Professional Documents
Culture Documents
AtVijayanagar,Dist.Ballari,
Karnataka
ProjectReport
TechnoProjectsManagementLtd.
Mumbai
August2016
JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
CONTENTS
LIST OF DRAWINGS
This document is the property of JSW Paints Private Limited and contains
confidential information and proprietary intellectual property. This is not to
be copied or used for other projects unless expressly permitted by JSW
Paints Private Limited.
JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
01 INTRODUCTION
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
02 MARKET ANALYSIS
02.01 Introduction
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
The current Indian Market size is 4 million tonnes per year i.e.
about Rs 40,000 crores.
The Indian paints market was ~Rs 35.5K Cr. in FY14 and will
grow at ~12% to about Rs. 56,500 crores by 2018, driven by
favourable demand drivers as shown in fig 02.01.
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
Fig. 02.01
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
Fig. 02.02
Detailed Market Segmentation
IndianPaintIndustry
DecorativeSegment IndustrialSegment
(80%) (20%)
Consumer
PremiumRange MediumRange Distemper Automotive CoilCoating&
DurablesMarine
(Highend (EnamelPaints) Range Sector General
PaintsOther
Acrylic & (LowEndPaints) Industries
OEMs
Emulsion) Emulsions
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
The water based paints are the target market to start with and
then it is proposed to expand the operations.
Looking at the Indian markets, it is proposed to produce water
based emulsion paints and enamels.
Since the market is substantial and well developed in the South
and West of India, it is proposed to set up the first plant in the
Southern part of India.
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
03.01 General
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200,000 KLPA Paint Plant Karnataka
Project Report
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200,000 KLPA Paint Plant Karnataka
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200,000 KLPA Paint Plant Karnataka
Project Report
a) Dispersion Stage
This stage is the most essential and in fact determines the
paint quality. It should also be pointed out that pigment is
the most expensive paint component and is usually
introduced into a finished product system in the physical
state of dispersion.
A great deal of attention should be accorded to the
processing of dispersions in order to achieve maximum
pigment utilization, that is optimum hiding power (opacity)
and colour.
1. Wetting
2. Particle separation
3. Stabilization
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
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200,000 KLPA Paint Plant Karnataka
Project Report
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200,000 KLPA Paint Plant Karnataka
Project Report
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200,000 KLPA Paint Plant Karnataka
Project Report
Mixing
Other raw materials like balance emulsion resin, water, and other
additives are also measured and added into the mixers, as per the
recipe.
The mixer is run for specified time as required by the recipe to
prepare the paint. The density, viscosity, strength are checked in
laboratory.
Filling
If the paint meets all quality parameters in the mixer, the paint is
filled into the containers of different pack sizes 1litre, 4litre,
10litre and 20litre.
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
started and after attaining 78 deg C the sample is taken out and
checked for wetting. If wetting is good, Pre Emulsion addition is
continued for four hours by means of metering pump.
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
03.09 A typical equipment list for the plant is given in table 03.01
Table - 3.01
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
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200,000 KLPA Paint Plant Karnataka
Project Report
04.01 General
The main raw material for the proposed plant would be pigment,
emulsion, additives, extenders, monomer & water. The plant
would produce water based paints to cater to the market
requirements.
The raw material requirement for the paint may vary based on the
final grades/product mix of paints.
The product mix considered for the proposed decorative paint
plant is as below:
Ph-I Ph-II
Sr. No. Item Quantity (Tons)
1. Pigments 10,200 10,200
2. Emulsions 21,200 21,200
3. Extenders 51,500 51,500
4. Additives 4,500 4,500
5. Water 45,400 65,400
6. Monomers - 20,000
7. Additives - 800
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
Apart from the major raw material, there are many other
materials required for paint manufacturing in small quantities.
The list of major material, state and packing details are as below-
04.02.01 Pigments
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
04.02.02 Binders
04.02.04 Additives
04.02.05 Chemicals
04.02.06 Extenders
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
05 PROPOSED SITE
Longitudes : 76 42 09 E to 76 42 19 E
05.02.01 General
The area requirement for the proposed plant has been estimated
based on the following factors:
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
05.04 Logistics
05.04.01 Road
05.04.02 Railways
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
05.05 Water
The water requirement for the proposed plant will be about 530
KLD for 200,000 KLPA paint plant and will be sourced from the
existing network of the steel plant.
05.06 Power
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
06.01 General
Make-up water for the proposed plant is about 530 KLD which will
be drawn from the existing network of the steel plant after
obtaining necessary approvals.
Water is required for cooling needs, process needs, fire fighting,
drinking needs, etc. of the plant.
The plant envisages the electric power supply & distribution for a
Decorative Paint Plant along with auxiliary drives, composite grid
earthing, illumination system for in plant and outdoor area, road
lighting.
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
A covered fire water sump has been considered for storing water
for fire fighting. Make up water will be added to fire water sump
by gravity from makeup water storage tank. This water will be for
external as well as internal hydrants. A ring main is considered for
the plant.
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
06.09 Warehouse
06.11 Laboratory
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
06.14 Roads
The total direct manpower required for the proposed plant will be
about 600 (200 at site & 400 for marketing, warehousing,
logistics, accounts, taxations etc. at multiple locations).
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
07 ENVIRONMENTAL MANAGEMENT
The major wastes that the paint industry produces are empty
paper cartons, gunny bags, dust from air pollution control
equipment, off-specification paint, spills and sludge from
treatment plants. The disposal methods for the wastes are given
in subsequent sections.
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
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200,000 KLPA Paint Plant Karnataka
Project Report
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200,000 KLPA Paint Plant Karnataka
Project Report
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
The hazardous waste will be sent for disposal into hazardous waste
landfill site authorized by the State Government.
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
07.09 Greenbelt
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
08 PROJECT IMPLEMENTATION
08.01 General
08.02 Schedule
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JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka
Project Report
The estimated block capital cost outlay for the paint plant of
200,000 KLPA capacity is estimated as Rs. 600 crores.
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200,000 KLPA PAINT PLANT AT VIJAYANAGAR, KARNATAKA
PROJECT IMPLEMENTATION SCHEDULE
11 Production to commence -