BERGER

PAINTS
PAKISTAN
LIMITED
INTERNSHIP
REPORT 2017

By: MUHAMMAD JUNAID

Submitted to: - Mr. Zafar Iqbal (Senior Manager)

Department: - Engineering

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TABLE OF CONTENTS
COMPANYS HISTORY PAGE 3
INTRODUCTION PAGE 6
INVERTERS PAGE 8
AUTOMOTIVE PAGE 10
POWDER COATING PAGE 12
RESIN PLANT PAGE 14
EHS PAGE 16

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Berger was established two centuries ago and now it has grown to become one of the worlds
largest paints manufacturer. In Pakistan, history of Berger is as old as history of Pakistan. Berger
started its operations in Pakistan in 1950 and was the first organized Paint Company to offer
premium products through import from the United Kingdom.

BERGER PAINTS PAKISTAN LTD. became a public limited company in 1974, when 49.38% of its
shares were acquired by Pakistani investors, while the remaining 50.62% were held by U.K.
parent company, Jenson & Nicholson Limited. In 1991 Slotrapid Limited, a U.K. based company
with diversified business interests, acquiring control of Berger Paints Pakistan Limited by
gaining 50.62% shares of the company.

Berger established its first local manufacturing facility in Karachi in 1955. As the countrys
economic and industrial sector expanded the demand for quality paints also grew and Berger
continued to make extensions in its product range to meet these requirements.

In 2006, Berger established state of the art manufacturing facility in Lahore. This plant has
provided Berger an edge over its competition through enhanced production. It has enabled
Berger to meet the growing demands of its valued customers across Pakistan. Berger Paints
Head office is located in Lahore.

Consistent quality has always been Bergers trait. This has been the driving force in making it
the leading brand name backed by premium quality across Pakistan. Berger has the most
comprehensive product range for various paint market segments at different price points.
Berger has earned the admiration and trust of customers by virtue of its superior technology,
product quality and a very high level of customized services.

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Berger has entered into a number of technical collaboration arrangements with leading
international manufacturers. These include the largest paint company in Japan, which enables
Berger to develop Automotive, Vehicle Refinishes and Industrial Paints conforming to
international standards; a Japanese chemical company, for Bumper Paints; PCS Powders, UK for
Powder Coatings; DPI Sendirian Berhad, Malaysia for Road & Runway Markings; Cerachem for
Construction Chemicals and Asian Paints for Decorative Paints. Recently, Berger acquired
distribution rights of DuPont for Pakistans vehicle refinish paint segment.

Berger is also operating Resin manufacturing facility at its Lahore factory. The resin plant has
high production capacity and has enabled Berger to meet its entire resin needs for the
manufacturing of a wide range of quality paints. Berger was the first paint company in Pakistan
to set up its own resin production facility.

The company has regional offices in Karachi, Lahore, Islamabad and Territorial Offices in
Gujranwala, Multan, Faisalabad, Peshawar and Hyderabad. A large team of sales personnel and
a wide network of dealers and distributors serve customers in all urban centers across the
country.

Berger: Vision and Mission

Vision

We will become the leading paints and associated products manufacturing and
marketing company in Pakistan ensuring best returns to our investors & highest
customer satisfaction.

Mission

We will lead by innovative ideas and technological development in the paints and
associated products in Pakistan ensuring efficient utilization of resources yielding high
returns.
We will ensure highest level of commitment to achieve best quality products and
services.
We will vigorously promote and safeguard the interests of employees, shareholders,
business associates & all other stakeholders.
We will act as a good corporate citizen ensuring service towards community and shall
focus on environment, health and safety.

A Commitment to Excellence

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Berger is the most trusted name in quality paints, coatings and allied products for household,
commercial and industrial sectors. The company has built this proud reputation by not
compromising on quality standards.
As an ISO-9001-2000 certified company, Berger continues to upgrade and improve its range by
introducing innovative products in line with consumer needs.
All products are tested at the companys own facilities before leaving the factory so that the
highest quality control standards are maintained at all times. The company also follows a
continuous process of investment in new equipment, such as computerized color matching
technology, to ensure fast and accurate testing results at all times.
An on-going training system is also in place so that the most rigorous testing methods and
procedures can be applied at the finished product stage.

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INTRODUCTION
Definition of Paint
The general definition of paint is that, paint is a mixture of chemicals which creates color,
increases beauty and protects from fading away when it is implemented on a surface. The
functional definition of paint is that, paint can be described as any fluid material that can be
spread over a solid surface and dried or harden to an adherent, coherent, colored skin or film.

Contents of Paint
There are four basic chemicals that are found in all types of paints. These are:

Pigment and Filler:

Pigment is the component of the paint which is responsible for creating color and opacity or
hiding power. On the other hand, fillers are used to fill up the gaps of pigments. Fillers are
necessary for Matt Finish paints as these reduce the gloss of the paint. But these are not always
necessary for the Gloss Finish paints. These are sometimes used in the paints to reduce the
costs. As fillers fill up the gaps of the pigments and extend the performance of the pigments by
reducing cost, fillers are also called extenders.

Resin or Binder:
Resins are the components which bind the various chemicals of paint together. Resins also bind
the paint with the surface and create a film on the surface. Resin is responsible for the adhesive
power of the paint.

Thinner:
Solvent or thinner is the component of the paint which dissolves the resin and makes the paint
liquid. It is also used to control viscosity of the paint. Water works as the solvent or thinner for
the water based paints whereas various solvents or thinners do the work for the solvent based
paints.

Additives

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These are basically various chemicals used in very small "quantity for specific purpose. For
example, Dryers (various oxidizing agents) are used to make the paint easy and fast dry one,
preservatives (used only for water based paints) are used to preserve the paint till use and of
the paint, Anti Fungal solution is used in the exterior paints to protect from fungal attack,
Defoamer is used in the water based paints to protect the creation of foam in the paint. It gives
the paint the desired shelf life, dispersers are used to faster the dispersion process.

Types of paints:

Paint can be divided into various types by considering different aspects.

Painting is mainly of three categories:

i) Decorative
ii) Industrial
iii) Marine

In Decorative sector, the two major classifications are

i. Interior
ii. Exterior

From the application sequence, paints can be categorized as

i. Primer
ii. Under coat
iii. Finish coat

Paints can be divided into two categories according to thinners/ solvent usage:

i. Water based
ii. Solvent based

Parameters to categorize Paint

There are seven parameters, using which we can categorize different paints into major categories. These
are

Whether the paint is Water based or Solvent based

If the paint is Solvent based, what is the solvent?

Whether the paint is Decorative or Industrial or Marine

Whether the paint is used as Primer or Undercoat or Finish coat

Whether the paint gives Matt finish or Gloss Finish

What type of surface the paint can be used on

Whether the paint is used in exterior or interior surface

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INVERTERS

A power inverter, or inverter, is an electronic device or circuitry that changes direct current
(DC) to alternating current (AC).
The input voltage, output voltage and frequency, and overall power handling depend on the
design of the specific device or circuitry. The inverter does not produce any power; the power is
provided by the DC source.
A power inverter can be entirely electronic or may be a combination of mechanical effects
(such as a rotary apparatus) and electronic circuitry. Static inverters do not use moving parts in
the conversion process.

Applications
Electric motor speed control
Inverter circuits designed to produce a variable output voltage range are often used within
motor speed controllers. The DC power for the inverter section can be derived from a normal
AC wall outlet or some other source. Control and feedback circuitry is used to adjust the final
output of the inverter section which will ultimately determine the speed of the motor operating

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under its mechanical load. Motor speed control needs are numerous and include things like:
industrial motor driven equipment, electric vehicles, rail transport systems, and power tools.
Switching states are developed for positive, negative and zero voltages. The generated gate
pulses are given to each switch in accordance with the developed pattern and thus the output
is obtained.

In refrigeration compressors
An inverter can be used to control the speed of the compressor motor to drive variable
refrigerant flow in a refrigeration or air conditioning system to regulate system performance.
Such installations are known as inverter compressors. Traditional methods of refrigeration
regulation use single-speed compressors switched on and off periodically; inverter-equipped
systems have a variable-frequency drive that control the speed of the motor and thus the
compressor and cooling output. The variable-frequency AC from the inverter drives a brushless
or induction motor, the speed of which is proportional to the frequency of the AC it is fed, so
the compressor can be run at variable speedseliminating compressor stop-start cycles
increases efficiency. A microcontroller typically monitors the temperature in the space to be
cooled, and adjusts the speed of the compressor to maintain the desired temperature. The
additional electronics and system hardware add cost to the equipment, but can result in
substantial savings in operating costs.

IMPROVEMENTS
Enhanced quantization
A proposal suggested in Power Electronics magazine utilizes two voltages as an improvement
over the common commercialized technology, which can only apply DC bus voltage in either
direction or turn it off. The proposal adds intermediate voltages to the common design. Each
cycle sees the following sequence of delivered voltages: v1, v2, v1, 0, v1, v2, v1 .

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Automotive Paint Department

Automotive paint is paint used on automobiles for both protection and decoration purposes.
Enamel paint is currently the most widely used paint for reasons including reducing paint's
environmental impact.

Modern automobile paint is applied in several layers, with a total thickness of around 100 m
(0.1mm). Paint application requires preparation and primer steps to ensure proper application.
A basecoat is applied after the primer paint is applied. Following this, a clear coat of paint may
be applied that forms a glossy and transparent coating. The clear coat layer must be able to
withstand UV light.

Preparation

High-pressure water spray jets are directed to the body. Without proper pretreatment,
premature failure of the finish system can almost be guaranteed. A phosphate coat is necessary
to protect the body against corrosion effects and prepares the surface for the E-Coat.

The body is dipped into the Electro-Coat Paint Operation (ELPO/E-Coat), then a high voltage is
applied. The body works as a cathode and the paint as an anode sticking on the body surface. It
is an eco-friendly painting process. In E-Coat, also called CED paint, utilization is approximately
99.9% and has great SST life compared to other painting processes.

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Powder Coating

Powder Coating is a type of coating that is applied as a free-flowing, dry powder. The main
difference between a conventional liquid paint and a powder coating is that the powder coating
does not require a solvent to keep the binder and filler parts in a liquid suspension form. The
coating is typically applied electrostatically and is then cured under heat to allow it to flow and
form a "skin". The powder may be a thermoplastic or a thermoset polymer. It is usually used to
create a hard finish that is tougher than conventional paint. Powder coating is mainly used for
coating of metals, such as household appliances, aluminum extrusions, drum hardware, and
automobile and bicycle parts. Newer technologies allow other materials, such as MDF
(medium-density fibreboard), to be powder coated using different methods.

Advantages of powder coating instead of other coatings

Powder coatings contain no solvents and release little or no amount of Volatile Organic Compounds
(VOC) into the atmosphere. Thus, there is no longer a need for finishers to buy costly pollution control
equipment. Companies can comply more easily and economically with the regulations.

Powder coatings can produce much thicker coatings than conventional liquid coatings without running
or sagging.

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 Powder coated items generally have fewer appearance differences between horizontally coated
surfaces and vertically coated surfaces than liquid coated items.

The wide range of specialty effects are easily accomplished using powder coatings that would be
impossible to achieve with other coating processes.

Types of powder coating

There are two main categories of powder coating: thermosets and thermoplastics. The
thermosetting variety incorporates a cross-linker into the formulation. When the powder is
baked, it reacts with other chemical groups in the powder to polymerize, improving the
performance properties. The thermoplastic variety does not undergo any additional actions
during the baking process as it flows to form the final coating.

The most common polymers used are polyester, polyurethane, polyester-epoxy (known as
hybrid), straight epoxy (fusion bonded epoxy) and acrylics.

Production
1. The polymer granules are mixed with hardener, pigments and other powder ingredients
in an industrial mixer, such as a turbomixer
2. The mixture is heated in an extruder
3. The extruded mixture is rolled flat, cooled and broken into small chips
4. The chips are milled and sieved to make a fine powder

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Resin Plant

Synthetic resins are materials with properties similar to natural plant resins. They are viscous
liquids capable of hardening permanently. Chemically they are very different from resinous
compounds secreted by plant resin.

Synthetic resins are of several classes. Some are manufactured by esterification or soaping of
organic compounds. Some are thermosetting plastics in which the term "resin" is loosely
applied to the reactant or product, or both. "Resin" may be applied to one of two monomers in
a copolymer, the other being called a "hardener", as in epoxy resins. For thermosetting plastics
that require only one monomer, the monomer compound is the "resin". For example, liquid
methyl methacrylate is often called the "resin" or "casting resin" while in the liquid state,
before it polymerizes and "sets". After setting, the resulting PMMA is often renamed acrylic
glass, or "acrylic". (This is the same material called Plexiglas and Lucite).

Types of synthetic resins

The classic variety is epoxy resin, manufactured through polymerization-polyaddition or
polycondensation reactions, used as a thermoset polymer for adhesives and composites. Epoxy
resin is two times stronger than concrete, seamless and waterproof. Accordingly, it has been
mainly in use for industrial flooring purposes since the 1960s. Since 2000, however, epoxy and
polyurethane resins are used in interiors as well, mainly in Western Europe.

Synthetic casting "resin" for embedding display objects in Plexiglas/Lucite (PMMA) is simply
methyl methacrylate liquid, into which a polymerization catalyst is added and mixed, causing it
to "set" (polymerize). The polymerization creates a block of PMMA plastic ("acrylic glass")
which holds the display object in a transparent block.

Another synthetic polymer sometimes called by the same general category, is acetal resin. By
contrast with the other synthetics, however, it has a simple chain structure with the repeat unit
of form [CH2O].

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Ion exchange resins are used in water purification and catalysis of organic reactions. Certain ion
exchange resins are also used pharmaceutically as bile acid sequestrants, mainly as
hypolipidemic agents, although they may be used for purposes other than lowering cholesterol.

Solvent Impregnated Resins (SIRs) are porous resin particles which contain an additional liquid
extractant inside the porous matrix. The contained extractant is supposed to enhance the
capacity of the resin particles.

A large category of resins, which constitutes 75% of resins used, is the unsaturated polyester
resins.

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Environmental Health and Safety

The environmental health and safety (EHS) department at Berger Paints is headed by Mr.
Shahid Butt.
There are various types of work permits which are required before carrying out any task. These
are:
1. Hot Work Permit
2. Work at Height Permit
3. Work in Confined Space Permit
4. General Work Permit
5. Electrical Work Permit

The EHS tries to ensure the safety of not only the companys assets, but also of its employees
and the general environment and vicinity of the company.
There are numerous safety measures that are kept in check and a strict monitoring system is
maintained. Fire alarms and fire extinguishers can be seen throughout the plant in case of any
such incident.

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