A Brief Study on the Water Based Paint Manufacturing

Process & Breakdown Analysis At Berger Paints India Ltd.

Naltali, Assam

Submitted in partial fulfilment of Summer Training, 2025 at

Berzer Paints india Limited-Naltali,Assam
Training Period: 2nd June to 30th June

Guided By: Debdas Pradhan

Submitted By :

Anurag Kalita
23EA4CE34
Institute: Assam Energy Institute, Sivasagar (A centre of Rajiv Gandhi
Institute of Petroleum Technology,Jais,Amethi)
 Declaration
Declaration we, the undersigned, hereby declare that the report titled:
“A Brief Study on the Water Based Paint Manufacturing Process & Breakdown Analysis
at Berger Paints India Ltd. Naltali, Assam”

Is a record of original work carried out by me during my industrial training at Berger Paints
India Ltd. Naltali Factory, as a partial fulfillment of the requirements for the award of the
Diploma in Chemical Engineering.

This report has not been submitted to any other institution or university for the award of any
diploma or degree. The contents of this report are based on my personal observations,
experiences, and understanding gained during the course of my training.

I have duly acknowledged all the sources of information and assistance wherever applicable.

Name: Anurag Kalita

Department of Chemical Engineering,
Assam Energy Institute, Sivasagar
(A Centre of RGIPT, jais Amethi)
 Acknowledgment

I would like to express my sincere gratitude to all those who have supported and guided me
during my summer internship at Berger Paints India LTD. Naltali factory.

First and foremost, I extend my heartfelt thanks to Mr. Banamali Jena, Factory Head, for
granting me the opportunity to undergo industrial training at this esteemed facility. His support
and encouragement provided the foundation for a truly enriching learning experience.

I am deeply thankful to Mr. Debdas Pradhan, Production Manager, for his valuable insights
into plant operations and for facilitating my training in the water based paint plant. His
guidance played a crucial role in helping me understand the intricacies of production planning
and process management.

I also wish to express my sincere appreciation to Mr. Bhaskar Jyoti Borah, Production
Executive, for his constant supervision, technical assistance, and hands-on mentorship
throughout my time in the processing and filling section. His willingness to share practical
knowledge and clarify doubts helped enhance my understanding of real-world manufacturing
challenges.

I am also grateful to the entire team at Berger Paints India Ltd. Naltali, for their cooperation
and for creating a friendly and professional environment during my training.

With regards,
Name: Anurag Kalita
Department of Chemical Engineering,
Assam Energy Institute, Sivasagar
(A Centre of RGIPT, Jais, Amethi)
 Table of Contents
Abstract
List of figures and tables Page No
Fig 1 3
Fig 2 4
Fig 3 5
Fig 4 8
Fig 5 9
Fig 6 10
Fig 7 10

Chapters
1. Introduction 1-2
1.1 About Berger paints and Naltali plant
1.2 Objective of The training
1.3 Importance of industrial training
2. Fire & Safety Management 2-4
2.1 Introduction
2.2 The fire Tetrahedron
2.3 Fire Extinguisher Types and Their Suitability for Different Classes of Fire
2.4 Conclusion
3. Manufacturing Process of Water-Based Paints 5-7
3.1 Raw Materials
3.2 Jelly preparation process
3.3 Charging & Mixing Process
3.4 Quality Check (QC lab)
4. Equipment standardize in water based plant 8-10

5. Breakdown Analysis 11-20

5.1 Purpose of Analyzing the Breakdown
5.2 10 days breakdown study on Auto-line 04
5.3 Major problem analysis during breakdown analysis
5.4 Result Analysis and Improvement Observation
5.5 Final remarks on Breakdown issues

Conclusion 21
References 22
List of abbreviations 23
 Abstract
This report presents a comprehensive account of the summer internship undertaken at Berger
Paints India Ltd. Naltali Factory, with a specific focus on the Wate Based Paint Manufacturing
Plant, particularly in the processing and filling section. The internship aimed to bridge
academic knowledge in chemical engineering with practical industrial applications by
observing and understanding real-time manufacturing processes, equipment operation, and
production management.
The report details the entire production workflow, starting from raw material charging and
high-speed dispenser to the addition of functional additives, in-process quality testing, and
automated filling of the final product. Special emphasis is placed on the analysis of frequent
equipment breakdowns encountered during the internship period. The root causes of these
breakdowns ranging from mechanical wear and tear to process inefficiencies are identified,
along with recommended corrective and preventive maintenance practices to improve
production reliability.
A special part of the report includes a 10-day breakdown analysis of Auto-line 04, where
common issues such as robot malfunctions, lid press faults, filling head overflow, and
container jamming on conveyors were identified and categorized. These issues were studied
to understand their impact on production efficiency and equipment downtime.
A three-day result analysis following the breakdown study showed improvement in one of the
problems—containers getting stuck on Accumulation Conveyor 1. This issue was found to be
minimal during the follow-up period. As a result, the average time to complete one Pallet was
reduced from 10 minutes to 9 minutes, demonstrating a measurable increase in production
efficiency.
This training experience has significantly contributed to the development of practical skills,
technical insight, and professional competence, offering a valuable foundation for future roles
in the chemical and process engineering industry.
 Chapter-1: Introduction

1.1 About Berger Paints and Naltali Factory:

Berger Paints India Limited is one of the biggest paint companies in India. It was started in
1923 and has its main office in Kolkata. The company makes many types of paints for homes,
buildings, cars, and industries. Berger Paints has more than 16 factories across India and sells
products in many other countries as well.
One of its important factories is located at Naltali in Assam. This factory helps supply paint to
the northeastern part of India. The Naltali unit has four main production plants:
• Water-Based Paint Plant
• Solvent-Based Paint Plant
• Resin Plant
• Wall Putty Plant
In this report, we are focusing on the Water-Based Paint Plant, which is the most environment-
friendly unit because it uses water instead of harmful chemicals. This plant produces paints
like emulsions and distempers which are used in houses and buildings.
1.2 Objective of the Training:
The main goal of this industrial training was to learn how Water based paints are made in a
real factory. The training helped us understand:
• How raw materials like water, pigments, and chemicals are mixed to make paint.
• What machines are used in different stages of production.
• How the plant team checks the quality of paint.
• What safety rules are followed in the factory.
• How different departments work together to keep the production running smoothly
This training also helped us connect what we have studied in the classroom with real-life
industrial work.
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1.3 Importance of Industrial Training:
Industrial training is very important for engineering students. It gives us real experience of
how factories work. We learn about machines, processes, teamwork, and safety, which we
can’t learn fully from books alone.
During this training, we saw how:
• Paint is made step by step using machines like high-speed dispersers and mixers.
• Quality control is done at every stage to make sure the paint meets company standards.
• Employees follow safety rules by wearing PPE and handling materials properly.
• Departments like production, maintenance, and quality control work together.
We also learned soft skills like time management, communication, and how to follow
instructions in a real workplace. This experience will help us in the future when we work in
industries after completing our studies.

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 Chapter-2: Fire & safety Management
2.1 Introduction:

Fire safety is a critical aspect of operations in any chemical or manufacturing industry,

particularly in the paint industry, where flammable solvents, combustible dust, and pressurized
gases are handled regularly. At Berger Paints India Ltd. Naltali, fire safety is embedded into
every operational level—from raw material storage and process handling to waste disposal
and emergency response. The company strictly adheres to the Factories Act, 1948, and
National Building Code (NBC) fire safety guidelines, along with relevant Bureau of Indian
Standards (BIS) codes to ensure the protection of people, property, and the environment.
BPIL has implemented a well defined fire safety management system that includes:
• Routine fire drills and training for staff,
• Clearly marked emergency evacuation routes,
• Use of flameproof equipment in hazardous zones,
• Installation of portable and fixed fire-fighting systems across all production units.
2.2 The Fire Tetrahedron:

Fig1: The Fire Tetrahedron

Courtesy: Google Image

The concept of the Fire Triangle illustrates the three elements essential for fire: fuel, heat, and
oxygen. Removing any one of these components is crucial for extinguishing a fire.

• Cooling: This method involves removing heat from the burning material, often by
applying water.
• Smothering: This is achieved by limiting or removing the oxygen supply, such as by
covering the fire with a non-combustible material.
• Starvation: This method focuses on removing or isolating the fuel source, preventing
the fire from spreading.
Beyond these fundamental methods, chemical interference is another vital technique. This
involves using agents that chemically interrupt the uninhibited chain reaction of the fire,
effectively extinguishing it.

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2.3 Fire Extinguisher Types and Their Suitability for Different Classes of Fire:

Fig2: Compatibility of Different Types of Fire Extinguishers with Fire Classes

Courtesy: Google Image

2.4 Conclusion:

Fire and safety management is a foundational aspect of responsible industrial operations. It

not only ensures the safety of personnel and equipment but also protects the organization from
operational losses, legal consequences, and reputational damage. Through the systematic
implementation of engineering controls, administrative policies, employee training, and
emergency preparedness, industries can significantly mitigate fire risks and respond
effectively in case of an incident.

Adhering to national and international fire safety standards is not just a regulatory
requirement—it is a commitment to sustainable and ethical industrial practices.

Page | 4
 Chapter 3: Process of manufacturing for Water Based Paints

Fig 3: Block Diagram of Water based paint manufacturing process

3.1 Raw materials:

In making Water based paints, we use different raw materials. Each one has a special job to
do in the paint. The main raw materials are:

Water:

• Water is the main liquid in water-based paints.

• It helps to mix all the other materials together.
• Water also makes the paint easy to apply with a brush or roller.

Chemicals:

• These are liquids that help the paint mix properly and stay stable.
• Some chemicals stop foam, some help the colour mix better, and some prevent the paint
from going bad.

Pigments:

• Pigments give the paint its colour.

• White paints usually use titanium dioxide to make them bright and opaque.

Page | 5
Additives:

• Additives improve how the paint works.

• Some make the paint thicker so it doesn’t drip.

Powder:

• It makes the paint stronger and smoother.

3.1.1 Quality check of raw materials:

Before starting the production of Water based paints, it is very important to check the quality
of all incoming raw materials. This helps to ensure that the final paint will have good
performance, stability, and appearance. At the plant, each raw material goes through basic
quality checks in the laboratory before it is approved for use in manufacturing.
3.2 Jelly preparation process:

In the process of jelly preparation, water is first added as per the required quantity, followed
by the addition of Deformer Q369 into the TSD tank. The mixture is then stirred for 10 to 15
minutes at a speed of 60 to 70 RPM to form a jelly-like consistency.
3.3 Charging & Mixing Process:
1. Pigment and extender addition:
First, pigments and extenders are added one by one into the mixing tank. These are dispersed
using a high-speed mixer at 1000 to 1100 RPM for about 35 to 45 minutes. This helps to
properly break down the solid particles and create as smooth or stable slurry.
2. Addition of ingredients:
After dispersion, the next set of ingredients like Deformers and Thickeners are added one by
one, and the mixture is stirred well for 10 to 15 minutes to ensure everything is blended
properly.
3. Check dispersion quality (QC lab):
A sample is taken to check whether the pigments and extenders are fully dispersed or not. This
is a part of in-process quality control.
4. Check the mill base fineness:
The smoothness or fineness of the grind is checked to ensure there are no coarse particles
remaining in the jelly base.
5. Let-down / completion stage:
Once the mill base is ready, the let-down stage begins. This is where the final mixing is done
to complete the paint formulation.

Page | 6
6. Add emulsion and other ingredients:
Emulsion (binder) and other ingredients and thickeners are added to the tank. The mixture is
stirred for another 10 to 15 minutes to form a uniform paint.
7. Discharge of batch:
After the paint is fully mixed, the batch is discharged from the tank into the next container or
storage tank.
8. TSD operation:
TSD is used at this stage to further mix the discharged material along with any jelly base. The
TSD provides both high-speed and slow-speed mixing simultaneously, ensuring efficient
blending without air entrapment.
9. Mill washing:

The disperser and tank are washed with clean water to recover remaining materials and prevent
contamination.

10. Washing transfer to main tank:

The wash water is collected and transferred into the main mixing tank to avoid material loss
and maintain batch consistency.

11. Tinting (colour matching):

If a specific paint shade is required, colorants are added (tinting) to achieve the desired colour.
2.4 Quality check (QC lab):
1) Final adjustments:
The batch is checked and adjusted for properties like viscosity, ph, and flow to meet product
specifications.
2) Specific gravity and viscosity check:
The specific gravity and viscosity of the paint are measured. A sample is sent to the quality
control lab to ensure it meets the required standards as per the quality plan.
3) Product declaration& dispatch:
Once the QC department approves the sample, the batch is declared as a finished product,
ready for packaging through the filling line.

Page | 7
 Chapter 4: Equipment standardize in Water Based plant

In a water-based paint plant, different types of machines and equipment are used to carry out
each step of the paint making process like charging, mixing and filling. These machines must
work properly and give the same result every time.
Below is a description of some commonly used equipment in the water-based paint plant.
1) Twin Shaft Dispenser (TSD) :

Fig4: TSD Tank

Courtesy: Google Image

It is used for mixing thick materials such as jelly and high-viscosity slurries. It has two Shaft
rotating at high speed and the other at low speed. This combination ensures that the ingredients
are mixed uniformly without trapping air. The TSD is essential during jelly preparation and
other stages that require smooth, bubble-free blending.
2) High-Speed Dispenser (HSD):
It is another important machine used mainly during the pigment dispersion stage. It operates
at a speed of around 1000 to 1500 RPM and helps to break down pigment agglomerates and
blend powders into the liquid medium. The result is a smooth, stable mixture known as the
mill base.
3) Printing orienter:
A Printing Orienter is used to position the containers correctly before printing. This ensures
that labels, batch numbers, and other markings are aligned properly on the packaging.
4) Lid Dispenser:
It automatically places lids on the filled containers. It reduces manual work and improves
efficiency by ensuring that lids are placed quickly and accurately.
Page | 8
5) Lid pressure:

After the lid is placed, the Lid Pressing Machine applies pressure to seal it tightly. This
prevents leakage during storage and transportation, making the packaging more secure and
professional.

6) Token Dispenser:
It provides printed tokens or labels that are used to identify each batch. These tokens are useful
for tracking production, quality control, and inventory purposes.
7) Inkjet Printer:
It is used to print batch numbers, manufacturing dates, expiry dates, and other important
information directly onto the containers. This ensures proper traceability of the product and
meets labeling regulations.
8) Forklift manual:

Fig5: Forklift manual

Courtesy: Google Image

A Forklift manual, also known as a pallet jack or manual pallet mover, is a material-handling
equipment used for lifting and moving pallets or heavy loads over short distances within the
plant. It is commonly used in the packing and filling sections of a water-based paint plant.

Page | 9
9) Material Handling Robot:

Fig6: Material Handling Robot

Courtesy: Google Image

A material handling robot is an automated machine that moves materials and goods within a
facility, often in industrial settings. These robots use various technologies like sensors,
cameras, and control systems to navigate, pick, and place items, streamlining processes and
reducing manual labor.
10) Lid pressure:

Fig7: Lid pressure

Courtesy: Google Image
The lid pressing machine applies pressure to seal it tightly. This prevents leakage during
storage and transportation, making the packaging more secure and professional.

Page | 10
 Chapter 5: Breakdown analysis and reduction
5.1 Purpose of analyzing the breakdown:
I carried out this 10-days breakdown analysis on Auto-line 04 in the Water-Based Paint
Plant to identify the main problems that were affecting the filling process. The purpose of this
analysis is to understand where and why breakdowns are happening so that we can take steps
to improve Overall Equipment Efficiency (OEE).
During these 10 days, several issues were recorded during the filling operation. These issues
were divided into major and minor problems based on how much they affected production.
Major problems caused longer downtime or stopped the machine completely, while minor
issues were small stoppages or delays that still affected overall output and speed.
By doing this breakdown analysis, we got a better understanding of:
4) Which equipment parts are failing more often,
5) What type of faults are happening repeatedly,
6) How much time is being lost due to each issue,
7) And what corrective actions are needed.
This analysis will help the plant team plan better maintenance, improve machine handling, and
take preventive measures to reduce breakdowns in the future. The final goal is to reduce
downtime, maintain a smooth filling process, and increase the overall performance of Auto-
line4.
5.2 10 days breakdown study on Auto-line 04:
1) Date: 04-06-2025

Date : 04-06-2025
Auto-line 04
Start End
sl no Causes Time Time Total Time
1 Container stuck on accumulation conveyor 1 3:48PM 3:50PM 2 MIN
2 Lid not properly adjusted on container 3:51PM 3:54PM 3 MIN
3 Filling Head issue 4:03PM 4:06PM 3 MIN
Total: 8 MIN

Page | 11
2) Date: 05-06-2025
Date : 05-06-2025
Auto-line 04
sl Start End
no Causes Time Time Total Time
1 Robot Jam 9:30AM 9:32AM 2 MIN
10:35A 10:37A
2 MIN
M M
2 LID Press malfunction
11:10A 11:15A
5 MIN
M M
10:50A 10:52A
3 Pallet Jam M M 2 MIN
12:40PM 12:55PM 15 MIN
4 Filler Head Empty
01:50PM 2:05PM 15 MIN
Filler head overflow due to valve sensor
5 malfunction 2:20PM 2:35PM 15 MIN
6 Printing orienter issue 4:26PM 4:30PM 4 MIN
Total: 60
MIN

3) Date: 06-06-2025
Date : 06-06-2025
Auto-line 04
sl Start End
no Causes Time Time Total Time
9:15AM 9:30AM 15 MIN
10:15A
35 MIN
9:40AM M
11:05A 11:20A
1 Robot not working due to motor failure 15 MIN
M M
11:50A 12:00A
10 MIN
M M
12:24PM 12:28PM 4 MIN
2 Cleaning 2:00PM 2:20PM 20 MIN
3 Water extraction 2:20PM 2:30PM 10 MIN
4 2200 roll verification 2:30PM 2:50PM 20 MIN
5 Pallet jam 3:17PM 3:19PM 2 MIN
6 LID press not working properly 3:55PM 3:59PM 4 MIN
7 Container stuck on accumulation conveyor 4:03PM 4:05PM 2 MIN
8 LID Stock Finished 4:33PM 4:50PM 17 MIN
Total: 154
MIN
Page | 12
4) Date: 07-06-2025
Date : 07-06-2025
Auto-line 04
Start End
sl no Causes Time Time Total Time
1 Cleaning 6:15AM 6:34 AM 19 MIN
2 LID exchange 6:38AM 6:45AM 7 MIN
3 Pallet Jam 6:58AM 7:00AM 2 MIN
4 Robot issue – only 3 containers picked 7:00AM 7:10AM 10 MIN
7:20AM 8:07AM 47 MIN
5 Filling head overflow 10:32A 10:50A
18 MIN
M M
8:29AM 8:30AM 1 MIN
6 Pallet positioning time delay 11:13A 11:16A
3 MIN
M M
Filling completion requirement or Tank 10:14A
7 over 9:46AM M 28 MIN
11:32A 11:40A
8 MIN
M M
8 Container stock finished
12:41A
10 MIN
M 12:51PM
11:45A 11:47A
9 2200 roll new addition M M 2 MIN
Total: 155
MIN

Page | 13
5) Date: 09-06-2025
Date : 09-06-2025
Auto-line 04
Start End
sl no Causes Time Time Total Time
1 LID not properly adjust 9:39AM 9:41AM 2 MIN
9:43AM 9:44AM 1 MIN
10:15A 10:16A
1 MIN
2 Pallet Jam M M
10:26A 10:28A
2 MIN
M M
3 2200 roll new addition 9:43AM 9:47AM 2 MIN
4 LID stock or PM delay 9:47AM 9:51AM 4 MIN
11:05A 11:13A
8 MIN
5 Filling Head Issue M M
12:18PM 12:20PM 2 MIN
11:19A 11:21A
Container stuck on accumulation 2 MIN
6 M M
conveyor 1
12:28PM 12:30PM 2 MIN
Filling completion requirement or Tank 11:24A 11:35A
7 over M M 11 MIN
Lid press adjustment required due to
8 screw problem 12:43PM 1:30PM 47 MIN
Total: 84
MIN

6) Date: 10-06-2025
Date : 10-06-2025
Auto-line 04
End
sl no Causes Start Time Time Total Time
1 Robot maintenance work 10:16AM 10:19AM 3 MIN
2 Filling Head issue 10:22AM 10:24AM 2 MIN
3 Pallet Jam 10:32AM 10:38AM 6 MIN
New carbon foil added to
4 printing orienter 11:05AM 11:10AM 5 MIN
5 2200 roll or Prize tag Finished 11:48AM 11:52AM 4 MIN
Filling completion requirement
6 or Tank over 11:58AM 12:15PM 17 MIN
Total: 37
MIN

Page | 14
7) Date: 12-06-2025
Date : 12-06-2025
Auto-line 04
Start End
sl no Causes Time Time Total Time
1 Container positioning delay 9:33AM 9:35AM 2 MIN
1:15PM 1:18PM 2MIN
2 Filling Head issue 9:39AM 9:42AM 3 MIN
9:46AM 9:48AM 2 MIN
3 Filler Head Empty 10:15AM 11:00AM 45 MIN
4 Robot malfunction 12:00PM 12:26PM 26 MIN
12:44PM 1:05PM 21 MIN
Total 101 MIN

8) Date: 14-06-2025
Date : 14-06-2025
Auto-line 04
sl Start End
no Causes Time Time Total Time
Container stuck on accumulation conveyor
2 MIN
1 1 9:24AM 9:26AM
12:20AM 12:22AM 2MIN
2 Container fall from conveyor 9:45AM 9:47AM 2 MIN
3 Container positioning delay 10:08AM 10:12AM 4 MIN
Filling requirement completion OR tank
4 over 10:22AM 10:30AM 8 MIN
5 LID press adjustment 10:30AM 10:40AM 10 MIN
12:04AM 12:08AM 4 MIN
6 Filling note not given 10:40AM 11:15AM 35 MIN
7 Air Pressure problem 11:30AM 11:36AM 6 MIN
8 Container fall due to LID press 11:40AM 11:55AM 15 MIN
Total 88 MIN

Page | 15
9) Date: 16-06-2025
Date : 16-06-2025
Auto-line 04
sl Start End
no Causes Time Time Total Time
1 Conveyor sensor issue 9:20AM 9:25AM 5 MIN
Robot issue due to the access computer
15 MIN
2 failure 9:25AM 9:40AM
10:00AM 10:12AM 12 MIN
10:23AM 10:26AM 3 MIN
10:30AM 10:32AM 2 MIN
3 2200 roll finished 9:46AM 10:00AM 14 MIN
4 Pallet positioning delay 9:48AM 9:50AM 2 MIN
5 Filling requirement completion or tank over 10:26AM 10:52AM 26 MIN
6 Pallet jam 12:17PM 12:40PM 23 MIN
7 LID press issue 12:40PM 12:50PM 10 MIN
8 Filler head empty 1:40PM 1:45PM 5 MIN
Total 117 N

10) Date: 17-06-2025

Date : 17-06-2025
Auto-line 04
sl Start End
no Causes Time Time Total Time
1 Conveyor sensor issue 9:25AM 9:27AM 2 MIN
2 Filling requirement completion or tank over 9:35AM 10:08AM 33 MIN
Container stuck on accumulation conveyor
3 1 10:26AM 10:41AM 15 MIN
4 Robot issue due to access computer failure 10:48AM 10:50AM 2 MIN
5 Pallet positioning delay 11:08AM 11:12AM 4 MIN
6 Pallet jam due to sensor not working 12:15PM 12:18PM 3 MIN
7 Filling requirement completion or tank over 12:20PM 12:45PM 25 MIN
Total 84 MIN

5.3 Major Problems Identified during Breakdown Analysis:

Based on the 10-day breakdown analysis of Autoline-04, the breakdowns were grouped into
five major problem areas. These issues were responsible for most of the machine downtime
during the filling process. Below is a summary of the major problems observed :
1. Robot Issues:
The most frequent and time-consuming problems were related to the robot system, which is
responsible for picking and placing containers. Multiple types of issues were grouped under
this category:
Page | 16
 • Robot jam
• Robot not working due to motor failure
• Robot malfunction
• Robot access problem due to computer/control system failure
These issues often caused complete stoppage of the filling line and required manual
intervention or technical support, leading to significant downtime.
2. Container Stuck on Accumulation Conveyor 1:
In several instances, containers were getting stuck on the accumulation conveyor, causing a
block in the container movement. This affected the movement of filled containers, and created
a bottleneck in the system.
3. Delay after filling completion:
After completing the required quantity during filling, the process takes additional time before
the next batch starts, which leads to major delays and reduces overall line efficiency.
4. Lid Press Issues:
Several breakdowns were related to the lid pressing system, which seals the container after
filling. Issues included:
• Lid not properly adjusted before pressing
• Lid press misalignment
These errors caused improper sealing, leading to rework, leakage risks, and machine stoppage.
5. Filling Head Issues:
Breakdowns in the filling head system were also significant. The filling head is responsible
for releasing the correct amount of paint into the container. Issues observed included:
• Filler head empty
• Filling head overflow
Both problems affected product accuracy and interrupted the continuous flow of the line.
5.4 Result Analysis and Improvement Observation:
After identifying the key breakdowns in Auto-line 04we monitored the line performance over
the next three days to check for any improvements. One of the problems- containers getting
stuck on Accumulation Conveyor 1 -was not observed frequently during this period. This
indicates that the issue has been partially resolved, likely due to maintenance or adjustments
made after the breakdown analysis.
Even a small improvement like this can make a positive impact on production efficiency.
Earlier, the average time taken to complete one pallet was 10 minutes. Now, it has reduced to
9 minutes, which means the production cycle has become faster. This one-minute reduction
may seem small, but over many batches, it helps in saving time, reducing delays, and
increasing output in real-time operations.
Page | 17
This shows that addressing even a single breakdown issue can help improve overall equipment
performance and support continuous improvement in the production process.
The following are the results observed over the past three days are given below:
1) Date : 18-06-2025

Date : 18-06-2025
Auto-line 04
Pallet Start Time End Time Total Time
Pallet 1 10:00AM 10:10AM 10 MIN
Pallet 2 10:10AM 10:20AM 10 MIN
Pallet 3 10:22AM 10:31AM 9 MIN
Pallet 4 10:31AM 10:42AM 11 MIN
Pallet 5 10:42AM 10:53AM 11 MIN
Pallet 6 10:53AM 10:54AM 11 MIN
Pallet 7 10:54AM 11:15AM 11 MIN
Pallet 8 11:15AM 11:25AM 10 MIN
Pallet 9 11:25AM 11:36AM 11 MIN
Pallet 10 11:36AM 11:54AM 18 MIN
Pallet 11 11:54AM 12:07PM 13 MIN
Pallet 12 12:10PM 12:21PM 11 MIN
Pallet 13 12:25PM 12:36PM 11 MIN
Pallet 14 12:36PM 12:47PM 11 MIN
Pallet 15 12:47PM 12:56PM 9 MIN

Breakdowns:

Date : 18-06-2025
Auto-line 04
Start
sl no Causes Time End Time Total Time
1 2200 roll finished 11:37AM 11:40AM 3 MIN
2 Pallet JAM 11:39AM 11:44AM 5 MIN
3 Container stuck on accumulation conveyor 1 12:01PM 12:04PM 3 MIN
4 Robot issue 12:04PM 12:10PM 6 MIN
5 Container fall from the pallet 12:22PM 12:25PM 3 MIN
6 Filling requirement completion 12:57PM 1:25PM 28 MIN
Total 48 MIN

Page | 18
2) Date : 19-06-2025

Date : 19-06-2025
Auto-line 04
Pallet Start Time End Time Total Time
Pallet 1 12:14PM 12:23PM 9 MIN
Pallet 2 12:23PM 12:31PM 8 MIN
Pallet 3 12:31PM 12:40PM 9 MIN
Pallet 4 12:40PM 12:51PM 11 MIN
Pallet 5 12:51PM 1:00PM 9 MIN
Pallet 6 1:00PM 1:08PM 8 MIN
Pallet 7 1:08PM 1:17PM 9 MIN
Pallet 8 1:21PM 1:29PM 8 MIN
Pallet 9 1:35PM 1:44PM 9 MIN
Pallet 10 1:44PM 1:54PM 10 MIN

Breakdowns:

Date : 18-06-2025
Auto-line 04
sl no Causes Start Time End Time Total Time
1 Pallet JAM 1:17PM 1:21PM 4 MIN

2 Pallet positioning delay 1:29PM 1:35PM 6 MIN

3 Container positioning delay 1:48PM 1:50PM 2 MIN

12 MIN
Total

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3) Date : 20-06-2025

Date : 20-06-2025
Auto-line 04
Pallet Start Time End Time Total Time
Pallet 1 9:03AM 9:11AM 8 MIN
Pallet 2 9:11AM 9:19AM 8 MIN
Pallet 3 9:19AM 9:26AM 7 MIN
Pallet 4 9:26AM 9:31AM 5 MIN
Pallet 5 9:35AM 9:41AM 6 MIN
Pallet 6 9:41AM 9:51AM 10 MIN
Pallet 7 9:51AM 10:01AM 10 MIN
Pallet 8 11:10AM 11:25AM 15 MIN
Pallet 9 11:25AM 11:35AM 15 MIN
Pallet 10 11:35AM 11:51AM 16 MIN
Pallet 11 12:06PM 12:16PM 10 MIN

Breakdowns:
Date : 20-06-2025
Auto-line 04
Start End Total
sl no Causes Time Time Time
1 Pallet JAM 9:20 AM 9:21AM 1 MIN
9:45AM 9:49AM 4 MIN
2 Pallet positioning delay 9:31AM 9:35AM 4 MIN
3 Filling tank empty 9:54AM 10:00AM 6 MIN
4 Cleaning 10:00AM 10:26AM 26 MIN
5 2200 roll verification 10:26AM 10:30AM 4 MIN
6 Arrangement of Containers 11:51AM 11:58AM 7 MIN
Total 52 MIN

5.5 Final Remarks on breakdown issues:

If these problems are solved with proper engineering support and regular maintenance, the
overall equipment efficiency (OEE) of Auto-line 04 can be improved. Reducing downtime
and avoiding repeated issues will also help increase production speed and output quality. This
analysis gives a clear direction for where improvements are needed and how they can make
the system more reliable and efficient.

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 Conclusion
The summer internship at Berger Paints India Ltd. Naltali has been a valuable and
transformative learning experience that enabled the practical application of my theoretical
knowledge in chemical engineering. The training provided me with in-depth exposure to the
manufacturing process of water-based paints, starting from raw material handling and mixing
to quality control, filling, and final product packaging.
One of the key highlights of the internship was the opportunity to observe and analyze real-
time equipment breakdowns in the processing and filling section. By studying the root causes
and understanding the impact of these disruptions on production efficiency, I gained practical
insight into the importance of preventive maintenance, proper operation protocols, and real-
time troubleshooting in process industries.
Moreover, the training reinforced the significance of industrial safety, good manufacturing
practices, and environmental responsibility. And the presence of systematic safety
infrastructure emphasized the high priority given to worker well-being and hazard prevention.
The interaction with experienced plant personnel helped me understand the importance of team
coordination, time management, and communication in a production environment. Observing
automated and semi-automated systems also broadened my understanding of how process
control and instrumentation play a key role in modern manufacturing plants.
Overall, the internship has significantly enhanced my technical competency, industrial
awareness, and professional confidence. It has laid a strong foundation for my future endeavors
in the field of chemical and process engineering, and I am confident that the knowledge and
skills gained during this period will serve as a vital asset in my academic and professional
journey.

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References :
1) www.google.com
2) Batch Making Sheet(BMS)

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 List Of Abbreviations

Abbreviation Full Form

AEI Assam Energy Institute
RGIPT Rajiv Gandhi Institute of Petroleum Technology
BPIL Berger Paints India Ltd.
TSD Twin Shaft Dispenser
HSD High-Speed Disperser
QC Quality Control
OEE Overall Equipment Efficiency
BIS Bureau of Indian Standards
NBC National Building Code
PPE Personal Protective Equipment
BMS Batch Making Sheet

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