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Asian Paint Internship Report
Asian Paint Internship Report
Submitted by
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CERTIFICATE
This to certify that A Vocational Training report submitted along with the Vocational Training
entitled A Vocational Training at Asian Paints LTD, Ankleshwar GIDC has been carried out
by Ketan R Patel during the period from 22th may to 3th June 2023 in our Organization as a
fulfilment of degree of Bachelor of Engineering in Chemical Engineering.
He was trained in field of Production Department.
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DECLARATION OF ORIGINALITY
I hereby certify that I am the sole author of this Internship report and that neither part of this
Internship report nor the Internship report as a whole has been submitted for a degree to any other
University of Institute. I certify that, to the best of my knowledge, my Internship report does not
infringe upon anyone’s copyright nor violate any proprietary rights and that any ideas, techniques,
quotations, or any other material from the work of other people included in my Internship report,
published or otherwise, are fully acknowledged in accordance with the standard referencing
practices. I declare that this is a true copy of my report, including any final revisions, as approved
by my report review committee.
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ACKNOWLEDGEMENT
I wish to express my sincere thanks to our respected Principal Dr. Kaushik Nath and deep sense
of gratitude to Dr. M S Bhakhar HOD, G.H Patel college of Engineering & Technology, VV
Nagar for their kind support and encouragement in completion of the Summer Internship Report.
I would like to thank Dr. Haresh K Dave, Asst. Professor, Department of Chemical engineering,
G.H Patel college of Engineering & Technology, VV Nagar and external guide Mr. Govind
Menon, HR Manager of ASIAN PAINTS LIMITED, GIDC Ankleshwar , who gave me golden
opportunity to do this wonderful Project in the esteemed organization, which helped me to learn
various concepts.
Finally, I express my sincere thanks to Mr. Haresh Patel & my Parents, Friends and all the Staff
of Chemical Department for their valuable suggestions in completing this Project Report.
Thank you,
Ketan Patel.
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ABSTRACT
This internship report serves the purpose to record the details of my industrial training which was
conducted in the Asian Paints Limited the times span of 2 weeks starting from 22th May, 2023 to
3th June, 2023. This report holds all the details regarding the training starting from safety measures
to the whole process description of RHPB, WPB, SPB, EIRS plant. Different kinds of raw
materials, many reaction processes and unit operations are involved to finally obtain Paints as the
product. Isomerisation, acetylation, neutralization, crystallization, filtration are some of them. The
internship ended with a visit to EIRS plant and even checking the air quality of the unit thus
concluded the training to be the best keep possible to gain the real-life exposure to all the practical
knowledge which would be helpful in the future endeavours.
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LIST OF ABBREVIATIONS
CS Carbon steel
W Watt
Mm millimetre
MW Molecular weight
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NOMENCLATURE
A Area M2
Ρ Density kg/m3
D Diameter M
Ε Efficiency %
Q Heat Load kW
H Height M
L Length M
M Mass Kg
P Pressure ATM
T Thickness Mm
µ Viscosity Pa-s
W Weight Kg
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List of Tables
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Table of Contents
Chapter 3 : Instruments………………………………………………………….25
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Chapter: - 1
General Information
The company was started in a garage in Gaiwadi, Girgaon, Mumbai by four Gujarati friends
Champaklal Choksey, Chimanlal Choksi, Suryakant Dani and Arvind Vakil. They all belong
to Jain families, and founded the company in February 1942. During World War II and the Quit
India Movement of 1942, a temporary ban on paint imports left only foreign companies
and Shalimar Paints in the market. Asian Paints took up the market and reported an annual turnover
of ₹23 crore in 1952 but with only 2% PBT margin. By 1967, it became the leading paints
manufacturer in the country.
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The four families together held the majority shares of the company. But disputes started over the
global rights in 1990s when the company expanded beyond India. The disputes resulted in Choksey
selling their 13.7% shares and exiting in 1997. Champaklal died in July 1997 and his son Atul took
over. After failed collaboration talks with the British company Imperial Chemical Industries,
Choksey's shares were mutually bought by the remaining three families and Unit Trust of India.
As of 2008, the Choksi, Dani and Vakil families hold a share of 47.81%.
Asian Paints Limited is an Indian synthetic substances organization which fabricates a wide scope
of paints for brightening and mechanical use. Its vision is "to wind up one of the best five
enhancing coatings organizations worldwide by utilizing its skill in the higher development
developing markets. All the while, the organization means to manufacture long haul an incentive
in the modern coatings business through collusions with built up worldwide accomplices. Asian
Paints is Asia's third biggest paint organization, with a turnover of Rs 109.70 billion. Other than
Asian Paints, the gathering works far and wide through its auxiliaries Berger International Limited,
Apco Coatings, SCIB Paints and Taubmans. Organization utilizes crude materials like Pigments,
Extenders and Minerals. Unlike most other industry, the paint business was moderately free of
guidelines. Anyway, for quite a while it was seen to be an extravagance thing and was liable to
abnormal amounts of offers and extract charges. The high extract obligation routine combined
with moderately ease.
The work that has been done in this internship has given some vital pieces of information to the
administration about the regions which however were doing great and not just this it has
additionally attempted to illuminate conceivable changes that can be made so as to accomplish
increasingly more productivity.
The principle motivation behind choosing this internship is to think about the angles associated
with buy creation and stock administration and the few documentation forms that are engaged with
the working of the organization.
Plant Location
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Address: - Plot 2602, GIDC Estate, Phthalic Division, Ankleshwar, Gujarat 393002.
As Bhandup Plant is Shutdown so Ankleshwar plant is the Oldest plant of the Asian Paints for
now. APL Ankleshwar is “Auto flex”. Established in 1990, India Asian Paints Ltd. has gained
immense expertise in supplying & trading of Paint, industrial paint, pig bristles paint etc. The
supplier company is located in Ankleshwar, Gujarat and is one of the leading sellers of listed
products. Buy Paint, industrial paint, pig bristles paint in bulk from us for the best quality products
and service.
Mr. Ashwin Choksi Non- Mr. Ashwin Dani Non- Mr. Abhay Vakil Non-
Executive Chairman Executive VC Executive Director
Mr. Amit Syngle Mr. Mahendran Choksi Mr. Malav Dani Non-
CEO Non-Executive Director Executive Director
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1.7 Mission
“To Provide paints as per the market demand and ensure that the
customer receives desired product quality and services, availability of
the right product mix of right quality at the right time “
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Chapter 2
Production Department
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In Asian Paints Ankleshwar the layout used in plant is Product layout. In product
layout all machines are arranged in the sequence and the production takes place. It is
also called as Straight-line layout because here the machines are arranged in a straight
line.
System Used (Continuous / Intermittent and their sub- systems) Asian paints
Ankleshwar plant uses Continuous production system involves a continuous physical
flow of materials. It does not require frequent changes in machine set-up.
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Change DSOFA, Glycerine FW, Mono Penta 98% ,Phthalic anhydride(Local) Maleic
anhydride and DBTO at room temp and close the man hole. Change the mixed Xylene through
dip pipe.
Start heating and Start Nitrogen Purging ( Approx. 200 litre/hr). Make stripper free and start
slow stripping . Heat the reaction mass to 140-1450 C and stop heating.
Maintain the the batch temperature at 150-1550 C for 45 minutes. Provide heating / cooling
jerk as required to maintain the temperature.
Cool the batch to 1500 C before Sorbitol addition if required. Add sorbitol(70%) while
maintaining batch temperature at 1250 C. Complete sorbitol(70%) addition in 50-80 min.
Remove water periodically maintain the Xylene Level in separator for smooth processing
batch.
Pigments:
Pigments are used to provide colour, hide, and bulk to the paint. They can be made
from natural or synthetic source and often ground into a fine powder before being
added to the paint. Organic colorants provide the brighter colours. These are not very
durable for exterior paint application. Inorganic colorants are the duller, earthy
colours and are more durable for exterior paint application.
Additives:
Additives are used to improve the performance of the paint. They can include
Thickening Agents (Gives Viscosity), Biocides (to keep paint Bacteria), Defoamers
(Bubbles Generate), drying agents, and UV stabilizers
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Binders:
Binders are ingredients that are used to hold pigment particles together to create a
dry film on the surface. A paints binder is the key ingredient that directly relates to a
paint’s performance, including adhesion, washability, scrub resistance, fade
resistance or gloss retention. Binders provide performance and support for dry paint.
Solvents:
Solvents are used to dissolve the pigments and binders to get from the can to the
surface.
Solvents are the drivers for allowing paint to get from the can to the surface and these
types of liquids differ depending.
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BDM/BSM
Sand Mill
Raw material
Godown
Packaging Lines
Finished Goods
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Raw Material Preparation: Raw materials such as pigments, binders, solvents, additives,
and water are gathered and prepared for the manufacturing process.
Dispersion: Pigments and fillers are dispersed in water using mechanical agitation or
milling equipment. This process helps to break down the pigment particles into smaller
sizes and distribute them evenly in the water.
Binder Addition: Binders, such as acrylic or vinyl resins, are added to the pigment
dispersion. The binders act as a film-forming agent, providing adhesion and durability to
the paint.
Mixing and Grinding: The paint formulation is mixed thoroughly to ensure uniformity and
consistency. The mixture may also undergo grinding or milling processes to further reduce
particle size and improve paint performance.
Quality Control: The manufactured paint is tested for various parameters such as viscosity,
colour, pH, and other performance characteristics to ensure it meets the required
specifications.
Packaging: The final product is packaged into containers, such as cans or drums, ready for
distribution and sale.
The specific process may vary depending on the type of water-based paint being produced and the
manufacturer's specific equipment and techniques. For detailed and accurate information about
Asian Paints' manufacturing process, it is recommended to contact the company directly.
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One major engineering problem that Asian Paints' industries may face is the optimization of energy
consumption and environmental impact. This is a common challenge in the paint manufacturing
industry, as it involves various processes that consume significant amounts of energy and generate
emissions.
Some specific engineering problems related to energy optimization and environmental impact in
paint industries include:
Energy Efficiency: Paint manufacturing involves processes such as mixing, grinding, and
drying, which require substantial energy inputs. Optimizing these processes to minimize
energy consumption without compromising product quality is a significant challenge.
Emissions Control: Paint production can release volatile organic compounds (VOCs) and
other harmful emissions into the atmosphere. Implementing effective emission control
technologies and practices to meet environmental regulations and ensure worker safety is
essential.
Water Conservation: Paint manufacturing requires water for various processes, including
cleaning, cooling, and mixing. Efficient water management practices, such as recycling
and reusing water, can help reduce water consumption and minimize environmental
impact.
Sustainable Materials: Finding alternative raw materials that are more environmentally
friendly and sustainable is another engineering challenge. This includes exploring eco-
friendly pigments, resins, and additives that have a lower environmental footprint.
Chapter 3
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INTRUMENTS
The Twin Shaft Disperser is used for processing and mixing of thick fluids like
paints, polymers, coating, resins, ink printing
There are dual shafts one with a dispersion blade for dispersion purpose and mixing
blade it grinds the raw material for final consumption. It is a Stainless-steel Container
which consist of 2 shafts. The capacity is around 500-600 litre.
Sand Mill:
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Sand mill machine in Asian Paints is used for Grinding and disperse of solids
in liquid. It is used to grind almost all fluids and semi-fluid materials. The
particles size is reduced up to 2 microns in single pass.
Ball mill:
Ball mills are the cylindrical drum used to grind and mix the raw materials to create a paint
mixture. It is a type of grinder that reduces size of materials by impact and attrition.
Paint Filing machines are used to fill paint cans or other containers with the finished
products. After the paints are manufactured the paint is filled in the cans or buckets with the
help of filing machines. It is a fastest way of filing of filing the paints.
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Vacuum Emulsifiers:
Vacuum emulsifiers are the multi-functional equipment that is used to mix and
emulsify high-viscosity materials such as resins and blenders into the paint base.
Forklifts:-
Forklifts can be used to transport raw materials such as pigments, binders, additives, and containers
to the production area. Forklifts can assist in disposing of waste materials generated during the
production process, such as empty containers or packaging materials.
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Pallet Trucks
Pallet trucks are used to move and transport pallets of raw materials, finished products, or
packaging materials within the production area. They can be used to load and unload pallets from
trucks or delivery vehicles, facilitating efficient movement of goods.
Conveyer Systems
Conveyor systems are commonly used in the manufacturing process of paints for efficient and
automated material handling. These systems help in the movement of raw materials, intermediate
products, and finished goods between different stages of production. conveyor systems can
transport raw materials such as pigments, resins, solvents, and additives from storage areas to the
mixing or batching area.
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Automated Guided Vehicles (AGVs) are commonly used in the manufacturing process of paints
for efficient and automated material handling. AGVs are self-driving vehicles that can navigate
through a facility using various guidance systems such as lasers, magnets, or vision-based systems.
GVs can be used to transport raw materials such as pigments, resins, solvents, and additives from
storage areas to the mixing or batching area.
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CHAPTER 4
Safety Department
- We shall comply with all statutory requirements. We consider compliance with statutory
EHS requirements as the minimum performance standard and are committed to go beyond
and adopt stricter standards. We shall work in partnership with the government and industry
associations for policy and regulatory reforms related to the environment. We shall
annually publish our environmental performance to all stakeholders.
- We shall source our materials and products from vendors that comply with the child
labour laws and other statutory regulations.
- Preventing Pollution & leveraging the 3R (Reduction, Recycle, Reuse) principle and
moving towards zero industrial effluent generation and zero hazardous solid waste
generation.
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Asian Paints is committed to ensuring safety and protecting the health of its employees,
service providers, visitors, neighbouring communities, customers and assets. Scope and
applicability of the Policy:
This Health and Safety Policy is applicable to all the operating sites of Asian Paints, its
subsidiaries, and joint ventures (where Asian Paints has Management Control). The
operating sites include Plants, Research & Technology facilities, Offices, Distribution
operations, Sales depots, Retail Sales & Services and Project Sales. This policy is
applicable at work, travel between home and work of employees, business related travel
including stay and all Company organized business events.
2. Move towards Zero Injuries, Zero Occupational illnesses and Zero incidents of Property
Damage
3. Comply with the applicable Safety Manual to achieve its safety, health and wellbeing
objectives.
4. Adopt and implement best practice standards of risk management to prevent and mitigate
1. Ensure compliance with all applicable health and safety legislations and relevant
standards.
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3. Ensure that all activities across the value chain are conducted as per the defi ned health
and safety procedures, including: -
5. Provide safe and healthy working conditions for the prevention of work -related injury
and ill health of employees and service providers.
6. Ensure that adequate resources, support and supervision are provided to employees and
service providers to carry out their job safely and to continually upgrade health and safety
standards.
7. Conduct risk assessments, safety audits and safety inspections at a prescribed frequency
and take all remedial measures to eliminate hazards and reduce health and safety risks,
arising out of operations. Risk registers are continuously reviewed and upgraded on a
regular prescribed frequency.
10. Assess the competence of individuals in the area of safety during recruitment and career
advancement.
11. Define roles and responsibilities of employees in the safety organization of the
plant/facility/operations.
12. Keep employees and service providers informed, educated, trained and retrained on
safety, health and wellbeing to ensure t he safe conduct of their jobs.
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13. Establish mechanisms for consultation with employees and their representatives,
contractors, suppliers, customers, local communities, neighbours and regulators to promote
safety and build a safe work culture.
14. Establish mechanisms for the participation of employees and service provider’s
representatives wherever applicable.
15. Ensure that each employee including contractors and visitors comply with all safety
rules and regulations framed for the operation.
16. Extend all possible help to industries /depots/offices around Asian Paints Operations
in case of emergencies.
17. Provide a resume of health and safety performance in the Company annual report.
4.4 The Company shall ensure the effectiveness of this policy through:
1. Setting goals and objectives on safety, health and wellbeing and reviewing these
periodically to ensure that these are being met.
2. Analysis of health and safety incidents, identification of root causes and implementation
of corrective and preventive actions (CAPA).
5. Periodic review of the safety, health and wellbeing standards for their
continued appropriateness and effectiveness.
Fire Extinguishers
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Type of extinguishers and the classes of fire for which they can be used
Water Extinguisher
They are used for Class A fires. Water removes heat and extinguish the fire. Water must
not be used on fires involving live electrical equipment as it can cause electrocution.
Water must not be used on metal fires.
CO2 extinguishers are mainly used for Class B and C fires.CO 2 extinguish the fire by displacing
oxygen in the surrounding air. CO2 is not suitable for fires involving metals. Its principal advantage
is that it does not leave any residue. Can be used on electrical/electronic equipment.
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The extinguishing agent is aqueous film forming concentrate in water which forms air foams
when discharged through an aspirating nozzle. It has a blanketing effect excluding oxygen
from the surface of the fuel as it spreads on the fuel. Prevents vapour formation from the surface
of the burning liquid.
The main base chemicals used in DCP extinguishers are sodium bicarbonate and potassium
bicarbonate. DCP extinguishers puts out fire by coating the fuel surface with chemical powder.
This separates the fuel from the oxygen in the air and prevent vapor formation. The powder also
interrupts the chemical chain reaction of fire.
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The extinguishing agent is aqueous film forming concentrate in water which forms air foams when
discharged through an aspirating nozzle. It has a blanketing effect excluding oxygen from the
surface of the fuel as it spreads on the fuel. Prevents vapour formation from the surface of the
burning liquid. It develops a floating aqueous film of solution under the foam on fuel surface and
cool the burning surface.
Extinguisher Operation
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SAFETY HELMET
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Glasses
Eye protection and safety glasses generally fall under the category
of PPE or personal protective equipment, and generally serve to
protect workers and consumers from hazards exposed to the job
safety glasses are very important because a lot of work place
injuries that occur are eye related.
SAFETY GLOVES
Safety gloves are designed to protect a worker hands from
hazards so that they can perform their job safely. Gloves come
in many different materials that offer protection against specific
dangers.
SAFETY SHOES
Safety footwear made from sturdy, durable materials can prevent
nasty burns from chemical splashes and other dangerous
substances that could injure the skin on the feet/hands or any other
part of the body.
PVC SUITS
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SAFETY SHIELDS
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Workmen compention policy is Applicable to the workers who are working with an industry
that are mentioned under the act. This act was passed in 1923.
In this act the Protection from injuries and losses occuring from any accidents in industries
are mentioned. And that are applicable to workers.
Calculations of compensations are as followes:
1. In case fatal accident results in partial permanent disability:
60% of monthly wage or Rs 1,20,000 whichever is more.
2. increases accident results to death.
50% of monthly wage or RS 1,20,000 whichever is more.
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we will continously improve the effectiveness of health and safety policy system which conform
to ISO 9001, ISO 14001 AND ISO 45001 standards by involvement of all employees.
BY- APL INDUSTRIES LIMITED
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ENVIORNMENTAL POLICY
APL, epoxy division, an epoxy manufacturer, recognize
that effective management of enviornment impacts is a
fundamental part of our unit. We shall strive to integrate
sound enviornment practice across the unit’s
management leadership position in enviornmental
stewardship.
APL Epoxy Division shall endeavor to:
Maintain positive legal complince to
enviornment regulations and conform to the
requirements.
Progressively develop, implement and
maintain an internationally accepted
enviornmental management system in our
operations and new projects.
Take initiatives towords efficient use of
natural resources and energy reduction and
prevention of pollution and promoting waste
avoidence and recycling measures in line with internationally disseminated technologies
and parctices;
Enhance enviornmental awareness through participation and consultation with
employees and contractors by training and effective channels of communication.
Influence our contractors and suppliers to adopt the APL Epoxy Division enviornmental
policies, principles and practices and encourage appropriate enviornmental management
across the supply and value chain.
Continually improve enviornmental performance of current and future products, services
and infrastructure of the division;
This policy shall be reviwed periodically for its sustainability as necessary.
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Conclusion
For a technical student it’s very important for the one to get the practical knowledge which he can
correlates with the bookish or theoretical knowledge he learned during his curriculum. I applied
for the summer internship at APL Ankleshwar. I gained all the knowledge about the working of
the plant with all the safety at the prior. Here I understood how the paints are manufactured. I also
learned about many unit operations happening here like Mixing, Drying and Packaging etc. At last
I would like to that my summer internship at APL Ankleshwar provided me the amount of
industrial knowledge which would be helpful to me in my future endeavours in this field.
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Reference
1. "Started by four Mumbaikers, how Asian Paints is today one of India's most valued
companies". Businessinsider.in. Retrieved 18 November 2016.
2. ^ Jump up to: a b c d e "Asian Paints Limited Financial Statements". Moneycontrol.com.
Retrieved 23 May 2023.
3. ^ "Asian Paints Limited Financial Statements". Moneycontrol.com. Retrieved 23
February 2022.
4. ^ "Asian Paints, Hindustan Unilever top innovative Indian firms on Forbes'
list". Ibtimes.co.in. 25 August 2016. Retrieved 18 November 2016.
5. ^ "Shares of Asian Paints jump 7% on good Q1 results". The Economic Times.
Retrieved 18 November 2016.
6. ^ "Local people demand jobs in Asian Paints' proposed plant". The Hindu. 29 June
2016. Retrieved 18 November 2016.
7. ^ "Asian Paints acquires 96.48% stake in Berger; open offer ends". The Economic
Times. Retrieved 18 November 2016.
8. ^ "Annual report 2019-20" (PDF). Archived (PDF) from the original on 26 September
2020.
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