Attached
TheexistingEmulsion paint was studied in detail. (The main aim is to identify the quality
levelof the existing Emulsion paint).
According to the existing Emulsion paint formulation the high cost centers were
identified.The highest cost contribution is coming from Titanium Dioxide and binder.
Themain objective of this project is to reduce the raw material cost of the emulsion paint.
Hencethe trials were carried out to reduce the Titanium Dioxide and binder level by
reformulatingwith a new cost effective raw materials.
Trial one was planned to introduce a new opacifying agent called Opaque polymer.
Opaquepolymer is non film forming aqueous emulsion polymer which aids to reduce the
rawmaterial cost of the emulsion paint. The polymer consists of hollow acrylic styrene
beadssupplied in emulsion form. Initially these beads are filled with water. When a paint
containingopaque polymer dries, the water permanently diffuses from the core of the
particlesand is replaced by air. These encapsulated air voids supplement the hiding effect
ofTitaniumDioxide.
In standard paint the Titanium Dioxide percentage is 27.5%. The binder percentage is
25%. But in the trial 1 formulation the Titanium Dioxide and binder percentage was
reducedto 16.5% and 15%. The quality level of this was tested against standard paint and
results show respectively. According to the results new formulation give very much
superiorquality than existing paint.
Second trial was planned to introduce a new extender called Polstar. Because of its
distinct benefits in opacity, whiteness and scrub resistance, the amount of Titanium
Dioxidecan be reduced. Here the trial was carried out by using 25% Titanium Dioxide and 25% binder and
incorporating 2.5% Polstar. However the results of this were also compared with the
standard paint. But the quality level of this was not up to the standard.
When compared the trial one and trial two with the standard paint the lowest raw material
cost contribute from trial 1 formulation. The highest quality level also can be seen in trial
one formulation. So that the main objective of this project is achieved by trial one
formulation as it has the lowest cost and highest quality when compared with the standard
formulation.
