Document 7MgBEK3rJzV3Yz66Qp7QMdpZ6

TECHNICAL ACTIVITIES IN 1951 f 0007-PTL-000957 TECHNICAL ACTIVITIES IN 1951 1951, like 1950, was a banner production year* Buffalo factory volume remained at about the same level that It did in 1950; Port Erie factory volume increased about 6* Our Buffalo factory apparently worked more efficiently in 1951 than it did in 1950, for it produced the same volume with 11% fewer batches* We also purchased fewer lots of raw material* Both factors eased the testing load on the laboratory* In 1950, laboratory control was barely able to keep pace with production; in 1951, the two activities intermeshed satisfactorily. Pewer laboratory projects were undertaken and completed in 1951 than in 1950, as is indicated in the summary appended to this report* The greatest numerical decline in projects occurred in the industrial field* 3l fewer new industrial finishes were developed in 1951 than in 1950* However, it took just as much laboratory time to formulate the new 1951 products as It did to formulate the 1950 products* Most new Industrial business is based upon supplying finishes that meet government specifications. The development of finishes to meet government specifications and tiie approval of these finishes by the appropriate agency la a long and 00stly process* While raw materials were scarce in 1951, no wholesale raw material substitutions were necessary--as was the case during World war II. Restrictions on the use of cobalt made it necessary for us to reduce the amount of cobalt drier In certain key items. The laboratory work on this problem cost 1614.2. The shortage of naphthenate driers led us to spend #505 in investigating tallate driers* In neither case were we forced to make any observable change in the quality of our products as a result of these substitutions* A considerable amount of laboratory time is being devoted to labeling nuisances* we are engaged in continuous correspondence with State of Virginia officials regarding the 1950 Virginia Paint Law. Thus far, all difficulties have been resolved to our satis faction, but they have taken considerable time* We also engaged in lengthy correspondence with the Minnesota State Chemist regarding the Economic Poisons Act of that state. Again, we worked out of our difficulty, but time and effort were consumed in doing so* Early in 1951, the laboratory supervised the microfilming of about 12,000 formulas and code sheets* These films have been distributed to afford maximum security of our records in the event of some major disaster. The Job will have to be repeated In 1953, If we wish to keep the records reasonably up-to-date. In 1951, our company received a certificate honoring us for forty years of continuous membership in A.S.T.M. Our company was one of 0007-PTL-000958 2 the first to recognise the need for rsliabla testing methods in the paint industry. While many paint organisations are now repre sented in A.S.T.M.# only five other paint companies have been members for forty or more years. In 1951* the laboratory developed and issued a paper-bound manual, "Standard Methods for Testing", for the guidance of technical employees at all of our plants. The standardisation of testing methods minimises intercompany technical problems and puts all testing on a businesslike basis. One of the laboratory's duties is to supply our Advertising Department with appropriate color standards for use in the preparation of color cards. This work cost $9Ii5 in 1951* Another laboratory duty which is developing into quite a ohore is the inspection of subsidiary company formulas and liquid samples to determine whether or not they deserve a Pratt & Lambert label. During the year, $366 were expended on this activity. BESEAftCH In April 195>1* Dr. Henry Woodburn, head of the Chemistry Department of the University of Buffalo, was employed as a company consultant on an annual basis. His specialty is organic chemistry. He attends all meetings of our Hosearch Committee and has worked on a number of outside projects for us. Dr. Woodbum's advice, experience, and suggestions have been helpful;* it is expected that even greater benefits will result from this association as Dr. Woodburn becomes more familiar with our problems. , PAINT FENCE For several deoades, our company has leased a small plot of land near Sworaville, Hew York, for conducting house paint exposure tests. The plot is Ideally situated in the open country away from vandals and away from heavily traveled highways. When we first leased this land, the owner was a Pratt & Lambert employee. In recent years, the property has changed hands twloe and this has xsade us aware of the Insecurity of our arrangements Our fences represent a big investment in technical hours (valued at $4000 per year for making experimental paints) and in fence construction (replacement value estimated at $*>000). It would be impossible to move the fences without mutilating them from a technical stand point. Our short term leases (3 year period) have placed us at the mercy of the property owner, neither of the recent owners would agree to sell the land on which our fences stand as this would break up the continuity of the property for farm purposes. 0007-PTL-000959 -3- After a year of negotiation* we finally obtained a 10-year lease on the property from the present owner. The annual rental remains unchanged. The Investment we now have in this location seems temporarily secure. THADS SALKS DEVELOPMENTS An unusually large number of new trade sales produots vero developed during 1953.. They included the followlngi Cellu-Tone Satin - $713 were spent in developing Gellu-Toae Satin colors. The major problem--developing the white--was completed in 1950. Sol Idea Colore - Formulation of the new colors was completed at a eosVof'fZgZT" Vapex Colors - $2768 has so far been expended in the development of latex' paint. Formulas have been developed and turned over to our production department; some colors have already been shipped* Ho field reporta have yet been received. Hedwood Stain - $286 were spent in the development of this item. The Hew Vltrallte Enamel Eggshell - $2ij.01 were spent in laboratory work on The New Vitraiite SnsaiblT Both the gloss and eggshell formulas were revised in 1951 at an estimated saving of $10*1+00 (based on volume produced from the time formula changes became effective until December 31 1951). The Hew Vltrallte Enamel Gloss White was revised to contain sine oxide in order to minimise after-yellowing. The New Vitraiite Enamel Eggshell was revised in order to eliminate dehydrated castor oil* our use of which was exceeding our quota. The substitution of safflower oil for dehydrated castor oil was also helpful from a cost standpoint. We were able to reduce our costs without sacrificing quality. Alkyd Flat Enamel - A promising alkyd flat enamel was developed at a cost of $1162 and is now undergoing field tests. / Lyt-all spectrum Colors - Lyt-all spectrum Green was definitely upgraded during the year by developing a more foolproof, streak resistant formula. Work on this improvement and other deep color work cost $61+0. Lyt-all Double Duty Primer Was changed back to an earlier fownula with a cost saving of $1+3^0 (based on volume produced from the time the formula was changed until December 31* 1951). 0007-PTL'000960 House Paint - Our tint base was revised to provide for better tint retention by substituting baslo elllcate white lead for the lead sulfate in the previous formula. It la estimated that this change saved our company #2300 during 1951. The exposure work on which the change was based was completed prior to 1951* A group of so-oailed ranch house colors were developed and exposed In Florida with satisfactory results. However, the oolors that were developed do not conform with the colors that we now wish to promote. An experimental House Faint 300 Outside white with better gloss and leveling properties was developed at a cost of #411. This was field-tested but was not adopted beoause of inconsistent performance in these field tests. A 10p white lead paint was also formulated when titanium dioxide was in short supply. A comparatively small quantity was actually produced. A two-purpose (mildew resistant and tinting base) white was developed but not adopted beoause of its comparatively high cost. Verdure Trim & Shutter Finishes - Were revised to permit use of purchased alkyhs in place of our own alkyds, the production of which was hampered by phthallo anhydride shortages. We were able to save $900 In 1951 as a result of this formula change. Laboratory work cost $2ij.6. Cement & Stucco Faint - Improved rubber base paints have been tested in Florida and have been tentatively adopted. These paints have better durability, better color permanency, and lover cost than our present oil-base Cement & Stucco Faint. Lyt-all Mixing Liquid - A special varnish suitable for admixture with Lyt-all spectrum Colors and Lyt-all Flowing Flat (to produce eggshell enamels) was developed but not adopted because of its conflict with baslo sales polloles. "61" Floor LaoQuer - Was developed at a cost of $116. XHPUSTHIAL SAL3S DEVELOPMENTS Buffalo factory production of materials for Industrial customers amounted to 920,163 gallons in 1951* This was 29g higher than It was In 1950. This increase seems remarkable In view of the shortage of metal and our comparatively small volume of military business. 0007-PTL-000961 5 Wrinkle finlah production increased to 121,900 gallons and was 22% greater than it was in 1950. We are probably the third largest wrinkle finish producer in the United States* Pittsburgh Plate Glass Co. and Interohemioal corp* are believed to be larger producers* A comparison between 1951 and 1950 wrinkle fini ah activities is shown below: 1951 1950 Gallons produced for: Royal Typewriter Co. International Business Machines Others Total 51*000 34*500 21,000 29*000 1*9*900 36.150 Cost of laboratory work: Royal Typewriter Co. projects I.B.M. projects Other work for specific aocounte Research Total $ 309 403 2029 ^709 t 329 317 3014 ^763 $5423 Research work on wrinkle finishes during the past year has centered on revising manufacturing methods to improve product uniformity* 60% of our wrinkle finish volume is now handled in 1000 gallon batches, which are turned out in only two to three days' time* The grinds are short and color and texture adjustments are quickly and efficiently manipulated* In addition to wrinkle finishes, both Royal Typewriter and Inter* national Business Machines buy substantial quantities of primer* The former bought 19,000 gallons of primer in 1951 and this required laboratory work costing $1238. International Business Machines primer purchases amounted to 9100 gallons and represented $393 worth of laboratoxy work* Production of hammered metal finishes in 1951 remained at the same level as it did in 1950--13*000 gallons* Interest in this novelty effeot seems to be wearing off. The following statistics pertain to the metal decorating fields 0007-PTL-000962 -6 1951 1950 Tonnage Decrease In U. 8* Can Production (aa compared with 1950) Gallons produced fori American Can (U. 8* only) Brooklyn Kotal Decorating Co* Ha*el Atlas Glass Co* national Can Co* Total u* 8* Production Per cent Increase P&L U* 8* Production 6jC# 53#600 28,900 10,000 9CT0 18* 81,600 Total Canadian Production 32,400 38,900 Cost of laboratory work! American Can Co* projects Brooklyn Metal Deooratlng Co* projects Other specific sales projects Hesearch Total 6 628 675 1639 168 15115 $ 469 1178 705 ^Source - "Modern Packaging" One item. Aluminum Mixing varnish, accounted for 4Q of our metal decorating finish business in 1951* 40*000 gallons were purchased by The. American Can Co* to brighten up black plate cans so they would resemble tin cans* The non-scorch varnish problem, which has been "hanging fire for four years, has apparently been solved* Five drums were successfully used by Brooklyn Metal Deooratlng Co* Unfortunately, a raw material house, Soheneotady Varnish Co*, seems to be able to produce an equally good produot at a far lower sailing price* As a result, our hoped-for sales volume has not materialised* Heretofore, we have sold either oleoreslnous or alkyd sises to the metal decorating trade* Both types have been satisfactory for soma uses, but nelthsr type consistently passed the pasteurising and processing testa used to evaluate costed food packages and crowns* W* have now developed a new vinyl-alkyd else that appears to meet every sising need and which withstands pasteurisation and processing* The new else has been given a successful preliminary test by Amerioan Can Co* of Canada and a barrel has been ordered for a full scale production run* Our position in the collapsible tube field continued downward in 1951# as indicated on the following page* 0007-PTL-000963 1951 1950 Decrease in U. S. Tub# Production (in gross, aa oompared with 1950)# 7*7> gallons Produoed Fort Wheeling Stamping Co* 6,580 Peerless Tuba Co* 1,300 national Tuba Co* 975 Standard specialty & Tuba Co 900 Othar 0* S* Aocounta Total u* S* Production 1*225 Toim Par cant Daeraaaa P&L TT* F. Production ijJLjC 7,000 4*000 2,200 1,000 if2fs*6s0s0 Hodam Container#, Ltd* (Sola Canadian aooount) 1,120 2,200 Coat of Laboratory Work* Wheeling Stamping Co. project# Paarlaaa Tuba Co* projeots Othar apaolflo tales projects Research Total # 442 not segregated 1501 ^Source "Modem Packaging" During the five years previous to 1951, ve #pant over $25,000 in development work on collapsible tuba finishes, but our five year sales record was so disappointingly poor that We discontinued all research work in 1951* In 1951* our production of collapsible tube finishes fell off far more than the industry*a production of tubes. All metals used in the production of collapsible tubes, as well as tubes themselves, are on the government list of orltleal materials. Department of Commerce atatlstioa indicate that tube production has fallen by about 305 since the post-Korean boom* Our 1951 production of oollapslbla tube finishes was composed of the following product types* Alkyda Oleoreslnous Lacquer Vinyl 70 22 6 2 ioo After years of talk about vinyl tube coatings and thousands of dollars worth of research work, we sold only 300 gallons of vinyl 0007-PTL-000964 -0, tube finishes In 1951. Tube manufacturers are still talking about vinyl ooatings* but vinyl coatings are not yet replacing alkyd finishes. We have been told that Lever Bros. Co. has approved one of our vinyls for use on Pepaodent tubes. If vinyl coating is used in the future on these tubes and we obtain the business* it will supplant part of our alkyd business. Feddera-Quigan purchased more than 60*000 gallons of our products in 1951* These Included baking enamels* primers* and thinner. Probably the biggest single item was Condenser Coating Black* of which we produced 12*300 gallons in 1951* Laboratory work for the benefit of this account totaled $1310. Helnts Mfg. Co. bought approximately 20*000 gallons of baking enamel and 6*000 gallons baking varnish during 1951 for use on metal television cabinets. Laboratory work cost $713* Trloo beoame a substantial customer again in 1951 and bought about 10*000 gallons of government specification finishes. Laboratory Work ooat 6451* Pratt-Whitney purchased about 13*000 gallons of black baking enamel* 3000 gallons of gray baking enamel* and a large volume of sine chromate primer. Little laboratory work was required. Zinc chromate primer proved to be its usual headache in 1951. We produoed 26*000 gallohs of primer meeting Specification MIL-P-6889A, Type I. This was almost five times our 1950 production of sine chromate primer. However* we had numerous rejections on the grounds of drying* lacquer hold-out* and adhesion. These difficulties have now been overcome. Laboratory work on sine chromate primer amounted to $4599 in 1951. Another unusual specification primer promises to be a big volume item in 1952. It is termed "wash primer" and meets Specification MIL-P-15328. Wash primer is a polyvinyl butyral composition containing sine chromate and phosphoric acid. It la really a metal pretreatment rather than a surface coating. Wash primer* so far* ia being used solely in the aircraft field. One item* Ounatock Coating Walnut* was developed for Springfield Armory. About 6250 gallons were aold in 1951* Laboratory work on the development of Industrial finishes to meet military specifioations totaled more than $14*000 in 1951. Thia figure includes $1867 spent in preparing Wavy inspection forms. In 1950* $903 was spent in the preparation of these inspection fonss. This is one measure of the increase in our military activities in 1951* 0007-PTL-000965 W -9' Kasell Manufacturing Co* bought 10,700 gallons of green and gray baking enamels for use on filing oabinets last year* $837 worth of laboratory work was done for the benefit of this account* Our production of fabric coatings in 1951 slumped k3 below our 1950 production (11,700 gallons in 1951: 20,995 gallons in 1950). We spent $1383 on speolfio sales projeots. Carborundum Co. purchased k3 000 gallons of sandpaper adhesives in 1951 as compared with 65,000 gallons in 1950. $1092 was spent on laboratory work. Carborundum "Fast Cut" and "Red-I-Cut" lines are still considered the outstanding waterproof papers in the industry. These are the papers that are made from Pratt & Lambert adhesives. After two years of sales and technical effort, General Felt Products adopted Pratt & Lambert finishes as a second source of supply for making paper liner inserts (for jar and bottle tops). 1200 gallons of varnish were sold during the last half of 19511 a current order for 5000 gallons is being manufactured. Laboratory work performed for this account in 1951 amounted to $522. Considerable technical effort was devoted to the following accounts, which have been, are, or promise to be large purchasers of industrial finishing materialst Aocount Value of Laboratory work Virginia Metal Products (steel partitions) Xngersoll Rand (heavy machinery) R.C.A. - Victor Bell Telephone and Western Electric Co* Markel Electric (lighting fixtures) Eastman Kodak Eclipse Pioneer (machinery) General Electric Hard Mfg. Co. (beds) f 0007-PTL-000966 -10- COKPLAINTS Complaint Record - Buffalo Factory Year Total Complaints Received Par Cant Justified Complaint Index* 1951 1950 1949 Avg. 1936-1940 lnol. 230 268 33 34 27 *Nuaber of complaint* par million gallons of manufactured goods* The number of complaints, the number of justified complaints, and the complaint index dropped in 1951* Distribution of Complaints by Salas Offices Originating Sales Div. Central Industrial Western Eastern Canadian No. Complaints 1951 mo No. "Complaint Records" 1951 1950 85 72 69 59 __ iZ 302* 100 94 72 fi 313* 68 None 56 46 None 170* 64 None 47 24 None 135 oThese totals do not agree with totals In previous table as they include subsidiary and Port Brie products as well as Buffalomade products* causes of Complaint Color Viscosity Gelled, Lumpy Drying Gloss All Other i. of im Total justified Complaints This Group 16 11 6 8 6 J 100* 39 53 70 18 % of Total^^justified Complaints This Group 14 14 2 6 12 -12 100J6 32 52 60 23 53 12 0007-PTL-000967 W 11 As in previous years* color and viscosity complaints were moat numerous. There was a marked decrease In gloss complaints. There was also a marked decrease in complaints due to mislabeling. In 1950* there were nine such oomplalntsj In 1951* there were only three. In both years* only Buffalo faotory products were involved in mislabeling oomplaints. Certain divisions seem to specialise In the nature of their complaints. The Chloago office* for example* registers kO* of all the color complaints reported to the laboratory. The Industrial Sales Division registers 37* of all the viscosity complaints reported to the laboratory. Half of all streaking oomplaints originate in the Central Sales Division. LABORATORY BXPBHSE The total cost of operating our Buffalo laboratory during 1951 was $252*906* or 7.7* more than in 1950. 6% represented wage and salary increases; 1*7% represented the increase in general expenses. The money was spent as foilowe t Activity 1951 1950 19k9 Research Special Sales problems Manufacturing Services Total $ 61*900 70*000 121.000 $252*900 $ 65*600 56,200 111.100 $23k,900 $ 67*700 63,600 96.600 $226*100 These figures, representing dollar expenditures, reveal that we are doing less and less research* but the extent to which this activity has been curbed is best illustrated by time card studies (which are not influenced by the inflationary effect of wage Increases). In 1951* we spent only 8l* as much time on research as we did in 1950 and only 76* as much time as we did in 191*?. 3% more hours were spent on special sales problems in 1951 than in 1950. Total hours spent on all research and development activities in 1951 was 96* of what it was in 1950. Cost of Cost of Research Manufacturing and Development* Services 1951 1950 i2l Per Gallon Buffalo Faotory Production Per Batch Made at Buffalo Per Gallon Combined Buffalo and Port Brie Production As Per Cent of Dollar Value of Sales of all Products Made at 3uffalo and Fort Brie 2.9* 1.1* 3.5* $6.95 3.2* $5.75 0007-PTL-000968 ^Excludes that portion of paint work that benefits our subsitiary companies* but includes paint work for benefit of Fort Brie faotory. T 12 PERSONNEL 1951 1950 im 1941 Resigned Transferred to othsr divisions Discharged Enlisted or drafted Total Separations Average number employees Separation Hate 7 16 -11 J> 7 11 -3 3 _ 13 20 7 22 60 20* 61 33i 61 U* Wn Labor problems were fortunately few in number in 1951 While we now have nine former laboratory employees In military service, most of these men were comparatively inexperlenoed. We were able to replace them with young women. So far, we have had no difficulty in attracting young women of high calibre, but this labor source oan dry up, if Buffalo area manufacturers obtain large military contracts* We cannot compete with defense contractors on a wage basis* Only two of the 1951 resignations resulted from the appeal of more attractive jobs; nearly half of 1950 resignations resulted from this reason* The chief cause of 1951 resignations was pregnancy. NSW EQUIPMENT The following new equipment was Installed in 1951: Gardner Washability Machine Salt Fog Corrosion Test Equipment A.S.T.M. Distillation Unit Toraion Balance ' $ 200 1879 200 80 P35? Probably the most expensive piece of equipment ever acquired for laboratory use was ordered in 1951 for delivery eome time this year* It le a Blaw-Knox Experimental Resin Plant that is a small aoale replica of our factory alkyd and oil kettles. The laboratory equipment is jacketed end is designed for use with Dowtherm* The kettle is fitted with a reflux oondensor, a vacuum pump, an agitator, and gauges and controls* The entire unit will cost $10,400 and installation Is estimated to coat another $2000* Ever since the first Blaw-Knox alkyd kettle was installed in the factory, there has been no way to duplicate this operation on a small soale* Consequently, experimentation had to be conducted in the kettle itaelf at high cost and with an interruption in 0007-PTL-000969 -13- productIon. The laboratory has never been able to do oil processing work on a small acale. The new experimental Blew-Knox unit should put us In a position to duplicate all existing factory resin and oil operations. Xn addition, it is hoped that we can prove the advantages of the solvent reflux method for making alkyds. We are presently using the fusion process for making alkyds. Xn the solvent reflux method, a small amount of solvent in the batoh is continuously refluxed. It is claimed that the solvent reflux method offers these advantagesi (1) Aids water removal (water being a by-product of the chemical reaction that produces alkyds) an4 therefore, shortens processing time. (2) Self-cleaning. The accumulation of "burned on" resin at the top of our kettle creates a difficult and costly cleaning problem. The solvent in the reflux method washes down over the upper part of the kettle keeping it clean. (3) Reduces losses (claims of l-2 savings are made). (4) Improves color and uniformity (by eliminating the possibility for charred material to drop back into the kettle). Solvent refluxing cannot be performed satisfactorily in existing laboratory and factory equipment. The operation is too hssardous for present laboratory equipment. Present factory equipment is not fitted with s reflux condensor. but it is estimated that such a condensor could be attached for about $3000. should this step be desirable. The new experimental equipment will also enable us to study vacuum methods, which are necessary for production of certain newer types of alkyds. such as the styrenated alkyds* 0007-PTL-000970 SUMMARY OP 1951 LABORATORY WORK Maw Products Developed Sales Problems Submitted to Laboratory Soles Problems Reported Mew Research Problems Assigned Research Problems Completed Mew Raw Materials Investigated Raw Material Shipments Tested Batches Tested - Buffalo Control Labs. Batches Tested - Port 5rie Control Lab* Service Calls by Technical Personnel Technical Department Bulletins Issued Point Manufacturing Bulletins Issued Formula Analysis Bulletins Issued 19!>1 1*096 1*1*35 1.382 54 52 312 2,857 17,346. 2,589 131 20 54 35 1950 1.514 1,666 1.693 61 71 309 3.024 19.224 ' 2,557 133 33 71 255 March 10, 1952 0007-PTL-000971