selectively absorbing some parts of the visible
spectrum whilst reflecting others. It's used both to provide color, and to make paint opaque,
thus protecting the substrate from the harmful effects of ultraviolet light while also
increasing paint's hiding power.

Role :

1. Provide color & give opacity.

2. Responsible for hiding.
3. Enhance film durability
4. Reduce moisture permeability & serves as a barrier
5. Protect the film by reflecting the UV light.
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As refractive index

As particle size
Opacity of pigment
As surface area

As volume concentration

Extender :
Extender pigments are added in order to reduce the cost of a paint formulation.They are also
used to modify the flow (viscosity), sedimentation stability and film strength.Most extender
pigments appear white and possess a refractive index similar to commonly used
binders.Most of the extender pigments occur naturally and others can be produced
synthetically.Aluminium silicate, magnesium silicate (talc), silica, calcium carbonate
(synthetic and natural) and barium sulfate are some commonly used extender in paints and
coatings.

Adhesion or Binders:

A binder is a material used to bind together two or more other materials in mixtures. Its two
principal properties are adhesion and cohesion. The binder determines many of the
necessary film properties such as adhesion, gloss level, hardness, abasing resistance,
flexibility, drying & durability.

Role:
Hold pigment in dispersion
Convert liquid coating to solid film
Adherence to substrate/ undercoat
Gloss
Elasticity to film
Water/ Chemical resistance
Abrasion resistance
Durability to paint film

Additives :

Impart specific properties

. Used in small proportion

. Available for all stages

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Processing: Wetting, Dispersing agents

Application: Thixotropic Additives
Storage: Anti- skinning agents
Performance: Biocides

Some important types of additives are -

Types:
Fungicide Algaecide
Freeze-thaw Stabilizer Rheological additives
Thickener Scavengers
Coalescents Dispersing Agents
Wetting Agents Anti-settling
Anti-floatation Drier
Thixotropic Defoamers
Rust inhibitor Ph stabilizer
Bactericide

Inhibitor Or Initiator:
Critical Function - It Acts as a Catalyst.

Nature Of Surface
Type of Surfaces

Wood

Masonry

Metals

Others

Surface Preparation Before Painting:

Following Subjects have to be followed Before Painting on the Surface:

• Identify the Type of Surface to select the Paints Product Selection.

• Surface Should be cleaned Properly with Biocidal or Fungicidal & Clean Water
Wash.
• Filling of Cracks and Dents.
• To Remove all the Loosely Adhering Particles and lower down content of soluble
salts at surface level.
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• To Ensure The surface is free from Rust, Dust & Oil material like as Grease, Oil.
• To Ensure the surface is Dry and free from damp. - Moisture and Salts. Moisture
content must below 17% for new painting.
• To Check Alkalinity Up to PH- 9 is Ok for Painting
• To Select Appropriate Paints Product for Appropriate Substrates and Follow the Use
instruction in Technical Guide Books or Container Body.
• During Painting Use PPE for Health & Safety.

Solvent Or Thinner:
In paint, the solvent serves to adjust the viscosity of the paint. It is volatile and do not
become part of the paint film. Solvents are also known as diluents and thinners. Dissolve /
dilute film forming agents to provide consistency suitable for application

Properties:

Should be colorless
Should be completely miscible with the paint at room temperature.
Should be evaporate from the dried paint film
Should act only on binder, not with pigment.
Should be free from any residue
Function of Solvent:

It controls flow and application properties, affects stability of paint while in liquid state. Its
main function is as the carrier for non volatile components.

Paint Processing Stages

4 stages---
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Premixing:
At This Stage, All The Powders (Pigments, Extenders Etc.), Part Of The Medium And
Solvent Along With Dispersing Agents Are Added Into A Premixing Vessel (TSD Or
HSM) And Mixed Thoroughly.

• The Purpose Of This Stage Is To Achieve A Homogeneous Mass, Known As

Premixed Millbase.

Twin Shaft Disperser (Tsd)

Critical Parameters:
Batch charging to be done under slow speed only.
Maintaining of addition sequence.
Mixing &Dispersion at high speed / shear force .
Control on mixing time.
Control on mixing speed.
Preventive maintenance
Ceanliness of mixer.
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Grinding:
This is the second stage of Paint Manufacturing, where in the premixed mill base is ground
in a grinding equipment like Sandmill, Ballmill Batch Bead Mill, Attritor.

• The Purpose Of This Stage Is To Achieve The Required Size Reduction Of

The Powder Particles.

Critical Parameters:
Pre-mixing
Mill base viscosity
Processing temperature
Flow Rate
Grinding media quality
Grinding media quantity
Preventive maintenance
Cleanliness of mill

Ball / Pebble Mill Processing:

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Attritor

Batch Completion (Mixers):

Batch Completion Comprises Of 3 Sub Stages –

 Thinning

 Tinting

 Final Adjustment

 Thinning
– At This Stage, Balance Quantity Of Medium And Solvent Are Added Along
With The Driers in the batch discharged in Mixer.

– Important Properties like Drying Time, Viscosity ,Weight Per Litre (WPL) ,
Reducing Strenght are checked.
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Batch Completion
Tinting

Tinters, As Specified In The Formulation Are Added To The Batch, Step By Step And The
Shade Of The Batch Is Matched Close To The Standard Shade Panel. Final Shade Matching
Is Done Visually Or With The Help Of Colour Computer.

Final Adjustment

The Batch Is Adjusted Step By Step, With Addition Of The Ingredients, As Specified In
The Formulation, To Achieve The Specified Properties.

Packing Operations
Packing Consists Of Following Operations

• Filling
• Lid Pressing
• Printing / Stamping / Labeling
• Secondary Packing (In Case Of Small & Retail Packs)

Filling Unit
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Lid Pressing Unit

Paints classification & its production

Classification of paints
Currently there is a wide range of paints available on the market, knowledge the bases,
characteristics and properties of each family of paints, allow us to make the optimal
decision in the selection of paints based on technical and economic requirements required
by the job.

Among the various forms of grouping families of paints available today, we can cite the
following classifications:

By the level of specific layer of the paint itself:

 Primers
 Sealants
 Topcoats

The primers are the first layers of paint applied on the surface, the primers are designed and
formulated to protect the surface against oxidation and corrosion and to be the basis for a
good anchorage and adhesion for subsequent layers of paint.

Sealants are the layers of paint that are located between the primers and topcoats, are
generally used when apply putty, to seal and isolate putty to finish coat as well as improve
adherence and support for the following layers of paint.
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Topcoats refer to the entire set of paints that are used to colour the surface, are paints which
are to be resistant to abrasion, ultraviolet light, chemicals, moisture, etc. ... due that kind of
paints are in direct contact with the outside.

By the sector to which it is intended that the application uses:

 Paints for the automotive industry

 Paints for general industry
 Paints for the construction
 Decorative paints (home)

The paints are designed according to the sector which will go, for example primers used in
the automotive sector are totally different from the primers used in the manufacture of ships,
due to the different functional requirements (the paints of ships must be very resistant to
humid environments and extremely saline) and the different materials on which the paint is
applied (cars widely used aluminium and plastics of different compositions, while ship used
primarily steel).

By the number of coats applied in the paint system:

 Direct paint
 Monolayer
 Bilayer
 Trilayer

Direct paint : Direct paint are those paints that are applied directly on the material or
substrate, these paints offer some resistance to both oxidation and ultraviolet radiation and
other external agents, providing directly the colour, gloss and aesthetic finish.

Monolayers paints : Monolayers paints are known to the classical application of 2 coats of
paint, primer plus enamel, the primer layer protects the material from oxidation and
corrosion and promotes adhesion of the next layer of paint, the top layer commonly called
enamel or direct gloss is provided by the colour, gloss and resistance to light and
environmental agents.

Bilayers paints: Bilayers correspond to the paint coating system consisting of three layers,
primer plus basecoat plus varnish, in this case the final finish is achieved by means of two
different layers, basecoat is the first layer that provides colour and metallic effect, final
transparent varnish layer provides gloss and protection against external agents.

Trilayers paints : Finally we found trilayers paints, in which the paint application system
consists of 4 layers, the first coat of primer and the last 3 layers correspond to the finish,
with the latter three layers is achieved pearlescent or chameleon effects (colour change
depending on the light incidence and the angle at which we see), this type of paints are used
primarily in tuning automotive sector.

By the degree of emission of volatile compounds:

 Powder paint
 Water-based paint
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 Paint with high solids content

 Solvent-based paint

For ecological reasons and job security, it has developed new ranges of paint that are
designed to reduce the amount of solvents that are emitted and used during mixing,
application and curing paint, due it produces a source of emission of volatile organic
compounds (VOC's) harmful to both humans and the environment.

Powder paints are more environmentally friendly due it does not require or contain any
concentration of solvents, water-based paints contain a tiny concentration of solvent which
is negligible, follow the high-solids content paints which require less amount of diluent to
the solvent based paints.

By the number of components or containers need to dry or cure the paint:

 1-component paint
 2-component paint

1-component paints are those paints which not need to be mixed with any hardener so that
drying occurs, this type of paint dried by the action of moisture, ultraviolet light, high
temperature, etc.

Main Productions Of Asian Pains Bangladesh Ltd.

Water base paints :

The paint in which various water are used as thinner and emulsions are used as binder is
called as Water-based paint.Recently water base paint become most popular because of its
low price and hazardousness quality water base paint is appropriate for protecting and
decorating of concrete surface. It contain more than 25% water.

Water based paints are two types:

1. INTERIOR PAINTS :

• Asian paint acrylic distemper (APAD)

• Apcolite acrylic emulsion(AAE)
• Asian paint premium emulsion(APPE) etc.

2. EXTERIOR PAINTS :

• Asian pain weather proof exterior (AWPEE)

• Apcolite exterior emulsion (AEE) etc.
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Raw materials for Water based Paint:

 Solvent (H2O
 Binder(emulsion)
 Additives
 Stainer
 Filler

Solvent-Based Paints:
The paint in which various solvents are used as thinner and resins are used as binder is
called as Solvent-based paint or oil-based paints. It can have various combinations of
solvents as the diluents, including aliphatic, aromatics, alcohols, and ketones. Some
common thinners are used for solvent base are – Mineral terpentine oil (MTO), Xylene,
Mineral terpentine (MTT), Toluene, Butyl Acetate etc. Resins are used - Alkyd Resin,
Epoxy Resin etc. Solvent-based paint are widely used for industrial application.

Some important solvent-based paints of Asian Paints(BD) Ltd. Are –

• Apcolite gloss enamel (APGE)

• Decora synthetic enamel (DSE)
• Primer – ANTI corrosive primer (ACP)

Raw materials for Solvent based Paint:

 Resin
 Additives
 Pigments
 Filler
 Thinner

Resin:
Resins acts as binders in solvent base paints. In BPBL, following resin systems are used in
solvent base paint-

1) Alkyd Resin

2) Epoxy Resin

3) Polyurethane Resin

4) Chlororubber Resin

5) Phenolic Resin
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A brief description about the resin plant is given below-

Alkyd resin
Alkyd coatings are a class of polyester coatings derived from the reaction of an alcohol
(alkohol) and an acid or acid anhydride hence the term alk-yd from "alcohol and acid or
anhydride]" and are the dominant resin or "binder" in most "oil-based" coatings sold to the
consumer market. Alkyd coatings today are typically manufactured from acid anhydrides
such as phthalic anhydride or maleic anhydride and polyols such as glycerine or
pentaerythritol and are modified with unsaturated fatty acids (from plant and vegetable oils)
to give them air drying properties. The unsaturated oils react with oxygen from the air
which cause the oils to polymerize or crosslink with each other. The drying speed of the
coatings depends on the amount and type of drying oil employed (more unsaturated oil
means faster reaction with oxygen from the air) and use of organic metal salts or "driers"
which catalyze crosslinking between the unsaturated oils used to modify the base polyester
resin. Traditionally organic lead salts were employed but have been replaced with cobalt
and other alternative driers such as zirconium, zinc, calcium, and iron. Most driers are
colorless but cobalt is a deep blue purple color (iron driers are reddish orange) thus the
colored driers are typically employed only in paint colors where the blue color of cobalt or
reddish orange color of iron can be easily masked.

Alkyd coatings are typically sold in three classes; Long, Medium, and Short. These terms
represent the relative fraction of drying oil component in the resin. Long oil alkyds have a
high percentage of drying oil content and are generally sold as medium duty coatings for the
consumer market. Medium oil alkyds have less drying oil and have a higher percentage of
large molecular weight polyester backbone. They dry slower and are employed as high
gloss coatings and wood finishes. At the bottom end are short oil alkyds where the
percentage of drying oil is very low in relation to the base polyester polymer or backbone
chain. These coatings will not air dry or harden unless heated. Short oil alkyds are employed
as baking as enamels for finished metal products.
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Because the major components of an alkyd coating, i.e. fatty acids and triglyceride oils, are
derived from low cost renewable resources this has kept the cost of alkyd coatings very low
despite ever increasing cost of petroleum which is the predominant raw material source of
most other coatings such as vinyls, acrylics, epoxies, and polyurethanes. Typical sources of
drying oils for alkyd coatings are sunflower oil, safflower oil, soybean oil, fish oil, corn oil,
and tall oil (resinous oil by-product from pulp and paper manufacturing).

Decora cement paint (DCP)

Putty (in pug mill)

Total batch cycle time of AWP –white in pugmill

Stream/route/equipment Putty-pugmill
Standard Actual
Activity Time(min) Team Time(min) Team
strength strength
Cleaning time 10 2 10 2
Water taking time in a barrel 0 0 - -
Water charging in pugmill 10 1 3 2
Liquid charging 15 1 10 2
Mixing/jelly preparation 20 2 17 2
Powder charging 85 2 23 2
Adjustment (powder cleaning 5 1 4 2
&flushing with water
Grinding / reaction time 30 0 30 0
Inspection for finish 10 1 3 1
Thining (emulsion) 25 2 3 2
Viscosity testing at QC 48 1 31 2
Approval 48 1 31 1
Discharging time 15 1 10 1
Total cycle time per batch 273

Total batch cycle of APW –putty in pugmill is 144 min.

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Raw materials (commercial name)

• Supertintblack
• Supertint Red Oxide 223
• Supertint Sudaperm Red 2987
• Supertint Permanent Borodex
• Supertint Permanent Red H2bm
• Supertint Toluidene Red
• Supertint Violet Fastogen Rns
• Super Tint White R-900
• Supertint White R-215
• Misc Super Tint Intermediate
• Supertint Middle Chrome 1329
• Supertint Lemon Chrome 1229
• Supertint Scarlet Chrome 1475
• Supertint Yellowoxide1814/C190
• Supertint Irgalite Yellow B3rn
• Supertint Sudafast Yellow 123
• Supertint Sudacolor Orange-211
• Aquatint Ultramarine Blue
• Aquatint Red Oxide 445
• Aquatint White
• Misc Aqua Tint Intermediate
• Aquatint Yellow Oxide C 190
• Epotint Blue 2661
• Epotint Green Gnxl
• Epotint Black
• Epotint Scarlet Chrome 1475
• Epotint Per Red Frr In
• Epotint Toluidene Red
• Epotint White R 900
• Epotint Middle Chrome 1329
• Epotint Lemon Chrome 1229
• Ep-Sol-01
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Machineries

• Bead mill-(1-2)
• Attritor-(1-3)
• Twin speed disperser-12
• Basket ball mill
• High speed disperser- (1-2)

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

 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.
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Manufacturing Process Of Water Base Paints

Preparation of Batch Card:

 First batch card prepared by Research and Development department of Asian Paints
Bangladesh Limited.
 Then the raw materials used for respective paint production is issued by Raw Material
department of Asian Paints Bangladesh Limited.

Charging of raw materials:

 Pigment manufacturers send bags of fine grain pigments to paint plants. First, Water and
dispersing agent is added to the Twin Shaft Disperser or High Speed Disperser
depending upon the nature and quantity of the paints. To this mixture, dry pigment and
pigment extenders are added. Four additions of materials occur in this tank. First,
plasticizers are added to the mixture; second, a preservative and an antifoaming agent
are added; third, an emulsion is added; and fourth, water is added as a thinner. There,
the pigment is premixed with emultion (a wetting agent that assists in moistening the
pigment), one or more solvents, and additives to form a paste.
 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.
 After a pre-determined time the grinding is checked by Quality Control department. If
the grinding not fulfills the required condition the grinding operation is repeated several
times.
 If the grinding fulfills the required condition then the bulk mixture is dropped into the
mixing tank of the strainer zone, where the color is matched by Quality Control
department.
 If the required color is not matched, the required amounts of pigments are added into the
bulk mixture in the mixing tank. After completion the mixing the color is again checked
by Quality Control department.

Canning the paint:

 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. A certain number of cans (usually one and two) are then
boxed and stacked before being sent to the warehouse.
 24

Preparation of Raw Material Follow Machine

batch card issue by RM color sequence
dept.

Charging of Dispersing agent,

Titanium, filler, other powder,
Emulsion, water etc.

Grinding Check

If not ok

ok

.
Drop in mixing Tank

Mixing and color matching

If not ok

Samples send to Quality Control for

color matching and other parameters.

Flow chart of water based department gazipur RFF status and filling as per pack
factory, APBL. size
 25

Manufacturing Process Of Solvent Base Paints

Preparation of Batch Card:

 First batch card prepared by Research and Development department of Asian Paints
Bangladesh Limited.Then the raw materials used for respective paint production is issued
by Raw Material department of Asian Paints Bangladesh Limited.

Charging of raw materials:

 Pigment manufacturers send bags of fine grain pigments to paint plants. First, Resin and
dispersing agent is added to the Attritor machine or Batch Bead Mill or Ball mill
depending upon the nature of the paints. Then the machine is operated for several hours.
Then dry pigment and pigment extenders are added. Then 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.
 After a pre-determined time the grinding is checked with grind gauge machine by Quality
Control department. If the grinding not fulfills the required condition the grinding
operation is repeated several times.
 If the grinding fulfills the required condition then the bulk mixture is stabilized into the
machine for 15-20 minutes.
 Then the bulk mixture is dropped into the tank or pot or drum depending upon the
quantity of the paints of the slurry dropping zone, where the color and opacity is matched
by Quality Control department.
 If the required color and opacity is not matched, the required amounts of pigments are
added into the bulk mixture in the mixing tank. After completion the mixing the color is
again checked by Quality Control department.

Thinning the paste:

If the required color and opacity is matched the bulk slurry must now be thinned to produce
the final product. The bulk paste is agitated with the proper amount of solvent for the type of
paint desired. The sample paste is send to the Quality Control department for testing the
viscosity and specific gravity. If it is matched the required level the paste is ready for filling.

Canning the paint:

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. A certain number of cans (usually one and two) are then boxed and
stacked before being sent to the warehouse.
 26

Preparation of Raw Material Follow Machine

batch card issue by RM color sequence
dept.

Charging of Dispersing agent,

pigment, filler, resin and thinner etc

Grinding Check with Grind Gauge

machine

If not ok
Stabilization for 15/20 min.

If not OK.
OK

Drop in mixing Tank/ Pot/ Drum

with balancing part

Mixing and color matching

Samples send to Quality Control for

color matching and other parameters.
If not ok

Flow chart of solvent based department gazipur factory,

APBL. RFF status and filling as per pack
size
 27

Key function of production

Performance Parameters For Production

Deliverables Target
Priority SKU compliance 95 %
SKU Variance Controllable 20% at Month level
Plan Compliance ( for Plant) 95%
MPM efficiency 95%
Over Time 10% over MPM fig.

OAE 95%

QRI 10
Power 85 units
Quality Zero Defect

Safety Zero Accident

Factory Level Losses 1.95 %
 28

Some Name Of The Finished paint Products

Decora Cem Pt Mid Cream
Decora Cem Pt Golden Brown
Decora Cem Pt Apricot
Decora Cem Pt Brick Red
Decora Cem Pt Off White
Decora Dist Ice Blue
Decora Dist Wild Lilac
Decora Dist Leaf Green
Apco Al Paint
Apco Cl Varnish
Mc H. R. Aluminium 500
Metacare Epoxy Primer Ro
Decora Dist Crystal Green
Decora Dist Kaptai Green
Decora Dist Cream - B
Decora Dist Rose Pink
Decora Dist Off White - B
Royale Silk Emulsion Rse-1

Ap Tractor Emul Pigeon Blue-N

Ap Tractor Emul Sky Watch
Ap Tractor Emul Touch Of Rouge
Ap Marine Enamel Lt. Turquis
Ap Marine Enamel Tangerine
Apco Glo Enam Georgian Green
Apco Glo Enam Mid Green-B
Age Banglalink Orange
Apco Glo Ena Regatta
Apco Mat Enam Brilliant White
Apco Mat Enam Mb1

Productivity

Productivity
Productivity is defined as the ratio of output (of goods and/or services) to input (of resources
to produce those goods and/or services) and may be expressed as:

Productivity = Output ÷ Input

 29

Profitability
Profitability is the ratio of Revenue to Expenses, which may be expressed as follows:

Profitability = Revenue ÷ Expenses.

Now,

Profitability = Revenue ÷ Expenses.

= (Output X Price) ÷ (Input X Cost)

= (Output ÷ Input) X (Price ÷ Cost)

= Productivity X Contributing factor

Measurement Of Productivity
Changes in productivity levels are being recognized as a major influence on wide range of
social and economic considerations.

So, it is important to measure the productivity.

Generally speaking, productivity measurement means comparison.

The performance of individual enterprise is widely regarded as dependent on their

comparative productivity.

It can be made in different ways:

• comparison of current performance with a historical base.

• comparison of performance. between one unit and other

• comparison of actual performance with another enterprise.

In measuring productivity, the basic formula from the definition of productivity is applied:

Output

Productivity = ----------------

Input

Production volume for a period

Labour Productivity = -----------------------------------------------
Actual working hours for that period
 30

Production volume for a period

Material Productivity= ----------------------------------------------
Raw material input for that period

Production volume for a period

Machine Productivity = ----------------------------------------------
Machine working hours

One shift productivity calculation in solvent base section

Date : 27-08-2015 Shift : A (6.00 a.m – 2.00 p.m)

Description Solvent base

Plan Actual
Volume packed(L) 7600 7637.36

Workman present(person) 11 19
Present manhours 77 133
NPW manhours 25.71 33.1
Productivity(L/manhours) 148.154 76.45

NPW : Non Productive Work

Purpose Of Paint

Paint has four important uses.

Protection

Paint is used to protect all sorts of building and structures from the effects of water and sun.
Wooden buildings such as houses are usually painted because a coat of paint prevents water
seeping into the wood and making it rot. The paint also helps to prevent the wood from
drying out in the hot sun.
 31

Metal structures and objects of all sorts are painted to stop them from rusting. A very large
steel structure such as a bridge must have a team of painters who keep the paint in good
condition all the time.

Decoration

Paint is used to decorate all sorts of objects. Since pre-historic times, people have painted the
inside walls of their houses to make them look attractive.[1] Painting and decorating the
exterior (outside) and interior (inside) of houses is an important industry in many countries.
There are many types and colours of paint to chose from.

All sorts of other objects are painted to make them attractive. This includes furniture, toys,
tools and utensils, and street fittings. Sometimes things made of wood such as furniture are
painted in decorative patterns. In some countries, many people enjoy decorating furniture and
other small things like trays and boxes. This is often called Folk art. In other countries such
as Japan, painting furniture is a very skilled profession and an antique piece of decorated
furniture is very valuable. Other people enjoy the hobby of painting small objects such as
model planes or soldiers.

Art

Paintings are pictures that are done in paint. Many different types of paint are used for
paintings. They include tempera, oil paint, gouache, watercolours and acrylic paints. The
paintings are usually done on board, canvas or paper. Many other famous paintings are done
on the walls and ceilings of buildings, such as the Sistine Chapel ceiling which was painted
by Michelangelo.

Many artists are famous for their painted pictures. Old, beautiful and famous paintings are
very valuable and are sometimes sold for millions of dollars. Famous painters include Giotto
Leonardo da Vinci, Titian and Rembrandt.

Information

Paint is a very good way to give important information to people, using painted signs.Painted
signs include lane markings on the road, street signs of all sorts, advertising signs and
warning signs.
 32

Future plan

The company plans to consolidate its dominant position in India by launching new products
in line with the market developments in both decorative paint and industrial coating
segments. The company is focusing on further improving the operations of all of its
subsidiaries in India and abroad and has already launched E-Strides, an ERP initiative through
which all the overseas ventures are being covered for sharing of global knowledge, best
practices and better control on operations. The company’s objective is to be among
the top three players in each market where it is currently operating or plans to operate in the
future

➢Introducing Water – based Paints of advanced quality

➢Repositioning of existing Brands in Rural Market

➢Broadening of Distribution Network

➢Adding more choices for shades and effects

➢Enhancing Better Quality

➢Demand will be generated through the new

➢constructions coming in housing and industries

 33

Conclusion

An independent survey named Asian Paints to be one of the best companies in Asia in paint
industry and other.

Business Today showed that the company was one of the most transparent and a leader on the
issue of innovative methods.

Excellent Management System

Effective Operational Mangement
Good Number Of Suppliers And Distributors.
Lots Of Awards
No.1 Paint Company In Paint Industry
Playing Leader Role In Paint Industry
Giving More Impotance For Human Power.
Highly Innovated In Technology
 34

Reference

1. The families that lived in the town of Catal Huyuk in Anatolia, 7,000 years
ago, white-washed their walls every year.
2. https://www.asianpaints.com/company-info/about-us/corporate-
information.aspx
3. https://www.scribd.com/doc/22700968/Asian-Paints
4. www.asianpaints.com/bd
5. Asian Paints (Bangladesh) Ltd.
Factory : plot#317 &757, Bahadurpur, Gazipur.