1st Visit to Dolphin Inks

Details of 1^st Visit to Manufacturing Unit of Dolphin Inks Pvt. Ltd in Badlapur.

The Machinery Used:

1)      Grinder

2)      Mixer

3)      Viscosity Measuring using Viscometer

4)      Measuring the pH value using neutral solution and actual solution.

5)      Draw down process using 2 sheets.

6)      Packaging in containers.

7)      Sealing using Sealing Machine.

 

The Process Flow:

Process 1 –

• Grinding in the grinding machine (Indo – German Technology) and then keep for 6 hours in the grinder itself.
• There are small white balls in the grinder to help the grinding process.
• The grinder has to be washed after every colour. Even if the next colour to be ground is the same color, still the grinder is washed.
• The coolant used for the process is water. The water comes in through a tap and goes through a pipe in the grinder body, comes out after cooling and is then reused.
• After the process, the grinder has to cool down.
• Then add the required additives.

Process 2 –

• The Mixer has a huge rod with a circular blade.
• The components are mixed in the mixer.
• Then they are kept for 6 hours to settle down.

Process 3 –

• Transfer the paint from the Grinder to the Drum like container.
• During this process, the paint is filtered using a net kind of sheet to remove impurities.

Process 4 –

• Measure the Viscosity of the paint by using a non digital viscometer
• Fill the viscometer and then allow the paint to completely flow out and record the time taken.
• White Paint (34 sec) > Red Paint ( 24 Sec) > Blue Paint (23 Sec)
• Viscosity becomes higher as the paint settles.
• 
  

Process 5 –

• Measure the pH value of the paint by measuring it against the pH of a liquid whose value is already known.
• pH Value of Solutions are 4 and 7. These Solutions are used for calibration.
• White Paint – 8.5
• Blue and Red Paint <>
• So, add amine solution approximately 200 ml to balance the pH value.

Process 6 –

• If the pH value is acceptable, then Draw down process is done on 2 sheets of paper.
• One Glossy paper and one Absorbent paper.
• 2 Paints are taken. One paint which is okay for sure and the other one which is newly manufactured.
• Using spatula, put both paints on the sheet and then draw them down using a rod like instrument.
• The paint is left to dry off and then compared with the finish of the already approved paint.
• The difference is visible right away.
• The defects which can be found in this stage are :

Ø      Blotching – Not filling or too dense.

Ø      Powdering off or Peeling off of the paint.

Ø      White spots or Spotting

Process 7 –

• Packaging in 25.8 Kg containers.
• The weight of the Container is 800gms. So that is taken into consideration while packing and weighing on the scale.

Process 8 –

Sealing with the Sealing machine.

Process 9 –

• Data Entry as to which paint is which in the books. Sticker on the can.
• The sticker contains details such as Batch # , Manufacturing Date and Color Details.
• There is a kind of bin card maintained behind which the pH value and Viscosity value and the Draw down sheets are all attached to maintain a record.
• The Card contains columns such as Raw Material, Quantity and Additional Quantity added .
• It also contains the Client’s name and the Overall order quantity.
• The specific color name which is manufactured is also mentioned.

 

Product Range:

In Water based Inks the different colors available were:

White

Hans Blue

Green

Red

Black – used for printing

 

In each of these colors, there is a grade such as

Premium

Deluxe

Super

 

Rough understanding of the raw material used:

Resin – Viscous like gum for bonding…so that the color does not come off.

Amine Solution – To adjust the pH value

Pigments – To add color

Water – As a major constituent and a coolant.

Anti foam agent – To reduce the foaming

XLA

W&D

 

Who and how much do they manufacture?

The firm manufactures basic colors and sells them to other companies who enhance these shades.

Approximately 10 tons  in a month per ink.

 

Manpower Statistics

11 to 12 people working.

Ownership of the firm – 3 people together.

Mr. Kumar – main owner

 

Manager in Badlapur plant – Mr. Nayak

Technical Consultant – Mr. Talwar

Mukkadam (Head) – Mr. Babu

 

Work culture of workers

Very good process knowledge, but their knowledge is experiential not bookish and hence it is limited. If anything goes drastically wrong, they will need help.

They have a good relationship amongst themselves.

Overall, good work culture.

And very helpful.

Obsolete Machinery:

There were 2 machines which were obsolete.

They are not used because they are time consuming, manpower consuming and also there were a lot of safety issues.