Document 3QKX0oRoR1dZdGyrmLE5NGmda

PRATT & LAMBERT-INC 19 5 5 TECHNICAL ACTIVITIES 0007-PTL-000989 1955 TECHNICAL ACTIVITIES In retrospect, 1955 was a year of technical expansion with respeot to both the physical facilities of the laboratory as well as its breadth of attack on research problems* To provide added work space, two new laboratories, an office, and a storeroom, were built for the Varnish Department on the second floor of Building 3* The space vacated by that department on the top floor of Bldg* 3 was remodeled and is now providing added facilities for the Architectural Enamel & Paint Laboratory. These structural changes were made at a cost of $10,660. In 1955* we undertook 20$6 more research problems than we did in 195M-J we investigated 35 more raw aaterlalst and exposed 37$ more experimental paints on test fences* Virtually all of this added research effort was in the architectural field. Exposure studies Initiated in 1955 at our Sworaville teat fence have filled our racks to capacity and we now face the problem of leasing more land to take care of 1956 tests. In 1955* we doubled the number of exposures we normally make in Florida. Increased weather testing activity resulted from the need for information on exterior finishes made from tube colorants* Most colors in our exterior lines have been standard for a number of years* The Budden desire for Information on dozens of new oolors in house paint and possibly in other exterior lines has, therefore, created a flurry of testing. The enaotment of new labeling regulations for lead-containing paints by the New York City Board of Health caused us to make a critical examination of our caution labeling practices* As a result of this study, twenty three standard cautions were developed to fit all the raw material combinations we might use in making paint. Both health and fire hazards were considered. Next, machinery was set up to key each listed item with Its appropriate caution. Finally, acceptance of our proposed labeling plan was obtained from certain interested agencies, auoh as the Virginia Department of Agriculture and Immigration and the Buffalo Fire Department. An appreciable amount of time was required to complete the details of this seemingly simple program. /. The Technical Department has also been responsible for the annual registration of those products that qualify aa economic poisons In the four states now having Economic Poisons Laws. The annual registration of all listed ltema in Virginia la likewise a laboratory responsibility. These activities, like the caution labeling program, consume time and entail a lot of correspondence without providing anything tangible to show for the effort. GENERAL RESEARCH Early In 1955* polyurethane foam seemed to offer bright promise as a local outlet for a large volume of polyester resin. During the 0007-PTL-000990 T -2- year, prospects for developing this market grew progressively dimmer. Dunlop Tire & Rubber Co., our most likely prospect, cancelled plans to construct a pilot plant for making polyurethane foam and has seemingly lost interest in the development. HewittRobins, Inc. Intends to make polyurethane foam in New Jersey, but this location eliminates the economic advantage we might have In a local operation. O-Cel-O has never been an encouraging prospect and its plans are as vague as they were a year ago. Ve have spent $3690 on polyester foam work. Our work on foams has not been wholly wasted as interest is now developing in polyurethane for making smooth paint films with unusual ohemieal resistance. We have also investigated another film former that has unusual resistance. It is an epon ester that makes a better collapsible tube finish than any similar product made from purchased epon esters. As insurance, an offset was developed for the very complex alkyd vehicle that is used by Rockford Paint Mfg. Co. in making our tube colorants--in the event that we may wish to manufacture colorants ourselves. The work cost $3027* We found the Rockford vehicle to be an unusually good grinding liquid with properties superior to X89J4., our own general purpose alkyd grinding liquid. Alkyds are inherently poor grinding media and our X89U- stock pastes have been a source of trouble in factory tinting operations (because of slow color development). It looks as though our offset for the Rockford vehicle can be used advantageously in P&L stock pastes and that we can save from $3000 to $12,500 per year in the process, depending on how completely we substitute the vehicle for X89I4.. This is a good example of serendipity; i.e. finding a solution to a problem without trying to do so. A timesaving procedure was developed in 1950 for determining Stormer viscosity. Heretofore, all paint samples have been conditioned in water baths to a standard temperature of 77P* before viscosity was determined. Temperature conversion tables have now been developed so that viscosity can be determined at the temper ature of the sample (whatever it may be) and then converted to the reading that it would have had, if the temperature were 77F* Since we make thousands of viscosity determinations, the time and laborsaving features of the conversion tables are obvious. It took a year to accumulate the data for the tables, but It was a one-time expenditure of effort. The older system required endless repetition of effort. TRADE SALES DEVELOPMENTS The P&L Tube System was our major trade sales development in 1950* While the basic principles underlying the tube system were well understood, long hours of painstaking and repetitious color work had to be handled in the laboratory before the system could be launched. After the bases were formulated in the proper strengths, 1850 color mixes were made in New Lyt-all Plowing Plat. An initial screening by Mr. Fischer eliminated 1150 of these colors. The final seleotlon of 186 colors was made by the Color Committee from 0007-PTL-000991 * -3- the remaining 700 colors. Hew control techniques had to be developed for the bases. One phase of the control problem--determining how much carbon dioxide gas to introduce in each can-- was a major research project in itself. The entire tube project to date represents an investment of $11,686 in laboratory work. Supplemental weather tests on Bouse Paint and other lines that might become components of the tube system at a later date will result in an expense of about $2000 during the present year. A paralleling project of considerable magnitude was the reformulation of Vitralite Enamel Eggshell Colors so they would yield intermix colors the same as, or close to. Hew Lyt-all Flowing Flat intermix colors. Again, this entailed tedious trial and error color work. Hie completed projeot represents a $6646 investment. Intermixes have caused us a great deal of trouble. Conceived as a means of expanding the color possibilities of our standard lines, they are based on an unsound principle (i.e. that the consumer can mix two colors that are not accurately controlled in tinting strength and obtain the intermix color shown In a color card). It is hoped that intermixes can ultimately be eliminated now that we have a tube system. Resurgent sales interest in latex paint caused us to expand laboratory activities In this field. Of $9117 spent on latex paint work in 1955, half went into exterior masonry paint and a quarter each went into interior wall finish and Primafil Whits. Our ability to develop Primafil White was possible only because of extensive general work that had already been done In the latex field. * The publicity given to HdripleseM paint In consumer magasines led us to develop Gel-Enamel Eggshell at a cost of $1108., We also developed an offset for the purchased vehicle contained in this product in the event that we might wish to obtain a manufacturing license under the Washburn patent. Our resin would enable us to make Gel-Enamel Eggshell for 12 cents per gallon less than we now make it and also pay a 5 cents royalty fee to Washburn. However, this saving could become a reality only if our sales volume were high (in excess of 10,000 gallons} Production of Gel-Enamel Eggshell amounted to 2100 gallons in 1955* In spite of its disappointing acceptance, Gel-Enamel Eggshell represents a unique attack on the brushing and settling problem. Vitralite Enamel White Gloss was improved in hiding at a laboratory cost of $1020. Considerable effort was also devoted during 1955 to reproducing the purchased alkyd now used in that item. It now appears that we have an offset, the production of which would save us from $10,000 to $13,000 per year. However, we have neither the production capacity nor the right equipment (solvent reflux) to undertake the Job. It is appropriate to consider the purchase of another alkyd kettle as the kettle might pay for itself in a comparatively short period of time. Added alkyd facilities would also make us less vulnerable to the effect of a fire if it occurred In our one Dowtherm kettle. We would gain the Intangible benefit of an exclusive Vitralite vehicle. 0007-PTL-000992  *- Two flat varnish problems--the bodying of "61" Floor Varnish and the settling of "38" Pale Trim Varnish--seem to have been brought under control at a laboratory cost of $2632. Of two 1955 oomplaints involving the bodying of "61" Floor Varnish, neither was Justified. There were no 1955 oomplaints on the settling of "38" Pale Trim Varnish, although one batch has given preliminary evidence of settling in periodic laboratory inspections. From ten to twenty oomplaints per year have been registered on these two varnishes in recent years. The stigma attached to lead-containing finishes triggered two research problems in 1955* Analytical procedures for determining small amounts of lead are notably deficient in accuracy. Research work failed to uncover any better procedures than the ones which have been in use for years. It seemed worth while to determine whether a lead-free line of Effeeto colors could be developed. Such a line was formulated at a cost of 6853* hut proved to be of no sales interest because of high cost and poor color permanency. The pinholing tendencies of Alkatlte Floor Finish when brushed on concrete surfaces were greatly minimised (they seem to have been overcome). This work cost $89h* INDUSTRIAL DEVELOPMENTS Of the thousand or so industrial finishes that were custom-made in 1955# space permits a discussion of only a few of these developments. The metal deoorating trade provided us with our biggest outlet for industrial finishes in 1955* We produced 192,000 gallons of these finishes in the U. S. and 36,000 gallons in Canada. llj.0,500 gallons or 73$ of our U. S. production went to one customer, the American Can Co. Most of this business is represented by White, OX130$, or tinted enamels made from GX13Q5* We are the only source on these enamels at the Fairport and Hudson plants of American Can Co. and are a preferred source for the finish used on pressurized containers at the Hillside plant. Special control tests (fabrication and boiling water resistance) are made on every batch that we make. The American Can Co. is pleased with our service and with the uniformity of our product, but is forever trying to force prices downward. The possibility of losing this large volume of business because of price is always a nagging thought. Other metal deoorating customers include Brooklyn Metal Decorating Co. (30,000 gallons), Fein Tin Can (8000 gallons), and Hazel-Atlas (8000 gallons). A perennial problem at Brooklyn Metal Decorating Co. has been the development of a satisfactory wet ink or wet print varnish. We have gotten nowhere on tills problem because a trial plant test requires an Interruption in production. Samples of our varnish have been held k to 8 months before a production teat could be conveniently arranged. It is the nature of these varnishes to have poor package stability. As a result, our samples \ have failed to perform as well as fresher varnishes made by competitors and used in regular production. Brooklyn Metal I 0007-PTL-000993 -5- Decorating Co* now refuses to make new tests unless our varnish has worked satisfactorily at some other plant* $3362 were spent In laboratory work in the metal decorating field during 1955* Approximately half of this went toward research. $1235 was spent on specific sales problems for the American Can Co* The business machine field probably provides us with our second largest outlet for industrial finishes. Total sales amounted to 85*000 gallons in 1955* of which 50*000 gallons went to Inter national Business Machines. Wrinkle finishes represent the bulk of IBM purchases, but most of our laboratory work has been concerned with the development of a new type of vinyl finish to simulate pigskin in appearanoe. The vinyl problem has a three-year history, and we have spent about $10,000 in solving it. It has gone through many stages. As initially conceived* the problem was to produce a vinyl wrinkle finish. Then* we were asked to make the texture smooth enough to permit a machine operator to write on paper in contact with the finish. Hext came a demand for greater film thickness (k mils) and a finish that would match Ami tags Armorhyde. As soon as we had made such a finish, the sights were raised to 10 mils film thickness. 10 mils is 3 to k times the thickness of the average industrial finish. We discovered patent complications. After negotiating a tentative arrangement with Armltage to manufacture under their patents, our sales organisation lost interest because of the high royalties demanded by Armltage. Hext came the Manything goes" stage, when the problem was simply to develop a finish that would retain its new look for as Ipng as possible. As soon as we submitted such a finish, IBM returned to its previous objective and demanded a rough textured finish at 10 mils thickness. Hew samples were developed, following which IBM asked that the finish be smooth and fine textured at 16-18 mils film thickness. Ho work is currently being done on the problem. The following tabulation summarises sales and laboratory effort in the business machines field: Customer IBM Royal Typewriter Ozalld Masell Other 1955 Sales in Gals. 50,000 27* 000 2,000 6,000 - 85,000 1955 Lab. Expenditures $3303 1959 k86 268 632 $6614.8 Since most of the foregoing sales represented wrinkle finishes, a brief review of that field follows. 1955 sales of wrinkle finishes amounted to 77*500 gallons in the U. S. and 5500 gallons in Canada. 1955 gallonage exceeded 195k gallonage by about 8%. Wrinkle finish sales to Royal Typewriter are expected to show a substantial increase in 1956 because of our Improved relations with that company. 0007-PTL-000994 -6- Eastman Kodak Co* (Camera Works) now purchases most of its wrinkle finish from our company? 10,000 gallons were purchased In 1955* Ozalid adopted wrinkle finishes in 1955 in plaoe of hausnered metal finishes beoause cost savings of $10 to $25 per machine (photo copying) could be attained* Ozalid selected P&L wrinkle finishes because they wanted their machines to look like IBM equipment* Laboratory work on wrinkle finishes cost $36114. in 1955* The Carborundum Co* purchased 1|.T*000 gallons of various adhesives and sizes in 19$$ as compared with 35# 000 gallons in 1954* 1955 laboratory work cost $1156* The primary laboratory goal is to make even better adhesives using blends of new types of resinous raw materials* Collapsible tube coating volume dropped from 7700 gallons in 1954 to 6900 gallons in 1955* We have little U* S. collapsible tube ' business at the present time? Canadian production represented 75# of our 1955 sales* Canadian production showed nearly a $0% Increase over 1954 production. The following tabulation lists some of our larger industrial customers for whom laboratory work was done in 1955* 1955 Cost of Customer Nature of Business in Gallons Work Heintz Mfg* Co* Radio, TV cabinets Zenith Metal Kitchen cabinets Beznor Metal work Union Fork & Hoe Garden tools . Western Electric (and subcontractors) Telephone equipment Haartz-M&son Football covers Storkline Nursery furniture Gilbert & Bennett Brake linings, screens Kittling Spaoe heaters Taylor Instrument Temperature recorders Talon Zippers American Sanitary Partition Steel partitions Houdailla-Hershey Stock absorbers Eboo Water coolers Fedders-Quigan Air eonditloners General Electric Electric fans Jeavons Japanning Custom finishers Markel Electric Lighting fixtures Philco Radio, TV cabinets Dunlop Tire k Rubber Automobile tires Naval Air Matl* Center Zinc chromate primer 19,900 ,, $1681 13#000 ^ 710 6,400 292 8,200 303 20,700 6,30 5# 100 10,600 7.400 5.400 8,000 449 758 104 & 249 591 6,500 7# 000 *' * <* * 9,700 172 25 7 932 1101 581 719 1293 2136 403 1278 *NOt determined or not readily available. 0007-PTL-000995 7 COMPLAINTS there were considerably more Justified complaints* Details Year Total Ho* Comolaints Per Cent Justified Complaints 1955 1954 1953 401 48? 515 36 27 35 The basic causes for 195$ complaints were as follows* Classification Cause Per Cent Ho. of Total Justified Package change Faulty formula Cl) Faulty quality control Faulty manufacturing procedure Subtotal 68 46 2? __ 5 146 17 11 7 1 36 Hot Justified and Indeterminable Total Presumably due to faulty application (2) Presumably due to faulty surface preparation (3) All other Subtotal 86 57 112 255 401 22 14 28 64 100 Cl) Included in this category were complaints on the peeling of Hew Lyt-all Plowing Plat Cocoa Brown and Bone White* bubbling of Alkatlte Floor Finish* end drying and gloss of Bouse Paint 310 Blind Qreen* Formulas for all these Items were revised in 1954 or 1955* because of their faulty performance* (2) Included In this category were oomplalnts on the sagging end wrinkling of House Paint* flashing and streaking of Hew Lyt-all Flowing Flat* and spooky work* (3) Included in this category were complaints on peeling of House Paint and Alkatlte Cement & Stucco Paint* flashing of House Paint, drying problems. 0007-PTL-000996 T Cash Settlements Merchandise Settlements Division ifo* Justified Total Value Justified Complaints of Complaints Only Policy Eat. Value* Settlements Canadian Central Eastern Industrial Western 176 5302 42 UT $ 166 1872 149 -- a* $3385 $ 25 293 - am 1S27 #1845 $ 78 221 1510 am 728 82337 8 271 2386 1459 ' e 3hSl #7567 Based on assumption that average billing cost plus freight and package totals $2*51 per gallon * 1955 cash settlements were 42$ higher than 1954 cash settlements* The value of 1954 merchandise settlements was not calculated* so no comparison between 1954 and 1955 merchandise settlements can be made* The Western Division with 29$ of the company's justified complaints made 02$ of the cash settlements. It disbursed more money in policy settlements than it did in settling justified complaints* The Central Division with 11# of the justified complaints made 42# of the cash settlements. The Eastern Division with 22% of the justified complaints made 3% of the cash settlements, but 56# of the merchandise settlements* f It would seem that the various sales offices have differing philosophies relative to the settling of complaints* The Eastern Division apparently takes s firm attitude and settles as many complaints as possible with merchandise. The Central and Western Divisions display more liberal attitudes and seemingly lean toward oash settlements* The Canadian Division appears to have been the most successful in settling complaints with minimum expense to the company* LABORATORY EXPENSE 0007-PTL-000997 Cmut the pRrent company $331,160 in 1955, or 4^ more than in 1954* The money was spent as follows: 135$. Research $101 640 Sales Problems (Laboratory Requisitions) 76^610 Manufacturing Services 152.9^0 $331,180 m $ 66,200 77,500 .15i.,5po $317,200 !r0h "P,ndltur** w*nt lnto rohiftur.l -9- In terms of production, research and development cost the company 4.15 cents per gallon (see footnote) in 1955* and 4*00 cents per gallon in 1954* Manufacturing services cost 4*15 cents in 1955 and 4*25 cents in 1954* It cost $16 to test each batch of varnish and enamel made at Buffalo in 1955 as compared with $5*20 in 1954* It cost $7*13 to test each incoming raw material shipment in 1955 a compared with $7*07 in 1954* Note: All figures presented in this paragraph refer only to Buffalo (main plant and lacquer plant) production. They exclude research and other expenses applicable to products made at Port Erie and subsidiary plants. PERSONNEL Separations i2S i2k i2ki Dissatisfaction with rate of pay or job opportunities Resigned for other reasons (marriage, pregnancy, health, education) Discharged Transferred to other departments 6 3 17 11 8 14 1 JL 3 19 16 23 Average number of employees Separation rate 64 62 51 30$ 26$ 45$ With one exooption, all separated employees had been with the company less than a year. One laboratory assistant, who had been on leave of absence since June 1954 to undergo treatment for tubercolosis, returned to work January 3, 1956. M. S. Armstrong returned to work on a part-time basis beginning October 6, 1955 after an absence of nine months. He is now working almost full time. He has been given no administrative assignment, but is serving as a general consultant. The most serious detriment to increased laboratory effectiveness is the national shortage of qualified research workers. We should be developing more young technical personnel than we now are, but we cannot attract the right kind of worker. NEW EQUIPMENT 0007-PTL-000998 The following equipment was acquired in 1955 to replace existing worn-out equipment: Still (for making distilled water) 4 Paint Conditioners Office Furniture $ 297 623 1365 $2285 -10- SUHMAHY New Products Developed Bales Froblems Submitted to Laboratory Sales Problems Reported New Research Problems Undertaken Research Problems Completed New Raw Materials Investigated Raw Material Shipments Tested Batches Tested - Buffalo Control Labs. - Ft. Erie Control Lab. Service Calls by Technical Personnel Technical Department Bulletins Issued Paint Manufacturing Bulletins Issued Label Bulletins Issued J--955, 1,362 ^ 1,510 y Am 1.361 1,596 1,489 1,539 56 48 56 39 475 ' 350 2,635 ^ 2,689 19,314 / 19,071 2,861 y f 2,777 133 ' 141 40 / 45 33' 33 65 ' 42 0007-PTL-000999 February 29, 1956