Document gaZp325Nmgrrd086YvQkERYja

Du r>uOnNTi f!MF r\.* ' * * < m u i ru. IHN'flA! INfORMATSO! The three mu, Oh 3. Ociin^ 3.03 1 (Pigment) 2-4MMer)______ 3 (Thtimers) 2 sain lunations c: net are: 1 (protection)- 2-(decoration).. 3. Other functions are: 1 .._(IjghtUjigX^--ts^fefcy.) and 2 (sanitation) rtemperature cnntro 1) The two types of film formers are (-thermoplastic). ana 2 (conversion)____________ j ctn 0yCctnijpl|S Of. ss-0jn 3_o j _ > and 2. _(drying The solid film former is sometimes called the (binder) Si o*. if h'Ct in a pigmented paint. 5. Three ways a paint may dry are: 1. (Air drying ) b, Latex Paints (water based) dry by evaporation of water anda ...Xt.oalescencje__________________________of the paint particles. 7. ana OLsogiiar-)- are names given to solutions of a film former-in a solvent. When used with pigments- fch solutions are cui-ied (vehiclg) - Some of the name gi*ven to pigmented finishes are.: 1. (primer) 2 s__4anameL)______ ___ 3 -_4paint.)...... ..,...........__........3 (filler.)___ anc3 b (snrfacer). . 9 Paints may be classified by their end use as l. (trade)_______ Sales paiucsj i.__(industrial)products or 3. (malnfenanca) _paints. , l O. The F & F Department classifies their paint products into five O\uOo a. . -iflth*-t..ada)-4-lndu s t. tial)- .uO._i.u-S j i-- i XAntomior.ive)L 4. 4Refini~sh)- _and 3.(Industrial) DU PGM! TECHNIC, n: v.r U i 8 id i S i ih. L UNIT ONE INFORMATION An oil is a combination o: Continued .one cnain .fattx. witn glycerol. Write the formula for an oil using any fatty ac: 0.... _ag.ldj O0 D- 13. Name ells used in paints .lupyg. 2. Linseed 3 Sova Bean is Coconut 5- Castor o. Oiticica (Tall Oil') l 4, Oils may be classed for paint use as Non ____ keying. drying oils. 15. Fatty acids which promote drying are: 1. aiftnataarir 2 . linoleicanc3 3 _Jnolenic__________________________ 16, Tung oil is a valuable oil because it contains a large proportion of eleostearic ; .....acid which has .....three____________^double bonds.. 17. Castor oil has a fatty acid called rieinolaic i .which.',, contains a hvdroxyl _______group. Due to this group Castor Oil can be dehydrated to produce con ligated_________ double_bor.ds which increases its drying 18. Oils are used as the binder __ property. : in outside: House Faint> a part' of an aIkya resin and as a plasticizers for nitrocellulose lacquers. . . . ' ; 19. Besides oils, film formers used in paint manufacture can be: classed as natural resinsand synthetic ___rasins. Among the converting type of resins used by the F & F Depp, are: 1. Oil Modified alkvds2.Ure: and 3. melamine ________formaldehyde. DUP030049673 r> t'-' A\ f` *f' UNIT ONE - Continued it h\sf OK.Vs^Xirr^lic) Nitrocellulose_vinyl_ resins are examples oi onermop. ;ic or non converting type film formers. The volati; portion of a paint may 00 divided into two classes. * Solvent _and 2. diluents IVlGS 3.5. a-C1 2^~`OUp IS U.SOG *0O rfiduc6 COS -Mater________________is dae onlM arc V* ~ jo^vcn^/ us6( manux aenure. ,.n 24. The tv/o most v/idely used types of organic solvents are: 25. 26. The hydrocarbon type solvents are: A1 iphatic _and 2. aromatic- Two of the most common aliphatic solvents are - Mineral..Spirits,________aad 2 V M. ahdLEJSapthe_________ 27. Aromatic solvents include 1. tnltiol and 2. yyi nl 23. The three most important properties of solvents for paint use are: 1- solvency2. volatilitynd 3 29. Highly polar compounds 1. alcohols__________2. waters 3. ketones 4 ___ethers. nitrocellulose resins. 30. Benzene and Methanol are used sparingly in paint because of their toxic;properties. 31. The functions of pigments in a paint are to 1. hide (obscured 2. decorateand 3- protectthe surface upon which the paint is applied (substrate) to increasethe durability of a paint and to reduce the cost of a paint. DUP030049674 p: y ['* ,. u I Vjr! n\Jp1 V: * !i'V- Mi i ''^ * Be S H C 6 3 y/.l1. tS sr'TI-HIG p 3-2^10 il '< usee 6XwGnGo.v6:ly in os.i.r.c3 . )i"uient: used to control the _&ias^_ O i. ci. p ex --.. i C U.: a. o ;ne cost:-------------- ^o:jr 33 The four types of white Prime Figments are:I. white lead T0 , 2 JULthopone3._______________I_2ana e-Mac_oxides_ 34. The five white extender types are: 1.silicates 2.barium sulfate 3- calcium_sulfate^.calcium carbonate and 5. Silica 3: Hiding power (ability to obscure a surface) of a white pigment is aue to \ r f CjOrepr.ee in refractive index ;he clear vehicle and the :y pigment po. Colored pigments hide as a result of color absorption 37. ri t-aninm dioxide__has the highest hiding power of any white pigment. 33. Two of the important properties of a colored pigment are: 39. psstone and tinJLing_ ` O.a. Clip, Oil , Most black pigments are some forra of carbon 40. The inorganic pigments are either earth ________colors or are manufactured by a Fire___________process or chemical 4l. -precipitation__.___ Sorae cf the organic pigments are phthalocyanine blue, Phthaloevanine green, Toluidine red and Hansayellow DUP030049675 UNIT TWO - Exercises I. The raw materials assigned the following permanent prefix codes are: a: "G"- ' ... 1. Natural Gums 2. Synthetic Resins 3..Blacks . 4. Waxes . 5. Driers and Hardness 6. Abrasives, Bodying Agents 7. Chemicals 8. Dyes 9. Processing Materials b. "H" 1. Oils 2. Solvents and thinners . 3. Plasticizers c. "W" 1. Pigments , . 2. Extenders 3. Metal Powders d. "PX" ' 1. Nitrocellulose - . 2. Temporary codes use the prefix y followed by gt w______>' or TaT to indicate the nature of the Material. 3. Sequential code blocks are assigned to various plants; the (3-l600 to G-1699 block is assigned to Philadelphia and the H-l to H-349 block is assigned to Pari in_________ DU P030049676 UNIT TWO - Continued 4. In the parenthesis following the color code number in . column 2, show the letter referring to the color: in column 2. ; Column 1 a. Red b. White c. Blue Column 2 100 (b ) 200 (s ) 300 (a ) d. Yellow e. Green 400 500 (f ) (c ) f. Brown . 600 ( d ) g. Black ' . 700 8oo (e ) (a ) 5. Give a Dupont raw material code for the following: 1. Glycerol h -2_______ ; 2. Linseed Oil h -253_____ ; 3. Rosin 0-40____ ; ' 4. Methanol K-41 ; 5. Mineral Spirits h -287____ . 6. Phthalic Anhydride g -243 7. Burnt Sienna -377___ 8. Iron Blue w-533 6. The F & F Dept, uses yi-r* kinds of linseed oil. 7. Describe the differences between H-19 and H-253 lin-seed oils and between H-22^ H-120 and H-156, castor oils. H-19 - Alkali Refined Oil H-253 - Raw Linseed Oil ' H-22 - Refined Castor Oil H-120 - Blown Castor Oil - * H-156 - Dehydrated Castor Oil / Ci DUP030049677 UNIT TWO - Continued 8. Indicate the Dupont name and write the chemical formula for the following: W-3Q1 Red Iron Oxide 98% Z:2--3 W-349 W-843 -H---i----O---x---i-d--e-----R---e--d----L--e---a--d---91% Cadmium Red Maroon Pb3o--04y ------------------------Cd S CdSe BaSO/j 9. The "SH classification indicates the type of Protective equipment to be worn in handling materials. 10. What are the 8 fundamental safety rules to be followed in handling raw materials. , See Page 2 PTSP #9 . 11. Strong oxidising agents such as Benzoyl Peroxide should not accidently come in contact with other raw_______ materials especially organic materials since they may react explosively. 12. Table 1 of PTSP #9 lists ______]jQ________classes of; hazards. This classification is the Manufacturing Chemist Association (MCA) method of defining the hazard by 1 Type of Hazard. 2 Precautions in handling and in 3 Storage. DU P030049678 UNIT TWO - Continued The MCA Class and the "S" class can be obtained from raw material soeci firation sheets or in the Raw ' Materia] Coda List. List the MCA Class and "S" class for the' following raw material; MCA S 1. G-201 ..........._3.7__ _____ .c> 3* G-213 6 1 6. G-405 6,7. 10 4 .... ... 9. G-675 3.7 10 S 13. G-688 2. H-l8 1C - 10. H~4l . 11. H-284 4. H-428 . IB. 4,10 .. 3.. 7, 10 .. 1C. 4....8 2 5 2 ' . 7. H-735 8. W-114 . 1C 6 . 1 . 12. W-307 10 5. W-384 ___6_________________ 1! . 14. W-1021 6 1 15. W-785 _ Besides classifying our products according to their hazardous nature by- the M.C.A. and "S" system of classification* the Interstate Commerce Commission also requires that materials be classified for shipping purposes. This information must be shown on'all formulas. What classification would you apply to the following laterials? cl H - 202 + 8GL b. G - 663 COR c. G - 748 OXY..M d. H - 35 . ___- -20L DUP030049679 UNIT TWO - Continued e. G - 781 __PilXS_B------------------------ f. H - 583 4- ROT. _______ l6. The Raw Material Code List has a column titled Preference. On the first page of the list are shown the codes and their definitions. Indicate the classification for each of the following codes /. R. M-. Codes Preference Class 1. G - 12 2. G - 243 3. G - 304 4, G - 419 5. H - 12 6. & - 154 7- H - 200 8. W - 120 9. w - 139 10. w - 362 ' ' ..................................A........................... _ C C B ......................................... C . ...... ................__.... c ....-......:...... - - .............-.....Obs.................... ......_......... - .... ....... Obs. ................. B .................. 17. You have developed several new formulations and you have ~ found that the following raw materials are required. Under the conditions listed determine whether you can use these based on simplification procedures. You may have to get W. P. Colio permission to use some of these materials., Contact him and determine whether you can use the.raw materials under the specified circumstances. Yes Yes No 1. H - 19 as an ingredient in a new resin. 2. W - 316 in a new red metal fence paint. 3. W - 851 in an Automotive Enamels. It is used now only in 794 - 12345 and 794 - 23456. No 4. W - 191 in a black finish for A.C. Spark. Plug Div. Yes 5. G - 18 in a Chemical Resistant Finish for The Chambers Works. DUP030049680 UNIT.TWO - Continued 18. You need certain raw materials with the following specific .- properties. Indicate below the raw material code meeting - A the. desired properties. ' a. A hydrocarbon solvent with an aniline point of 33-37C ; . (l/l dilution) . . o. An extender with a particle size of 96-100^ below 10 . : .microns'and 0.0035^ sodium content, . ; . c. An organic non bleeding red pigment. A d, A Sofo solid alkyd resin,, having A.N. of 18-25 and . a Gardner Holdt Viscosity of Z to Z-2. e.; An Epoxy resin having a melting pt. of 125-135C . - / and epoxy equivalent of 1900-2450. .. f, . ,A drying oil having an iodine No. of 177 mini. A A acid number 4 max., Sofonification No. of 189-195 . and color of 14 max. . ' ' A . i'.'. wA A Proit.d...u....ct .a. . 'I ....C..o...d..e.. - ; . ' ', ________U-7SR ' ___'____s^i2__ ' : "' .; ' <* ______H-m,, !w-a79 , . . d _G-1098 1 e ' ________Gm33LiL.._ .. ' 19. . " f" _____' H-253..... Letter designations, are assigned to designate plants for.accountings formula and batch card purposes. Match the letter, designations with the names of the Finishes Plants. ` 1. Chicago . a J (5) ;V'. :2.Everett b. F (3) 3. Flint ; /;. A- ;4.- Fort Madison 5" ?&rlin ." 6. Philadelphia A . 7. 'S. San Francisco A 8..; Toledo A c. P (6) dh T (g) : e. L (9) f. M -(4) g. E (2) h. C (1) ' ;9 ` Tucker ' . i. S- (7) DU P030049681 UNIT TWO - Continued 20. Give the total consumation and the consumation by plants for 1967 of the following codes: .. G-12 W-123 II-200 Total Chicago 574,666 lbs 125,790 6,735,093 lbs 704,687 1,683,922 lbs -- Everett 36,670 165,166 108.335 Flint 8,739 5418 648,089 Fort Madison 97,104 1,275,812 . 580,807 Parlin 447 34303 -- Philadelphia 188,360 1,619,293 20,538 S. San Francisco 55,085 687,965 191,305 Toledo 19,616 1,719,717 -- Tucker 42,855 522,732 134,848 21. The Pigments Dept, has advised the F & F Dept., that they have on hand 1,000 cons of a rutile which is slightly off in color. They have asked us to use this off in our products. a. If we were to substitute this material for the Tp02 with the greatest amount of consumption and used at the most number of plants, what coded TpOg would you select? b. If we were to substitute the off standard . rutile Tj _02 for the material selected at the rate of consumption at each plant in comparison with the total consumption and we can save 4c/ib. at South San Francisco and 3c/lb. at Chicago, Fort Madison, Flint and Toledo and 2p at the remainder of the plants, how much will the F & F Dept, save annually? a. W-123___________________ 1967 Consumption b. $ 55.089.81 22. If we were to substitute KH-1234, Xylene, for H-583 Xylene, what would be the total cost of revising all of the formulas involved if it costs $4.00 to revised a formula $ 8,904 (1/68) 23. Name the pigmented products which contain H-505, Creosole (Jan. 1968) (White Stencil Zinc Chromate Primer, Baking Dulux Pump Enamel #3 White, Exterior White Paste, Enamel, Dulux DUP030049682 UNIT TWO - Continued Enamel, New Holland Yellow. 24. Raw Materials for the laboratory may be secured from a. Weigh__________________ and Load Room or by ordering them from the Store Room. _ 25. Information regarding the supplier(s) of Raw Materials used in the Dept, is obtained from Specifications . 26. Information regarding material not now used by the F & F Dept, may be secured from Dale Reinecker and purchased through a Marshall Laboratory order issued by John Kissel. These new Raw Materials are given an PS code when they are used in the laboratory. DUP030049683 5XERCISES-UNIT 3-PART A 1. The three general types of materials handled by F & F Dept. 8.TQ 1. Paw Mai-Av? alfi 2. TntP-rwediates und 3 Finished__________ Products________ 2. Trtarmgdiatep; include manufactured film formers, 1. 'y~~---f and 2* 0i-pp and pigmented c\i s.oarsio^.s___________ . 3. A Varnish is made by cookingan 0ji_with a . hard <? ~~. 4. Oils generally used in making varnishes are.. I. t ,Indeed _______ 2. Tung (nWQ) , 3. Soya Bean_______, 4. Dehydrated Castor Oil and 5 Pit idea 3o Gums used in varnish manufacture are classed as 1. Natural Gums_______ or Modifiedrosin esters ______________.* _ t. . 5. A 25 gallon oil length varnish is formulated with 25_______ gallonsof oil and gum (resin). LQQlbs. : of 7. The higher the volume of oil used in a varnish the more flexible will be the film formed from the varnish. Sv Match the following code prefixes with the type of varnishes to which they refer. 1. VB 2. VC 3. VF 4. VG 5. VK 6. VM a. Miscellaneous Varnishes b. Gum Solutions c. Clear Varnish Blends d. Black Varnishes e Flat Varnishes J. Clear Varnishes (0 ) : (f ) ' (e ) (b ) ,(c ) (a ) 9- Other "V" coded materials include; 1._________j /q __________ 2...... v h 3._________________ VQ_.............. ...... 4.... yp __J5._______________ us. and 6 ,, \t z_________- KS DUP030049684 EXSRCISES-UNIT 3-PART A -Cont. 10. The conversion types of synthetic resins used by the P & F are: 1 A1 kyds2.t if 3 M F. 4. TTnnyy3. P1^r>nlip_and 6. Pnl vnrp.thane- 11. The non converting type resins used by the F & P Dept, are: 1 Tv-? t-.r a*'' ^ ~ ~ t , -> <: ______________ 2 .__\f\_riy 1___________ ____________ 12. 3 A^r-v! r*t j ............................................................ . , Materials used to increase the flexibility of nitrocellulose are called piasfieizerB* type products. These are generally PSfpr 13. Emulsion resins used by the F & F Dept, are: 1. (i.p.r.ton Ar.-ryli^) 14. 2., (Acrylic Latex)ana 3 ..............................(Teflon) .:_(_Ftyrene Butadiene.)... Identify the following code prefixes: 1. RC Resin ciear . 2. . RK Resin Blends ' 3. RL Non drying: Oil. Resins 4. RF Flat resins . 15. Alkyd resins are made from the following general types of com pounds: l.Acid Anhydride or dibasicacids 2. Polyols_________________ end 3. Fatty ______________ Acids ______________QP oils 16. The common oils used in alkyd preparation are; 1. Linseed ' 2. Sova ________3. Castor________________ 4. Dehydrated Castor _______ 5. Coconutend 6. Safflower . 17. Oil Acids used in alkyd preparation are: 1. Tall Oil: 2. Dehydrated Castor end 3 > Soya 18. Polyols used in alkyd resin preparation are;1. Olvcerol 2. Ethylene Glycol______and 3 Pentaervthritol . 19. Di Basic Acids or Anhydrides used in alkyd resin preparation are: 4_Jgptlhiic-----------------2....Maleic,--------------------_anci 3.__ Tsophfchallc DUP030049685 EXERCISES-UNIT 3-PART A-Cont. 20. Give the name and Du Pont code f-or the three common Monoglyceride Catalysts: Name Code t h arg f hi- 603 ,jg P A Tg 1 1 < VD-5822 3 SodiitTO Hydroxide G -- 218 21. Match the raw material codes with the following alkyd resin in gredients. 1. 2. 3. 4, 4. 6. 7. 8. 9. 10. 11. 12. 1314. 15- K-22 H-287 H-19 ' H-59 H-7 H-I56 K-344 H-663 H-255 H-2 II-514 G-419 H-632 G-24.3 G-811 Soya Bean Oil Glycerol Dehydrated Castor Oil Pentaerythritol Castor Oil Mineral Spirits Linseed Oil Phthalic Anhydride Isophthalic Acid Cocoanut Oil Tall Oil Fatty Acids Odorless Mineral Spirits Tung Oil Ethylene Glycol Linseed Fatty Acids ( -4 ( 10 (6 ( 12 (1 (2 (3 ( 14 ( 15 (7 (s ( 13 {5 ( 11 (9 .22 Monona:?s used in making acrylic polymers are:l. . Ethyl 2. Met; ..Methacrylate and 3. 23. Pa-- - ______________ are used as catalysts in preparation of acrylic polymers. 24. Ingredients used in making amine type resins are: . TTraa . 2Melamine3- Formaldehyde 2r>. Classify the following resins according to their preference classification, Classification 1. RC-3140 2. RC- 262 3. RC- 141 4. RC-3083 __ A___ Obs DUP030049686 EXERCISES-UNIT 3-PART A-Cont. 5. RC- 483 6. RC- 747 7. ' RC- 723 8. RC- 921 9. RC- 945 10, RC- 909 ___________B___ ___________B_____; .___________B__________________________ ___________obs. ___________C A _____________________ 26,, Give the codes for the alkyd resins with the following com positions . L A 60^ Soya bean oil resin containing 3.6^ excess pentaery- thritol thinned to 60% solids with H-287. r c .-4.67___________ 2. A dehydrated castor oil resin containing 3.8^ excess glycerol thinned to 60% solids with H-287/H-202= 8/5. .3. A 37^ cocoanu t oil resin with 5-6^ excess glycerol thinned to 60^ solids with .H-596. RL-314-1 4 . A TOEA analog of RC-461. RC-599 ' 27. Give the product line numbers using RC-311. 76 ^Q .. 23 .......... S3 67 thQ . 31 ;86 28. The alkyd producing plants in 1967 were: 1. 2. Toledo 5. Phila. 3. Pl-'-r.t- 4, 8. S. Pan. handscn Chi c p p -o Ft. Madison 29. The nitrogen (amine) resin producing plants are: 1. -nrlin 2. Tn 1 P' 1 3 Vf- Madison------------------:----- DUP030049687 EXERCISES-UK'j 3-PART A-Cont. Ths "incite" acrylic resins (RC-900 type) are produced at: 1. Flint 2. Parlin 3. SSF Par I in Plant is the major producer of RC-6000 type "Acrylic" resins, Chicago Plant is the major producer of "Lecton" Acrylic dispersions and Parlin_______ plant is the major producer of Furniture flat resins. DU P030 049688 EXERCISES-UNIT 3-PART B Functionality refers to the number of rpa^finn in a molecule of a -^nr.ome-r Indicate the functionality of the following: I. Glycerol ^ 2. Ethylene Glycol_ 3. Pentaeryfchritol 9 / 4. Phthalic Anhydride_ 5. Urea 2 L r-K..1 .. The functionality of glycerol may be reduced by the mono glyceride process in which an oil is heated with glycerol. Catalysts such as 1. Litharge ov 2. Lead Xallate may be used to oromote this ester _______- Infc erec hange Using the following symbols show the following reactions dia- grammatica1ly: '' Glycerol - 1" Cil - rf Aa 'fit Pentaerythriofcol X/ Phthalic anhydride u a. Reaction between glycerol and an oil, IE + El --4 3 ER Reaction between pentaeryfchritol and an oil, J- A !-- ^ \/ Q t--- R -v- LI --~- Av A Reaction between Phthalic anhydride and glycerol. h 3 3. --c a . . W>K> -lrl d, Reaction between a Monoglyceride and Phthalic Anhydride. U- <? Hr p, u f- R L* J DUP030049689 EXERCISES-UNIT 3-PART B-Cont These reactions indicate that the alkyd resin reaction is mainly an esterification process in which a hydroxyl group and a carboxyl hydrogen react to liberate water and form 3. es , The F &- F Dept, makes alkyd resins by the fusion and solution__ processes. In the solution method the reactions are performed in the presence of a solvent . The fusion process requires an excess of phthalic anhydride to compensate for its loss or sublimation . Calculate an alkyd resin having the following solid and solution composition on a 100 gallon yield basis (a solution process is to be used) G.P. - 34.37, Oil - 64.07, Excess Gl. - 1.77. Solids - 837o Thinner - H-632 Calculate the theoretical acid -number at gel of this resin* 7 - 11.5__________________________________________________________ Prepare a formula for the above resin on a green sheet, using RC-311 as a guide. Calculate the theoretical composition of RC-311. % G.P. 45 ,407 7. Oil ______52,,5Q7, % Excess Gl. 2.21 Calculate the cooking solids (%) of RC-311 (Solution Process). 93.97, DUP030049690  EXERCISES-UNIT 3-PART B-Cont. LS_________ coded solvents have aniline points falling within f 1F of the center of specifications. These solvents are used to insure a standard degree of IS. id8? #12 establishes Master resin formulas and operating formulas. It also lists the items to be shown in the Manufacturing directions of the Local________________ operating formula. 17. ,:Lueite" Acrylic resins are Vinyl type polymerization formed by addition______ reactions. 18. Polymerization of acrylic resins is initiated by a free radical mechanism. Peroxides______ are commonly used to supply these free radicals. 19. final properties of a acrylic resin depends on the concentration of peroxide catalyst used and cooking conditions such as . temperature and percent monomer 20. These conditions are mors Important in the control of "Lucite" Acrylic resins than in the control of "Dulux'1 Alkyd 21. Hotebook information should be written in ink. 22. Record the subj ect of the experimai .t giving the code and the name of the product involved. 23. The record of the experiment should be sufficiently complete so that someone else can duplicate it at a later date. 24. All materials should be identified according to code and Serial Ho.______ The laboratory code prefix for a new raw material is B,,S. , ' DUP030049691 :s ~u a it 3- Conc Retore ail test data and state a conelusion______. __ a______cut any unused portion of a page and sign ant date bottom of page. A Are no erg.si-.res cf data, signatures or dates.. Corrections should be made by crossing out the original entry, leaving it legible . Pages are not to be removed.. entries on each page .should be witnessed by a person who has knowledge that the experiment was conducted on the When should the lowing personal equipment be worn as faty protection during a. Safety Glasses at all times________________________________ b. Face Shield When transferring corrosive materials. c. Gloves When handling toxic, corrosive, hot or cold d. Apron When skin or clothing contact with materials should be avoided...______ e. Arm Shields When working around hot or cold vessels All reactions involving hot resinous materials must be cerformed in. a hood The equipment must be set up so that if the following unexpect ed situations occur they .may be controlled safely: - a. Equipment breakdown c d. plugging___________ or______ condenser DUP030049692 EXERCISES-UNIT 3-PART B-Cont. A fire________ extinguisher should be close by the reaction apparatus. ` Condenser hoses must be clamped or mired to apparatus. Ail tonic wr certf j ivc. materials must be handled, in a hood. A safety shield must always be used. The thinning step must be carried out in a hood_______ The material must be stirred______ continuously during thinning to prevent foaming. In preparing (cooking) a resin, the following should be con trolled carefully: 1. agitation___________ 2. temperature 3. distillation rate In condensation type reactions,, the addition of water to the resir. cook should be prevented. If the agitation is turned off, the heat must be turned off also. To stare up the reaction again, start the agit ation slowly, increasing it to full rate, then the heat may be turned on. Describe the method of sampling an alkyd resin during the cook. The sampling tube must be of sufficient diameter to prevent excessive pressure build, up in flask, control pressure by finge: over an escape tube ginger should be released periodically to keep pressure at a level sufficient to blow cut sample and no r{io2r0.<> Precautions must be taken in handling monomers________ and peroxides in acrylic resin preparations. DUP030049693 Agitator Shaft jnHfl, (j Reducer Fitting L__For Inert Gas C <. Blanket . J /4 or 5 Bulb | lS -c ondens er H Type Water Separator ! DUP030049694 7 . | sr*-**~- ,/y-o- ffe "S 3< y^ CrX yO*,, /"f "Xy G-M3 = 173SX 3^-3 rr 2(M3 //~L = -3W X 3t- 3 - 1! . 1 | H - *- /K? =. in o hf< 0 0 Mr*' t>*f, oo (^--273 2-C&' -3 #-*- = /*-**/ VLj l S^Jo /03 -. 37 --~ ;; 3 m !->- = 2-0 . 7xc, > 3 60 '"7' r 2'0 -f- /o f S' x l . 1.1- l|; t "T" 9-3 a- - -- * ^ 0 -V (j. 3 a- 3. M3 /g o a X j<-t Hy . s j *9j ~ /y y / = . * *#5~ r go.gO -- 2-77 - zx * y-5" ' | (*^ l-*/> 5,rk) /*f 50 -- 4 0 -f -- > 0 *7 1 If *# 6 I'f 3 : j oo - y $ ---- * 2 r: /0O,(?o O CgS*j0Ly,- K ,, -* . 7. 1 /t? ix 'Bix .m ' 13 n ------ -- 3 3 W--, 5*7*3 * 7X4 r (MS1 3 r /f . H X /*.;?*- ^ r Sf'*f Tv /.* *<f 5~/|-43u = ix^fx. f'3W: T^C-e.- 9S7'i*x. acJU^x^ju <* r 3.31 (<vO />/ *5& V* $, ^c-i3E TL`77 X S'vjX " -`ISry ?3 ?J6- *f DUP030049695 ficJL Vur- . GP 3/* /^.~/ ' -4^.-1, tii C* crd. r^ th ~ ^ V'Q X J~?y ~ ^f (87C)(i^O }i~] x ^ ^ H , ,... M.BI I III win mm......I.........................Ill ju X l 3i>3 i 7'^ f7 /' A/cJvv Gp^ 3*.3 V7 ^ -- / 2..f a (r )\f)( '/DO - //.^ DU P030049696 fl. H-*) H-tC-^3 2-SVIs S*/*0^ _121ii- i"l ^I X?_c>3 ^^4 I? 3i- ' ? ~~VZ$~lri W-vT ~ 27 * I 7 tf<f. fc 1. X, o J - ' %H 2-Z. - (3 ,X s? - Jfi- -32 5V.J ^ ' xv jr.vT y~> G P ~ T7T71 ^ rs. tyS *j > / ^xi H-V s (g* -7Z. tz 2 * 2.1 / ^ ,} x ^ -* H-t. jy* g ph'L n*i^s 'T7?S XXJT v-7 3M X 2.vr^7 - 72 f ? 0. )av s^v c -lliii- _ ^.?o/e i w 3/ ' DUP030049697 UKIT FOUR General Enercisas on Codes consist of a line number r.I a Color number :nx. _spersIons are general formulating umber of products containing the following ns: AV/ --9685_ O O 0-^1 r-. Ko. of Products 4 37~'62i 57 13 820-50 e. ~3S CA-iOO** OQxl.OO 35 preference class for the following: Preference a0 32-5442 A 34-5824 obs.' 42-550 548-947 5? V\- A i.o` 9i.3-,,StO h. 32-5890 i. 32-5707 D j. MB-3475 m _ types of ingredients a a solvent type dispersioi naei 3. Solvent add!trues (Surfactant) DUP030049698 Uhl?' FOUR - Continued w * In addition > uuc fo Hewing ingredients may be used: ' Inhibitors or 1 .pjzrji.______ 2m.t.l.lr'y'-ts,.............. 3._...budy. agents. 7,. Cb ~0-0 N.i M tO dl Rr,^^S; or the pigment. the 3 classes of surfactants and an example of each. Class Example o-. -O ;-J ~ J Sodium olea.de b. cationic Lauryl armnoniutn acetate c. nonionic Glycerol monolaurate 9. .Describe the ^differences between a pigment particle, cop aggregate u:: .d a pigment flocculate XSiilSJiiJinm H oggregafe. :-LIlfhLSTMfcf;, Li' ng ..nrygfca.l....ri:c...a...J-^o^?trc>f..a..crystal a . firroi ?,,9..,c f. sarfc ic les_hs.l d . neg ether. by. . f3ghiilli2_UUi . &MS2&m^A .. cigaent..flocculahe..i^g^gre^gaf..,,^^ ..... ........................................ ...... _.... ................. ....... 10. The fineness of a dispersion depends on the parfinlp . ^ p~i dispersion. or and ^.n6 dg'zeu-. of ii The fineness of a dispersion may be reduced by the u-^air',~g ,rp O- pigmeuo ."ip,c . . .. or agp-yag^i~aof pigment Oc Lj To JbC. S-UtO * i ?U~ ,,, <i The types of dispersion, equipment or process used in the "" " "O "_ - arc I. millj 2. grg'S c:rg;T of PT ,t <7 _________________ processs i. LMi DUP030049699 UKZ7. FC'JH " Continued two 'O roll process, m- j l arm* ;' wr.: cause pigment cracking? PUT w- ::. ;Ls the moot econoaieal method : rise ,u: seen., and is used mainly to produce Trade tales................. . products ,, fro roll mills are need to disperse difficultly cisgersihla pigments in thermoplastic resins, .. process is now generally called in the t.i " " "> tad grind" process,, .7, Since shearing of pigments requires iiierabls ctacs .of heat work . a is generated during poll: by water is required. -- 0 __~J 'w.J ij (g. finished product settle p: 1 -vrrl v ... y Vi.w^loWi <>^iW 3mA, .. If settling occurs, the settled ____ giTTarov _____. and of 'Vtitss. 19 Flocculated pigments in a finished' product settle very rapidlya the eat formed is of large volixe and is easily ..dispersed info - the sr.pematent vehicle ! DUP030049700 UFTT FOUR Cont inued useable products from the stiond. poxtiti ox sGtitzling d______._______________ a C- JLo If C-- n co OdbCi'.- a sf.u j .,ocLocy particle size - _________ hc pigment in the vehicle or by ___ the pigment particie or 2. produce & flocculated pigmented dispersion. Far fact art s in paint are classed, as 1. Wetting agents or c.isp nrsieg ________ agents and f'Loc.ciil.at5,ng agents. A1 kyd res in s' act as wetting ag ent s, Oil acids are also classed as wetting ___________ cu. '.i t A Soaps are also used to disperse pigments. These may be added as such to the dispersion but zinc soaps may be formed during the dispersion by the reaction of zinc oxide with an High acid resin . The following raw materials are used as flocculating or antisettling agents ; show the name for the given raw material code; G 12_____Rove beer thin, G-292 Id-522 k so oil -u7.: \L dll Aiuxibr- The time of grinding is reduced by reducing the thixotropy or me di soars ..on. . DUP030049701 Up: IT FC'GR Continued fcnrtguerg the extent of dispersion of a colored pigment it. a vehicle lucreasesits ________________tinting strength. The rareness gauge is used to measure the degree c.: dispersion obtained by grinding. Th_ types oi viscosities possible in paints are 1 Newtonian 2 Plastic________ 3 PseudoplaStic__________ and 4 dilatant Draw a typical thixotropic Flow curve. ^-r / Flow // .- / iy C-.........................................................._ Stress Define Thixotropy Thixotropy is the property of a system in which an internal structure is temporarily destroyed by stirring hut reforms agam on standing._______________________________ Define yield value of a dispersion Yield Value is the nlnimn shearing stress which produces flow of a system. The inhibitor content cf a dispersion or finished product is based on a certain percentage of binder in the forts la DU P030049702 1U.0 d :s sre <? rraiiy added to the dispersion r cna oasis or cne pigment content in the -` S' I-.------w' u-... of driers is used to calculats or soiut: drier to use in a finished DUP030049703 UNIT FOUR BALL AND PEBBLE MILL DISPERSIONS -'..l aa ` a. bla Lilli ...aa cyl-lndrial ia shape and ..a.::::'. .. pother steal calls or porcelain ______ cr Flirt_______ pebbles or "balls" as the grinding media. Productian Mills ia the P & F Dept, are generally either 5 or_______________6 ___ feet in diameter. Lit conditions for the grinding stage of a "46 Process" dispersion are 1. all the pigment 2 all thinner except to wash mill 2. 5-10% resin solids______________________ , Steel Mills certain 40 _______________ % of the mill volume as balls arc a pebble mill 60% of the rill volts'.a as a all las. lassie Mills are usually lined with Force lain. blocks. Define the following: 1. Grinding Ratio The ratio of the percent volume of pebbles or balls and veils to the total cereatt volume of grinding charge cf the disperseon and percent volume of pebbles or balls._________________ ________'__________ _______ 2. Overall Ratio __Ire ratio of the percent ,lurae of pebbles or balls and velds to the osreart volume af the total formula and percent volcraa of pebbles or balls. 3. Cubic Foot Factor PourIs of overall charge per cubic fee - all space.____________________________________________________________________________ pallia ft :r lbs/gal x % overall charge ........................ " 100% DUP030049704 Z::l7:7 . 10UR y Continued wW -J -- .oio -;.s ths ratio of pounds of pigment: ?;?') lbs of solid J; freer,............ _...... ............ volarr of ebr - c~. _ .. -J . k ' ... J \I _ -r -'.-1' pebbles ot steel palls ia a 0 %, -1 'AV w' ^ ,,sj iC,,< ;,,ebl,,pp in a dll having a pebble charge pic p v'ole.o.e of charge ir. a orill eeat airing 40% steel balls 't:i a total vclcio cf 60% Is 80-24 = 56% . %-- Vp --^ P>1 Vj l * Pebble Mill, ..f..lr.et. and water cooled. Sol Steal Kill, v.:-lined arid voter cooled. ICG, a high ......solids res in rid otagSo Additional grinding is daffemale ............ the pigment,, since . . orratal................................................. f thirmsr frsa the dispersion y-j tlo renin esasas ..agglcgigratloa..... ................ of the pigment. __...A ,000............._ ..................to ___ 4_?,Q00 .............cycles Lc .gore-rally orAfielerl , redis ? a. a the hrg:.cti after addition of add and grind resin, ' DUP030049705 vr- - rm"ri": SmmS?ERSlC ball grind having the 'Cl rcqriri; g follow!rg conditions v n\ r\ 3X'::..cn c- BC-3117/3C-59G1 . -h * . ." r> ' c* -=.- O i ;g Solid Ratio -=48/52 t-aintaln ratio in every stage grind laird stage ~ 1100/ 1G0 Overall stage - 550/100 inimor - 200 of Grind stage DO -.... OV OD '--02*450.: " -v ---, .-Oh.- O ,070 :t 6.0% of binder < m^ .O rW.-. binder -00 0? ,, g w o w is '-a -i tv-t- so-. * '..ndirg Cycles - iS^OOO cycles me at eptirar grind ratio to obtain zzasdxsssi capacity with titfactory effisiensy ci grind* op are a green sheet feeroaia for this grind* ; V " :e a gallon nil! of thi... forsaila, basing charge and char,QSBO-- steel halls on infernalion on page 10-1-2 of F & F .end the fomals based on charge added, shew the charge halls and grinding cycles ate* at end of grind cycle amino end record fineness of grind* Specifications - Hi Ic Han * Saw -1 ns a-for anrt--rrif-7 DUP030049706 UNIT FOUR "47 PROCESS'1 DISPERSIONS The types of ``47 Process" equipment used at present are I top and .bottom feed units. The "47 Pro ana ______ as the grinding media. o. Define the following: Packing index is the P/L ratio at which the fully dispars ed pigment is dyrlamically packed. D o Pigment Volume Vo luma o f' the pigment in formula. C o i_jx cj i-i d \/ o X utiles \7,o luma of the liquids in formula d. p/b ratio is the ratio of volume of pigment to volume of liquid. e. Effective diameter is the mean rotational diameter or an average carbide in microns f. Sire Ratio is the ratio of affective diameter of the lairger particle to the effective diameter of the smaller 4 Sand/Base Ratio is generally 50/50 . q the bottom feed "47 Process" unit, the viscosity \J .ispersicn should be between. 100 and 1,000 The range of the normal grinding temperature of a "47 Process" dl S 'O 0' " s ~~ CVi is 120F to 140 * O.rr*- * 7. Diapers ion Base p/L should be 25 to OC 07 _ /o O , _. -.'w i-hCiX imma particle size for "!47 Process" is 30 microns C o _ i.G^i dl1*1 d- b. Iwl ... i-f dd O. S 0 d to produce a "47 Process" r} ~i e 73^ ion, based on a 2.5 gal/ hr on a 1/2 gal. unit, the DUP030049707 gallon unit will be '61.5 ).3 Micron are generally considered as "47 Process" calculations, iLWo-Sl o3UA, y/o i "47 Process" Dispersion should be and 30% by weight._______________. atio of dispersion vehicle solids to resin add ' ' w. 'w- fc* i .L U. *d*. u d. ^ --Vnished product should be less than __2_ to prevent flocculation____ ____ DUP030049708 AA Prco ..... r> . ^ I" h c.o A r cy vji V W . w A .... - *W .. ho tin C? A `-A? .PROCESS" DISPERSION c using y'J^Ql-A lusitiom ..u .Icvc Information;, showing the premix s geuomAly. chomi for "47 Process". mo 5: And In I he grinning room - annex. : '.Alter ry -Ay Process" grind or above formula m ..,.--; ioC Alls. Show the plent equivalent :e or your formula 9 using the scale'up factors .1 Proseg g " Alum units. Record all pertinent data ~S-m'. fVG^w*- :e m prm.h: 5 "47 Process " formulating e to crtum. cutI: rectory finenesss temperature .and loud mg' other Information which may DUP030049709  , i-LCCha S i ..ia `' :v aarr. cr _____, drapers.non 2. "-v2 browv '..1 1ad : break down of Lo o t process, and 3. '..La r:v:aaiaa.ai affective db..:a. aax of the pigraris used in 'if >`oaisf! diaper.. . ..u........ . s. ...Lorens , Toaxitaum size ' ao depends::.; -or. the finenessof the product desired. 4. This prccaoc requires a vehicle of .....low_____to moderate viscosityj usually below 300_______________ centipoises. 5. Define Hydraulic Shear is the transfer of shear forces from a liquid to a solid body, * 2 * * S Direct Mechanical Action is the transmission of shear forces through partlaLe interlocking. Coarser I? art role .Attrition, is the shear force exerted by roars or a a ' si a. on fr./r partial"", 5.., 2. ssaa ratio cf 3/1 is required for development cf coarser particle attrition. /. baa three classes of pigment systems are 1. Balanced system 2 - 'dacess Fine system 3 . Excess Coarse system______. 8. "10 Process" Dispersion P/L Values should be in the normal range (between 1.. 0________ and 1.2$s) . ' S . live vehicle solids should he10______________ to 30% by a eight and veal;, is v;.. .osity should be between ,,a. 1 3 ._5___ ocices . 0.05 0. Let down vehicle solids so Dispersion base vehicle solids ratio should be lass than 2j I . DUP03004971 0 !../ r 'n a /. p > :sssn grind is dependent on the _ of the pigments or the which can not be dispersed r.rw frier: erferlaticns are based on the volume of figments and liquids in. the vehicle, figment Packing Index cafeuiateons can he made by the computer. Using the form for computer program ML-104$, cotann from the computer center the packing index data from she feffcuing pigment combination: f-iO U-165 V!~10C5 - 2.5 5 5 Op' h- ,, V p. Sea attached paper . 123 - 21.1 Calculate the liquid grinding portion based on total 1rgnentation above, using th w lowing liquids: 1. H-632 2. RC-539 . 3. Ii-555 4. VE-1833 i see sttached 5. VD-5822 H-555, VH-1833 and v'3-5622 added at the following percent of total pigment by xoaight. H-555 - 0.3% vlf~lf33 - 0.45% VD DUP030049711 /. 15% vehicle p c Lymer solids n C-* Cl* poses sii5h appropriate DUP030049712 "49 PROCESS1* j 1. The operation of "49 Process" is by mechanical dispersion through the shearing forces developed by mixing ... . with nitrocellulose fibers or vlnvl resin particles acting as ....gxXnMm_________media. 2. Upon completion of the dispersion active__________ solvents are added to dissolve _______ the nitrocellulose. 3. The two types of first stage "49 Process" Dispersion are ,l46" __________ Process and ________________Process. 4. The following wetting agents may be used to obtain minimum flocculation - in the first stage: a-....._pipwnj?il___.____________________________! b*__..Sypithgt.ic.....r-gs.ins:_____________________ . ..... c-____Natural gums, and..resigns-....................................... h. Refined Raw oils ___________________ ___________ . _____________. e*___Spg.fi.jaJL,,age.tLt.ff, CHr-im. (g'613.) IS.t.4228_ 5. Give the procedure for making a "49 Process " dispersion using a "46 Process" type first stage. { DU P03 0049713 W-612 W-622 W-630 W-679 W-697 Green Gold Y-562-D Molybdate Orange Ferrite Yellow Orange C. P. Chrome Yellow Lt. Shading Yellow i FP-Q1-C-3 | 8/12/58 j i The following laboratory procedure may be employed in the development of laboratory formulations similar to the above: 1. Select the diluent/alcohol system for minimum pigment flocculation for the particular pigment. 2. Charge these into a quart can withholding approximately 25% of the quantity available from the formula. 3. Add all the nitrocotton which agitating. 4. Add the pigment slowly while agitating. Additional quan tities of the liquids may be necessary in order to main tain the desired consistency which is similar to "oatmeal" and very thixotropic due to the presence of the nitrocellt lose fibers. The heaviest consistency (but still maintaining agitation in all portions of the mixture) is desirable in order to develop the highest shearing force and maintain good contact within the pigment /fiber mass. 5. If the desired consistency is obtain tinder Step 4, agitate 3 hours at 450 RPM. 6. Stop the mixer and add all the active solvents and remaining alcohols or diluents. * 7. Agitate 1 hour at 450 RPM to completely dissolve. (Solution generally occurs in 5 to 10 minutes, however, see section under Plasticizers). 8. Add remaining ingredients such as oils, resins, gums, plasticizers, etc., and mix 1 hour at 450 RPM to com plete the batch. ' The use of a cover over the can during the first portion is recommended in order to prevent excessive solvent loss with subsequent change in the consistency and rate of shear. The friction effects from the high intensity shear developed will result in a temperature rise which should not be excessive for the above mixing cycles. However, surveillance should be maintained so that a temperature of 50C is not exceedecT ` 1" 1! 1" DU P03004971 4 "49 PROCESS'* V") _, ' ; . 6. Draw the power curve for a typical "49 Process" dispersion. }j 1 o DUP03004971 5 )' "49 PROCESS" 7. The more aliphatic, hydrocarbon solvent used in vinyl dispersion the more fibers_______will be available for dispersion in the "kick-out"._______________ state. 8. The lower the molecular wt. of the vinyl resin the more aromatic hydrocarbon diluent may be used. 9. To determine the minimum flocculation point required for the first stage of the dispersion, a P/b ladder is made and the viscosity of the individual samples are determined on a Brookfield Viscometer. The viscosity is plotted against the P/B ratio and the lowest point on the curve represents ^ the minimum flocculation point. 10. It may be impossible to restart the mixer if it stopped at the end of the loading operation or early in the dispersion stage. Additions of pigment should be made while mixer is running. i ' \ 3 - ! ! DUP030049716 UNIT FIVE - Exercise 1 1. The three general film formers or binders used in Trade Sales Finishes are 1. nils ___________ 2. Alleyd resins and 3* Latexes ........ ._ j '' 2. "Lucite11 ' Wall e Paint .- is the biggest selling type of trade sales product manufactured . by the F & F Dept. 3. Another large volume type of trade sales product is the 310 line outside House Paint. It also uses an Emulsion/latex_________type film former. j 4. Oil based paints are used in exterior ________ paints, j 5. Outside trim paints use long ' oil alkyd ' '' ' ' '' resins. ' i 6. The three gloss level finishes used in interiors are 1. j Flat -- 2. Semi gloss and 3. High gloss Where is each used in a house? 1. ' ' . ` . and 3> Woodwork (trim) ......... Walls 2. Walls or trim |` j 7. Give 6 general requirements for a trade Sales Product. ` ' - Foolproofness .._________________--.; _________________________-- 2. stability ... .;,;.................___.................................................................?____ 3 - .Ease .Qf-aKP-ljcAtioa___________________________--_____--_________--__________ 4. Uniform film appearance ........................................' . . . . .... ' ....PQ.sit.te...dxy. --_______________________--................ Odor 7. Fire hazard ` _____________________' ' 8. A Trade Sales Paint should after several years storage have satisfactory 1. dry ________ and be free of 4. 2. viscosity skinning 3. settling____ .. '' DUP030049717 UNIT FIVE - Exercise 1 - Cont.i 9, Some of the properties required for various types of maintenance paints are 1. spppd nf resistance and 3. .moisture dry, 2. .chemical. i resistance. 10. The two types of finishes used in the Automotive industry are ...'...Lacquers _- .11 The Lacquers and .12 The 'Luc it e1 Enamels .. and____KP.affa.is....---....................................... used are tl DucoH used are 1. "Dulux" 2. "Dulux 100" and 3. thermosetting Acrylics Two of the most important properties of Automotive finishes are 1. Durability and 2. appearance. 14. In an Automotive finish; the color and gloss retention ' are two important appearance ___________ properties. 15,- Metallic than solid colored finishes are more flashy colored finishes. 16. The three kinds of undercoats used in an automotive paint system are 1. Primer 2. Primer .... surfacers . 'V and 3 . Surfacer each in an Automotive. Finishes System. Describe the function of . Printer is used to provide an adhering surface to the metal substrate upon which a surfacer or topcoat can be applied. Surfacer is an intermediate coat between primer and top coat to promote adhesion between primer and top coat. Primer surfacers are single coat which act as both primer and surfacer to promote adhesion of top.coat to metal substrate. DUP03004971 8 J 2- i UNIT FIVE - Exercise 1 - Cont. 17. Automotive primers are generally applied by dipping sheet metal or sprayingbodies__________________________ Automotive topcoats are applied generally by spraying 18. Name ten types of film formers used in industrial finishes and the types of end use for each. Film Former End Use 1. Nitrocellulose lacquer Furniture 2. Modified rosin varnish Can Coatings 3. Alkyd resin Signs 4. Alkyd/Nitrogen resin Metal cabinets 5. Thermosetting Acrylic Refrigerators 6. MLecton" Acrylic latex Wire Coating 7. "Teflon" Fry pans etc. 8. Epoxy Washing machine 9. Polybutadiene resin (Budium) Can coatings 10. Styrenated alkyds Furniture 19. Name ten different kinds of industries using Industrial Finishes (See Industrial Sub-Classification). 1. Insulation____________________________________________ 2. Industrial Machinery_________ _____________________________; 3. Electrical Machinery______________________ _______ 4. Farm Equipment_______________________________________________ 5. Can Coatings _________________ '_________ 6. Coil Coatings_____________ _________________________ . 7. Sign Industry 8. Wood Finishes ______ ___________________________________________ DUP03004971 9 ' : v UNIT FIVE - Exercise 1 - Cont. 'r;-'' 9 * Agpl lane a. .Finishes. (Vending-Machines)--'-----------_ 10* Furniture (Metal and Wood) ........ -.....................; 20.. Name ten kinds o substrates used under Industrial H:?;v' , topcoat- finishes. v'r'"'"' 1> ..Wood- .: . . T -v.;-: - :. ; ;Y : y ` 2* ! Wire - Copper .. ..................... ..... ...... > 3. Phosphate Coated steel....... ............ 4. .... Alodized aluminum....... ...................... -si:' JBtare steel......................... 6. Paper .......................... ' - 7/ Plastics , y : . *. .V ` 8. Prime coated materials ;. J . Galvanised steel ............... ...... : ', * \ 1 t "* f " ! ' ' , 10. Tin plate (Temeolate^_____________,__________ . V- ' '. . '' ;.r, 'V . ..." ; ' ... . ft ' , . 1 - r'.' ' . '' ' ; - . i V. c Name ten methods of application of finishes. 1. Soravine V:- 2. Flow coatine '* '* :: /. ; / ' ` '' ;y :3 . ` , r " ': :: i f - y.vi J i - . 3. Dipping.. .......................... /T ' 4. Electrostatic Spray .'' 5. Stencilling (Silk screen) 6. Rollercoating ' 7. Ternespray ..................... ..... ^ ' ' vf?; / " ^ ' >;v`. `1 v . 1 8. Brush 9. Doctor Blade 10. Electrodeposition , . - ' * . . : " ;'' ' yip- ; ; ' - 21. Name five, general properties which Industrial finishes . : ! must have. v. - ' ' " ' .. - .. -, . 1. Corrosion Resistance ;:Y v . ' : ... ' - * . . *. " . 2. Moisture Resistance ; ! : 1' r' ' '' ! , ..V;. -'.-^---jj : , ,, - r--' ,A| ......... . DUP030049720 UNIT FIVE - Exercise 1 - Cont. SV 3. Initial appearance____________________ . . . ;4* ,. Retained- aBP.sar.aRC.fi________ . ' ':::f . :- 23. Match the type of product with the special property of paint required. I. Refrigerator a. Heat Resistance (3) 2. ; Washing Machines 3.\' Stoves b. Non toxicity c. Alkali Resistance (4) (2) 4. Tin Cans d. Non-Sticking (8) 5. Signs ' 6. Aluminum Siding 7.;/. Wire ^ 8. Frying Pans 9. Wood Furniture 10. Fluorescent Lamp Fixture e. Grease Resistance (1) f. Light Reflectance (10) g. Beauty (9> h. Formability . (6) i. Electrical Resistance (7) 1 Outdoor Durability (5> DU P030049721 UNIT FIVE - Exercise 2 - Continued AUTOMOTIVEAND REFINISH FINISHES 10. 202 Line N.M. 4. "Duco" Lacquers use single pigmented tinting Lacquers in their formulation. 5. Define the three durability groups: 1. Group I shows no appreciable change after 4 mo. and good durability after 8 and 12 mo. j 2. Group II shows more change after 4 and 8 mo. exp, than Group I but equal to Group I after 12 mo. 3. Group III shows excessive change after 8 mo. exp and acceptable durability after 12 mo. Using 246 Line formulating practice answer the following problems and questions: 6. 246 Line products are formulated at 30 to 40 % solids and at a viscosity of 35 to 45 seconds ini a number 15 Cup. 7 246 Line products use 253 ______ Line single ppLgment tinting lacquers. 8. A blue ''Duco", 246 Line product was color matched in the laboratory and found to have the following pigment composition. W-50 - 58.37. W-505 - 14.57. ' W-312 - 18.17. W-222 - 9.17. io 'c t ;d 7.~" Since it contains W-50, B-630 was added to adjust for hiding at the rate of 1.75 times amount of 253-050 used. Calculate the ! 100 gallon formula using 253 Line Tinting Lacquers adding any modifiers required. J DUP030049722 UNIT FIVE - Exercise 2 AUTOMOTIVE AND REFINISH FINISHES 1 The general types of Automotive Finishes are 1. "mipn11 T.aoqnars ' __________ 2. Dnlmc__________Enamels. 3. Unci tjR 4. -IlDuluxiL Acrylic m .Lacquers... Enamels and 5 * Thermosetting_.Acrylic. Enamels 2. Show the type of Finish for each of the following lines. Lines Type of Finishes 1,93 Line "Dulux'1 .ftfcd- Refinish Enamel 2. 246 Line J'PucaV. ..Refinish Lacquer 3. 938 Line -Acrylic... thermos ett ing.. Enamel 4. 794 Line "Dulux 1QQ" Automotive Enamel------ 5. 867 Line 6. 780 Line -!?,Lucit&l,...Acr.y.ii<r.Lacquer_____ -'Dulux'..1.Automotive Baking .Enamels 7. 94 Line 8. 766 Line . ,,Dulux,?-.lQO-....Aul;omQtiyeJEnamel. "Dulux 100" Automotive Enamel 9. 942 Line 10. 253 Line "Lucite" Acrylic Lacquers '! "Duco" Automotive Lacquer . Indicate which o.f the following lines are Metallic or Non-Metallic. Circle applicable abbreviation 1. 772 Line 2. 181 Line ' ' - m. N.M.;v -^5 3. 93 Lirie ; 4. 794 Line , - M. (n Tm?) - M. 5. 798 Line / ^ N.M. -(mT) 6. 863 Line ' : 1 N.M. -@) 7. 877 Line ; ' ! N.M. 8. 945 -Line- 9> 930 Line `'"7 N.M. -(m) N.M. -() DUP030049723 i : /.; .; UNIT FIVE - Exercise 2 - Cont. ' ; . " / AUTOMOTIVE AND REFINISH FINISHES 9. Give the two basic formulating rules to obtain a specific `/J //-color. ' JL___veep the number of tinting lacquers tn a minimum. JL___Do not..blend..eompl lraenfcary ff>l nm .... .i- < V ;- .7.;? 10. 246 Line is formulated at i .s to 7 n mils dry hiding. / 11. The amount of B-630 which can be added should not exceed 4 ___________ times the amount of 253-050. 12. A 246 Line product requires the use of W-381, W-382, W-300 , and W-222 as 253 Line Tinting Lacquers. Describe procedures / : necessary to be sure these can be used in a Government Specification product. 1* Check Government Specifications. 2. Request permission from Flint Development Laboratory, ' ; y.;'n ----- --------------- . . . .f. . ' , ; . /J, . ' ' ;/ / to use pigmentation. v>`r ;/ /' " ' ' X-' > i DUP030049724 UNIT FIVE - Exercise 2 - Cont. I AUTOMOTIVE AND REFINISH FINISHES 13. In order to obtain proper color matching in the plant, the amount of 253-0527 required was 5.8% of the total formula. This percentage is over the limiting amount in the Formulating Practice. Consult the Responsible Plant or Development Laboratory to obtain permission to use this amount of the pigment. John Marshall of the Parlin Plant Laboratory is the Formulating Supervisor responsible for "Ducc " problems. 14. 246 Line Dark Greens contain 10 % or less of 253-050 15. 246 Line Vehicle has the following composition. 1. PX 2. RL-233 3. HE-111 4. H-116 r.V ('. 1 - ;. I i DU P030049725 UNIT FIVE - EXERCISE .3. "DULUX" FINISHES . ' !! ! X. 93 Line is a line o "Dulux" Enamels for . Refinish oil ja&x*. trade.. dry 2. 181 ____ Line is the Metallic line similar to 93 Line. . 3. What is the durability required for the line? r.m..p t t r hoM-ar 4. Flint is responsible for the line. 5. STPi #74 covers testing of 93 Line. .6 93 Line is applied by ^ 32*21___________--- ............ 7. W-323 . W-800 and JtMl. are bleeding pigments. 8. W-622 Molybdate Orange may be used in Olive Greens but flooding must be checked. 9. The vehicle for the 93 Line is RC-3179/RC-314Q. .10 H- 257 and H.-.325, ____are the solvents used in 93 Line. .i.iij 11 93 Line is packaged at 50 to 60 secs. in a Parlin #10 cup. .12 H-172, VD-5822 and H-173 are rnbal1 -Lead. and Manganese driers, respectively, used in 93 Line. ' 13. All 93 Line products are reactive -with ' I zinc. i 14. A 93 Line product was formulated to a standard using the follow- ' .vV' *v '' . t v . ' Formulating Table No. 84, FP-06-86. 42-655 42- 300 42- 225 42-5043(H) - 37.2 4.4 1.5 6.9 ... 30.0 76.5% ; 4.9 0.7 17.9 iooTor; -' 'V.'l - \ : '........ ...... -................... ~J. - 7. '' \ , . '- ' ' ' i' ' \ ^ . 4 V DUP 03 004 9 726 o> r. UNIT FIVE - EXERCISE 3 - Cent. 15. a. Calculate the percent of each pigment in the formula. b. Calculate Volume Solids, Figment Volume, Weight Solids and P/B by weight, see separate page. < i ' ;i 16. 780 Line quality is a blend of non-drying ... __________ i alleyd, .drying..... ..oil............alkyd and nitrogen resins. 17. It is intermediate in quality between and conventional ''Dulux" Enamels. 7Q4I ' Line j 18. Name the properties which must be checked when developing a 780 Line product. 1, Fading 2. Chalking ....... 7. Rl ead 8. Hiding 3. Checking........... 4. Bronzing 5. Blistering 9. ..Initial .g.loss ..... 10. Bake .discoloration ..... 11. Color drift: 6. Spot sensitivity 12. Flooding 19. Indicate the baking schedules for the following baking band prefixes': Baking Band Prefix Baking Schedule ("Color} 1. A ; . . _._4Q' x 99r*V 2. F . ; . - 901 x 300F 3. .G ' ./ \ 20' x 250F 4. k . ' .. " 30 1 x 25GF '5. M ' ': ' 30' x 225F 6. N 60' x..180F 7. o 30' X..250F ...... 8. w. 20' x 300 F 20. 780 is generally sprayed at viscosity of 18 to _______l ' 22 seconds in a #4.. ............JFord__________cup. DUP030049727 UNIT FIVE - EXERCISE 3 Cont. 21. In shading, select the tinting pigments which will require the least_____ shading to obtain the desired color. 22. Give four basic formulating rules for color formulation. 1. Keep the number of pigments to a minimum 2. Do not blend complimentary colors. 3. Do not blend colors with complimentary undertones 4. Do not use lightfast pigments to tone fugitive colors 23. The two blacks and two whites used in 780 formulations are: 1. W-123 2. W-13 3. W-224 4. W-225 24. W-13, Lithopone , is used only to tone , . reds and maroons darker than W-862. , 25. W-123 is used at P/B of i 20/100 or ___35/lOQl . 26. Determine which P/B Ti0 should be used with the percentage I of the following pigment combinations: | W-224 - 0.5% W-630 - 1.0% W-312 - 2i0% W-123 -96.5% Y7W~"~ T07100......... . W-785 15.0% W-519 2.0% W-225 1.0% "p7b ~ 3571001... DUP030049728 UNIT FIVE - EXERCISE 3 CONT. 27. W-224 has a brown _________undertone. W-225 ..lampblack has a blue______ undertone. 28. ......45...............- ,-..1224______-- is used when less than 0.5% W-224 is required. j 29. 0-780-57625, Green ''Dulux" Baking Enamel, use's 42-785, 743-123', 743-612 and 42-225. a. Which pigment is used outside formulating practice? 74^.619 b. What properties are affected by the above pigmentation. Bleeding, low hiding, expensive, improves durability. 30 What is the effect of adding W-582 at a rate exceeding 50% of the pigmentation? Increases mixing time and color drifts. 31 Give good and bad qualities imparted to a finish by the following: , Good Bad . i* w- 382 &..lighifaaflraag____-Expengiy.fi............ . ..Non..bleederHmnidifcy-color dril V 2. W- 300 a. Brighter color.....................-Cfllor...drifts b. Gloss Retention_______ Cost 3. W- 819 a. Lightfastness Expensive ' a\. 4. Wr 862 b. Non bleeding Hiding a. Durability __________ Bleeds b. moderately priced - ' Alkali spot resistance L DU P030049729 UNIT FIVE - EXERCISE 3 Cont 32. Whites must be toned with lightfast pigments such as W-505 MonastraX Blue . W-785 Monastral W-630 FerriteYellow ____________ green or 33. At least two . ' toning pigments are required in all white' enamels. ' 34. Give the resin combinations for the following qualities: a. 0 - Bake b. G - Bake c. American Motors 1. RC-3113 2. RC-3126 1.RL-3141 2.RC-718 1, RC-3113 2. RC-305 3. RC-731 3.RC-731 35. 1 % VH-5379, Silicone 3. RC-718 4. RC-731 must be added to 100 gallon formula. 36. What does VH-5379 do to a 780-line finish? Adds good working propsf such as flow, sag resistance and gloss. 37. What is the purpose of adding H-669, Triethylamine? To improve gloss and hardness stability. : 38. Describe the 5/50 rule as it applies to 780 line. . See next page. * 3v. STP 59 is used to control 780 line products. 40. Write up a 0-780 line formula for Chevrolet Truck, on a green sheet, with the following pigments: 743- 123 42- 686 42- 622 42- 224 65.7% 33.3% 0.7% 0.3% - P/B of 35/100 ' ^ :~l"0Ty7TO--- : b. Show the items required by FP-08 Sections 24, 25, 26 and 27-A. See attached page. 41. The plants have complained that a 780-line product i s too low in hiding and W-123 must be added at a P/B of 65/100 Calculate the values for the resins shown on FP-06-75 for this P/B. - SC-3126 - 41*5; RLr3113 - 47.5; RC-731 - 41.6 DUP030049730 UNIT FIVE - EXCERCISE 3 - Ccmt. 42, KW-8925 is a less expensive pigment than W-81? and experiments have indicated that it can be substituted for W-819 in 780 Line products. , permission to use KW-8925. Who would yoii ask for .| [ Permission to use KW-8925 should be obtained; from '| W. P. Colio and Flint Development Laboratory!. 43. A product is developed in 93 line which requires W-686 Chrome Yellow. What approval is necessary to use this pigment? None r o DU P030049731 '.j; ' >. .r-* ' UNIT FIVE - EXERCISE 4 , 8tLUClTEn LACQUERS AND ENAMELS 1. The name of 867 line products is_ i&fikjGio ssjSiermddFlaw. "Lucite'1 Acrylic Lacquer _______ .2 867 line contains a high viscosity grade of__Cellulose Acetate Butyrate . It is used to control Mottling 3. 867 line lacquers should not require polishing for at least twelvemonths Florida Exposure. 4. 867 line is tested by STP 43-B 5. These products are formulated at 33 ___to 34 % weight solids with a package viscosity of AO to 80___secs, in a #i0 Parljn cup. 6. These products are applied by sorav They are reduced with a "Lucite11 thinner to a viscosity of ____AO _to 45 secs. in a #1 Zahn Cup. 7. They may be buffed or obtain optimum gloss. bake . sand baked.. to 8. 867 line Metal lies are formulated with Single Pigment tinting lacquers and Metallic (Aluminum) Tinting Lacque rs. 7 JLinp. ifift. 9. 867. 0105 is the recommended Aluminum Paste to be ' used. / ' ' 10. Hiding is adjusted to 2.4 to 2.8 Mils. If the hiding is at 1.8 Mils. * how is the hiding adjusted? with the appropriate --i'V balanced clearly specified on fnwmila ^rH 11. m. 2115 is used to promote* ; wet color stability< DUP030049732 UNIT FIVE - EXERCISE IV-Cont. ltLUCITEtl LACQUERS AND ENAMELS 12. G-401, U V. Screener, is used to improve the resistance to checking. 13. The three classes of Metallic lacquers are 1. Low 2. Medium and 3. High containing 1. 0_____________ to 8 %, 2. 8 to 50 % and 3. , 50 to 100 % Aluminum Tinting Lacquer to Total Tinting Lacquer Content, respectively. 14. Give the general rules for addition of G-401, U. V. Screener, 1. Add TL G-401 on binder solids to all colors except v Maroons, Reds, and colors containing hvdrous iron_ oxide 2. Add 1% G-401 to all colors containing 1-10% hvdrous iron oxide,. I 3. Add no G-401 to all colors containing morel than 10% hvdrous iron oxide. 15. Following the shading of a low Metallic "Lucite'* Lacquer, using single tinting pigment lacquers, 25 j% of RK-3168, 'I based on the amount of lacquer, is added to tfcle development. ' j 16. Low Metallic 867 Lacquers should have 33 to j 34 % solids. Solids are adjusted with a 2/1 blend of H-30 / H-79 , 17. All 867 line products are doped with ___0,13% of VH-5379 18. Low Metallic Lacquers contain no high viscosity CAB. 19. High Metallic Lacquers contain 40 % RK-3158 of total formula. 20. High Metallic "Lucite" Lacquers use RK-3172 to adjust hiding. 21. A mill base formula is obtained by using the FC-11 computer program. , DUP030049733 u n it FIVE - EXERCISE IV - Cont, ; 'V "LUCITE" LACQUERS AND ENAMELS .22 Give the binder solids of a high Metallic Lacquer, Jf AJ.K i , r.-sis G-522 H-654 7-9% 11-13% 27.3-24.5% *;/.. . 23. The vehicle of 867 line is composed of the following: 1* Acrylic solids 2. Santicizer 160 .... ...................... 3. Cellulose acetate Butyrate 24. Silver formulations contain 5% 901-2115 fortifier to improve check * resistance. 25. An 867 line product shows 2.4% 901-253, plant experience has indicated, that an additional 2.0% is needed. What must be done to revise formula? Approval of Flint Development Laboratory is 'g-^^uired before revision of formula as it is outside of 5/50 rule. 26 Using the nomograph on Page 8 of FP-867 determine the amount of RK-3172 to be added to a factory batch of 867 line lacquer which initially had a hiding of 1.5 mils. 75 pts/100 pts unadjusted ; ': " lacqiiei| 27. Define 938 line. 938 Line enamels are non metallic baking enamels ' 28. The 938 line vehicle is composed of syt-rpn*> Arryi ir. polymer modified with Melamine Fnm.aldhyd * r^ DU P030049734 UNIT FIVE - EXERCISE IV - Cont. ,lXUCITElt ^LACQUERS AND ENAMELS 29. The following are, the general properties of products in the 938 line: 1. 2. , 3. 4. Color change________________ ________________ Alkali spotting of Chromes_________ ____________ Bleed^________________________________________________ Hiding deficiences______________________ ,______________________ 5. Color drift___________________________________________________ 6. Low - Initial Gloss______________;________________________________ 7. Reactivity of chrome pigments with catalysts. _______ 30. The minimum bake for 938 line is 30*x j 250F 31. Minimum hiding of 938 is 2.0 mils. 32. Define Group I and Group II colors. Group I - No blistering, checking or loss of film integrety after 24 months Florida exposure and no color change or significant chalking after 9 months Florida exposure. Group. II ~ Same after 24 months Florida exposure but, moderate color change after 9 months exposure. 33. The following pigmentation has been shown to give a . satisfactory match to a standard. Determine Whether it _ meets the formulating practice for D-938 line for American Motors. If not, in what way is it outside of practice. 909-630 - 52.0 909-630 and/or 909-582 909-582 909-224 - 31.1 9.3 are not used together. ! '' Either <1*09-630 is used 909-785 - 5.9 with W-' >05 or 909-582 is 909-124 - 1.7 1TO70 used wit:h W-687 .. \ DUP030049735 u n it FIVE - EXERCISE IV - Cont. "LUCITE" LACQUERS AND ENAMELS What deficiences will this pigmentation have? 1. Gloss retention \ . : .' 2; \ Alkali: Spot Sensitivity . ' ' ' . v' : ' -v'-' ' * Give the theoretical composition of RC-6025 and RC-6031. RC-6025 S ' . MMA 2-EHA HBMA MMA - - 30.0 26.4 25.0 16.0 2.6 RC-6031 " ' S 17% MMA - 26 2-EHA - 36 HBMA - 18 MMA -3 ,, >, n;. The viscosity of RCr6025 is wto . Y and' of RC-6031 is 0 to Q . To use a resin blend of RC-6031/RG-731 of 78/22 in 938 what must be done? Get permission from Flint Development Laboratory to use this blend. What precautions must go on the formula when. - 1. An iron blue is used and 2* H41 is used at 3.5% of the formula. } 1. Caution Contains Iron Blue ' V. Color Drift: Wait 15 hours or longer after.baking-hefore- Compairing to standard for colors. - 2. Do not use more than 3.9% of methanol on total hatch, weight.. The maximum W-224 allowed in manufacture of a B-938 line product is 7.2% 'when the formula amount is 4.8% W-224 Carbon Black .32 5979 is used to improve the mar resistance of D-938 line products.. / Why is H-41 limited to .3.9% of the formula? It is; limited to 3.9 & because at 4.0% or above products require . a methanol sticker on containers. ' ...' i '6 t*. * ; DUP030049736 UNIT FIVE - EXERCISE 5 INDUSTRIAL FINISHES 1. 707 line is used for General Industrial Trade. 2. It is intended for ' Metal ' fu' r"nn' iture1 I ni - - use. It bakes at 30 x ; . . 300 F. ;- 3. It is applied by spray over baremetal primers 764-29006 or 828-011 . or baking j 4. The following pigments are alkali resistant in 707 lU-ne* 1- ......JJ,=l 30Q.,______________VL?.55Q. 2; U-31 7 3. W-355 W-559 . .. .. W-785 i. 4. W-362 .......... W-608 ...... W-818........................ .........._ 5. W-383 ............. ...... W-612........ W-819 __ .............................. 6. W-393 ............ 7. W-630 8. W-505 ............ 9. .... W-514________ 5. The vehicle for 707 line is a mixture of RC-305 and RC-718 . 6. Flooding may be reduced by adding up to 0.4 of VH-5379 . 7. Up to 0.9 % of 732-912 may be added to provide adequate Mar____________ resistance______________ . 8. Using Table #51, FP-06-53 dated 9/20/67 prepare a formula using the following pigmentation: (Use - Low P/B White) 42-630 32.8 42-362 28.1 42-224 7.1 42-355 0.4 732-943 31.6 (see next page) 9. Following testing the enamel, it was found that additional mar resistance was required. If the maximum 732-912 is added, what amount should be added to the formula. 7.9 Lbs. DU P030049737 .{p i--Pp UNIT FIVE - EXERCISE 5 - Cont. if- * 10. Calculate gallon weight weight solids, volume solids, P/B r. T j.i . ` and pigment volume of your 707 formula. See attached page 11.; '752 line is a High bake__line for 700 Industrial ; 11 : Enamels. ' ' . . rP'' 12. Indicate whether the following resins are Alkyds , Nitrogen -o .j-' l ~ .mm V. h p -'<H ;|{- resins or Epbxy resins: 1* RC- 483 2. RC- 305 Alkyd Alkyd 3. RC- 731 Nitrogen 4*. VG-5924 Epoxy 5. RC-3108 Alkyd 6. RC- 718; Nitrogen ; I i '! 7. RL- 670 8. CP- 110 Alkyd Nitrogen :i;'K *l' P' i 9. RL- 495 .10 RC- 262 Alkyd Alkyd r'SSjT-Ci;mm !.;pK\pip ,, ) i US: . hfM . ` i w tv MY pp: ;} ' ii - pi; ' 'jA'-'h : .Y- ? ivfc! ; p. \ ft . ` iitifc., `t.\-i ,,P; Yt y ^ *. m`V: *$ -S'!-:"' iVt.lS;{.i: : rp, PPP p " T' : Y;' s .I--S ') !<.. liY 'ir$ i. 13^ Match the following intermediates with the property they. produce in 752 line products. 1; Improved Hardness ` a. RL-495/RC-731 (4) 2. Retained adhesion to zinc b. 732-912 ' *3-. Maximum Heat Stability c. VG-5924 4. Maximum Durability 1 d. RL-495 (6) ( 2) (3) 5. Reduced Gloss 6. Mar Resistance e. 32-17980 f. CP-110 (7) < 1) 7* Abrasion Resistance g. 32-5297 < 5X- ....., :rM r! isr . DUP030049738 UNIT FIVE - EXERCISE 5 - Cent. 14. FP 780 should be used as a guide for pigment selection / A;: 'i'> ' * r , ,* 4 , 1 in formulating 752 line exterior enamels. i : . . . 'Mvf- ' 1-r- i ,1 ' ; *. -1 j; 15, 732- 943 Xf- ;:;1; `1 *i-:. . ;& ! ' ^ ;i 16.. Give the is used Si ths white dispersion for interior use. " ` ` '' ' . i two white dispersions for exterior use. Indicate *%'L ; ! - Y;\ \ which should be used to give maximum gloss by using! the figure (1) '! ; 'r:.f '' : 'f ' ' . .' and which for resistance to pigment settling by using the 7; j; :> ` \' f ' figure-'(2)^i:-1:';-!: ; . ! " V; ' V'; :(1) `'.V-.; / / 42-185 v (2) -t i. fjll 17. Indicate .for what purpose each of the following Modifiers are . used. v: - ' iyW.r-.A.WV'^ If'vV, ; 'y , j , ./ 1. VH-5379 2. T- 8805 < b) (e ) a. Flooding and silking resistance b. Sag resistance w:; 3. VH-5324 4. VH-1260 <c ) (a ) c. Frosting resistance d. Aeration stability Ifi 5. VH-7552 <d) e. Reduction thinner 18. The minimum ratio of H-12 to nitrogen resin is as p*-a % *Uivy `-'.Vi 19. to - lQ.fil.Jit.8. In formulating a 752 line product, 300 grams of RC-^62 was used, vit[ '.{ " . ';'i r^r:j` A w`; k-i'i 20. to promote maximum viscosity H-669, triethylamine was added. How many grams: of H-669 should be added to the formula? (14.1) Refer to FP-05, state the rules for mixing '700 line products'* . .<*/ <r . r............> DUP030049739 UNIT FIVE - EXERCISE 5 - Cont. 21. Using the attached formula for 724-64730 determine the following: - 1. Pigments used in formula. W-384 96.04%, W-818 0.39%, W-259 0.03%, W-1021 3.54% __ 2. Percentage of each pigment based on total pigment. See above. 3. Pigment Volume 9.16% 4. Total Solids (weight and volume) 54.0% 40.77% 5. P/B 37/100 _________ 6. Vehicle composition (solids basis) RC-6028/RC-731 = 60/40 22. RC-6028 uses monomers. Styrene and Cardura E Ester Acrylic Acid. ______________________________ 23. Mar resistance is improved by use of 32-5979, Polymekon Wax ' dispersion . . DUP030049740  If, FP-05 Page 2 8/24/67 B./ Order-Of-Addition and Mixing Procedures - Non-Biended Non-Aqueous Pigmented Finished Products , 'f'; The order-of-addition and mixing cycles for noh-bTended ^ pigmenteti finished products should follow the format below: ............. Ingredierji (Noteil) Manufacturing Pi ona <1) (2) (3) Resyns Al/ninum Dispersions or Pigments Fomented Dispersions above 2.0#/100 Gal. (4) l/lers. Inhibitors, Additives ----------/------------------------------Add in order (Note:3) Mix . j 30 minutes. (5) j Pigmented Dispersions less than 2.0#/100 Gal. (6^; Solvents (Note:2) ' *' -----Shade to standard and thin to viscosity. NOTES: . '. j ;;Ai^ ,fri M 1. ;, j 2. ; ,, ,. . The ingredients listed in each ingredient category in any single stage are added in order of decreasing amounts except for the "Solvent" stage. The order-of-addition within the ' "Solvent" stage should be dictated by the individual require- , ments of the product. . If there are one or more thinners added for other reasons than for viscosity adjustment, these should be separated from . the thinner or thinners added for viscosity adjustment by a line. The manufacturing directions should be "Add and mix". Solvents added for viscosity adjustment should be added as the last ingredient (s) with manufacturing directions of "Shade to standard and thin to viscosity". \ ip' 3. While addition of ingredients with mixing may sometimes be an *. advantage, the phrase "add in order with mixing;" should be ? used only when necessary for quality reasons, etc. 'I '-"I-.: I i -:i " i;r.-: . - ' C. Order-Of-Addition and Mixing Procedures - 700-Line Pigmented Finished Products___________ ' - 4'? :,V; Special orders-of-addition for 700-Line gloss Pigmented Products are required to obtain maximum properties. There are two different orders-of-addition for 700-Line 1^. systems, classified as "alkyd portion first" or "nitrogen portion first". To determine which order-of-addition sequence to use for a particular product, separately total the weights of (1) all dispersions containing alkyd resins and all 330 Line dispersions, and (2) all .:;r dispersions containing nitrogen resins. If the total weight of the alkyd containing dispersions and/or 330 Line dispersions is larger use Q rm < 'v n;/ DU P030049741 * FP-05 Page 3 8/24/67 ) the "alkyd portion first" order-of-addition. . If the total weight of the nitrogen containing dispersions is larger use the "nitrogen portion first" order**oaddition. \ The order of addition and mixing cycles for all 700-Line gloss products should conform to the following procedure: (1) Alkyd Portion First Ingredient (Notesl) 1. Alkyd resins , ;. . -V, 1i , Manufacturing; Directions H , ' . >> ,..i" s. , V, T- 2. VH-7552 and VM-7790 3. . Alkyd containing aluminum dispersions or pigments. 4. 330 Line and alkyd containing pigmented dis persions greater than 2.0#/1QO Gal. l.'\ . r- :r . Add in order (Notes3) Mix 15 minutes. i 5. Nitrogen Resins. 6. Alcohols or other oxygenated solvents. 7i Nitrogen containing pigmented dispersions greater than 2.0#/100 Gal. f 8. Additives & miscellaneous minor ingredients. Add-in order with mixing* Mix 15 minutes. n 9. All dispersions less than 2.0#/100 Gal., 10. Solvents (Note: 2) . *' via ir> ' * J ,l' ' Shade to standard and thin to viscosity. (2) Nitrogen Portion First . '.'if;! ' Ingredient (Notesi) i Manufac turing Directions .: 1. Nitrogen ResinsT a .- . . -- . 'r -> _ , ! "' VXVilpy ' ' ' - N t. v-.o. dv i > j,r 2. Alcohols or other oxygenated solvents J.: : vfUJ 3. Nitrogen containing aluminum dispersions or pigments* 'Sr- Jf', *:A'V if 'yj'M -.vn-w* J::- .1- v mrnmmrnmmmnumm DUP030049742 FP-05 Page 4 8/24/67 r, -\A { 'V Ingredient (Note:!) 4* Nitrogen containing V A than 2.0#/100 Gal., > ' i k; ."A ' . ' '.: r"`- `3 , > ' ' I'i ; v rj; Manufacturing Directions dlaparaiona greater .' ,a a >-; a t a A/aa nol ` A . .. A'"''" A,A- $ A V- :---- in orderJ(Note:3) Mix j; ' . : .?1 a -I-a ,q')c a a a a v 5. Alkyd Resins. ,l( t f. i J ) j. ` U/ * i 'J 6. VH-7552 and VM-7790 . . ,. - *A 7. 330 Line and alkyd containing dispersions greater than 2.0#/100 Gal. . , A 8. Additives and miscellaneous minor ingredients. i: ;'A* lit: ... - *i'j vp'r A, AA " Add in order (Note:3) Mix 15 minutes. . . 9. 10* All dispersions less than 2.0#/100 Gal,., V J. . .. *. , . . _i ' V, ' Solvents (Note:2) Vb; Shade to standard and thin to viscosity. t NOTES: 1* The ingredients listed in each ingredient category in any single stage are added in order of decreasing amounts, except , .> , , for the "Solvent" stage. Order-of-addition within the"Solvent1*A stage should be dictated by the individual requirements of the A a ' ' a , product.' , .. ' _ . ' AA i> 2* If there are one or more thinners added for other reasons A . than for viscosity adjustment, these should be separated A A from the thinner or thinners added for viscosity adjustment I- by a line. -The manufacturing directions should be "Add and mix". Solvents added for viscosity adjustment should be ,A added as the last ingredient (s) with manufacturing directions' of -.A" "shade to standard and thin to viscosity"i i i' ' ' I i ' .' 3. While addition of ingredients with mixing may sometimes fee an advantage j the phrase "Add in order with mixing" should be us only when necessary for quality reasons, etc a: ' ' - ' , I a a ^a ^a^v H ' AfA-AA:'1; Aa a AAKAA^A"^ ;*. ;>-A;A 1!: i;AAftSf: . Aj' ,s>; AAMKA?:\ * \mm-i r!tAt$AAMK DU P030049743 UNIT FIVE - EXERCISE 6 AUTOMOTIVE AND INDUSTRIAL PRIMERS 1. y,V- Using the formulas 820-938 and-828-025 calculate the following for the product 828-025. . 1. Weight Solids 58.4% 2. Volume Solids J&J6X 3. Vehicle composition (solids)Stalls 79.U,.../jiC.rjUfi.. ?0.9 4. Pigment composition based on total pigment, 'r. a. b. u.19 W-1008: 11.4................................. ...............' ................................... c. W-636 ..... 0.9 d. ___W-93_____ 31.6 . ;.............. ................. . ............... 0 CM 1 !* ' ' e. _____T_________:___________. . ': .; f. ' .' .................... 1 ............ . 5. Ratio of prime pigment to extender pigment. 32.5/67.S ' 6. Pigment Volume 32.8________ ' . ! 7. Compare the pigment volumes and pigment to binder ratios of 828-025 - Primer and 724-64730 - Enamel. P/B Pig.Vol. ! ; 828- 025 - 168/100 32.8 724-64730- 37/100 9.16 .8 VH-7552 is used to prevent skinning | 9. .10 H-522 and VM-7790 H-39 is Diacetone -4-i. ' 1 . '' , .. /r i: } ' 1 ' v- . .f,` : ' % ' j k ' -4 . ;-y>f `V K`.\ ... *('" ... ; i vU'" , 4 ' :i ``V"' r~TT are used to prevent Jmmo L ... ... \ n ... . " . ;, i' settling- : ' ;' 14"- ' `:'v v ' /'V;:. K:V\'* ' " ; .. / M - .J DU P030049744 UNIT FIVE - EXERCISE 6-Cont. Using the Marshall Laboratory Computer Center form,(attached), request that the 828-1992 formula,(attached) be broken down into its basic raw materials. Upon receipt of the breakdown determine the .. .... . . ; . follow in. g. :. ,1. Weight solids 60.5% '; " "* . ` : 2. Volume solids 32.7% 3. Pigment volume 55.8% 4. P/B 450.7/100 v. J 5.,Vehicle composition - a. r c -5901/c -507 - 50% : bv RC-3117 - 40%____________ c ..RGt Z18--T.-iflX. 6, Pigment composition - V" V. -a. W-833 / W-870 b. W-1002 22.67%................ 17.66% :^VV- . !v.: c. W-12 d. 59.67% .................j 7. Solvent composition - ' a. : ' : ' . b. H-12 - 4.4 H-601 - 69,. 0 . ............'.............. f .. ^ " c. H-583 - 26.5 d. H-287 - .1 W-1003 is used to reduce hard settling . W-1002 and W-12 are extenders used to 1.reduce cost ,2. reduce gloss and 3. promote adhesion 32-1992 is a SOW dispersion. It contains W-12, a fine particle size barytes W-34 is a larger sized barytes and therefore '.* v . .: . ' ... cheaper than W-12. How would you go about determining whether W-34 could be substituted for W-12 in this.product? Explain li Compare W-34 VS W-12 in the laboratory in 828-195(2. 2.1f OKadviseFlintand request formula revision. DU P030049745 I, ' UNIT FIVE - EXERCISE 6-Cont. ij (y6. Compare 828-025 and 828-1992 for P/B and pigment volume. - : Code V P/B . ' \ ' Pig.Vol. ^v--"28-oa5' V: .V. 828-1992 ' ' 168' /100' ' 450.7/100 ' *32.8% 55.8% v ` ,, ' fT- J- ' I -Ml y\t i if I ;ii : :> v l';.- il 'ii- l i : I i ...f- Jv"v;j V f[- 'I, viM;; -j-vi-i '[ '( ' \ `V'hH, ir^fa'ir,yg.:Tr*9rr 1 >TrY;Y,|'t'W*.w'VV7V'^'--w"-'--P~r-- iri,"'iv^ t vr`-pjr---------- DUP030049746 UNIT FIVE - EXERCISE NO. 7 V. TRADE SALES PRODUCTS .1 ' ' ; v, v'r 'A'A ' . :: (603-904 as an example) ; I'-r. V^;'jv*V;j v -H A 'v '5 , ' . ' Exterior house paints or trim paints use a ''; -j : ` Long " ,f:': .. * '* , *.' :-fj v*1^' -1 ] ] -J l. Jaeanoi. solids alkyd resin using linseed / . . oil. or oil soya i,, 2. ; The Solvent used is a high Snivon^y hydrocarbon }>!' r'.* i-..' .. 't ` v. (H-601 ) which has alow evaporation rate. < t iV1, f,1 I 3. The V-'i: .,V 1.' 4.. ' {'. vl'?. The _ latter ~property Is .' driers used are 1. to provide sufficient . -IiUL h -173 >2-, VD-5822. " ' V IS ~ *> A'; - 3.\ ' time. and :j r i ^ !S5V . H"545 * Tertrarv.. *..JiUfeyl, -- Perbenzoate _... is a mildew , inhibitor used in colors only. 1' v *5 fi - ' a < .* *' .' 1 I 6. VH-5379, antiflooding agent Is a sMl.r.cm ...................... solution V=.'<r.-, ir ' , .,i ,., ... j used mainly with blue pigments - . ' >iW'J -i.i-ft-1f .: /. / rv! ` 7. iv`i* v j ; 4-f :;i ` V ; ' *-5j: >Vvi,, [ . fi-'V- ',5-v' I*. {,' j - ' .. : VM-7790, Sova Lecithin and 346-18323 are anti sag agents. The pigments used must have the following properties? gloss ~ retention. colorretention and ' ^haiir L, I resistance. The products are formulated at a wiiiamo solids of ,. : '* 45-50%, and at a pigment binder i -I reasonable film thickners . that will give hiding at i ..................10. , f` 1 ' . Composite dispersions and for sag resistance are used to prevent flooding , 34 ^ Line dispersions are used to tint exterior paints. iJii'- 3. \ t'. . ; !J i '-I'-'I ' V V'n '.. -h- ' v' ' DUP030049747 J'K JK' f'. *-'! v UNIT FIVE - EXERCISE NO. 7 - Cont. (Use 60-360 as an example) J .1 K-l 11. The vehicles for interiors are generally RC-537 and RQ539 lilfi: ' blwhlchlare long oil _alkyd resins.i The blend v- if. !. . _ " ,J,W. S'l't v'.of low and high body resins is necessary fog viscosity v; y and hold out. > ' . .. ... J. 12. The solvent for: interior oil paints is "\'c i'fVt [!: ': f ' b mineral spirits, H-632 or equivalent. bbbb: ; tbv- bb 13; Interior paints do hot contain lead Low j odor j driers because of their bifetbb-cb'; toxicity. b } " ' ' Ut>: hfi?s K 14v Interior paints use the following driers: bib'b,; ''blblilf]'.- `,ih: Calcium - Naphthenate . cbcii/ccH Cobalt '' . '. . ii i b j^bb;-b 3. Zirionium ,, ,, Butraldehyde 15. c H-580 Oxime Naphthenate ' Silicate ' is used as an antiskinning agent, 1!- bbwbb 16. Sag control is obtained by two groups of agents which must be mm'n: , used together . Match them up by drawing 4 1) > *1 . *** '* ^'v" '. ; 'i b"" ' .b group of two. It ' ' V'' ' ' J" Zinc Oxide.: Gelomer lines between each r\ : l (Caprylic Acid; Calcium Naphthenate ,b ,ri ,i 17.; W-10 and W-154 are ; !*:b ':? -u Tint- bn ' .*- r '.nil-lb In shape and have low .oxidea, particle size. they are .Modular. DU P030049748 M- : Vv { *;! ' : (. UNIT FIVE - EXERCISE NO. 7 - Cont* i-iMv-H-'f 18. ' The following pigments are used in most interior paints; ' '!I-;:/> ' '' m'mmm Indicate the reason for each. ! !f > > (c) 1. Rutile TiO? a. Reduces cost 2. Calcium Carbonate b. Sag control (d) 3. Celite . (b) 4. Zinc Oxide c. Hiding .t d. Gloss control myp 19. Zinc Oxide is added at the rate of 4-5 % on Pigment. , j-- .i ' J . 20. Like exterior paints interior paints are formulated on the .Mi Tvlf '* V *<:, i" .. ....... .. . basis of volume solids and pigment volume. Determine the ` `\ ' , ; j :v - ' - i. volume'solids and pigment volume of 60-360. ; % ... - ': : " ;; ?.lw*-i`T,rlj[??!/; I-;1 I r- ' .t1. Volu..m...e. eS^orl*idas~ ^ -y 2. Pigment Volume 39.49 ^ 0x,./y 22. 4i ' 'i < V J' : Bases There a. are ground "48"________Process * are three Ti2 bases used, show the code for Base for Whites and Light Tints q?-6iS7 each. % 'f 1 'fl . v :/ . .. vv>y;-'- ' '"V . 23. me yyyr;' *yv:'. - Mm l!fy b. Base for medium tints sa c. Base for deep tints _________;__________39-fii5Q Interior paintsmust have alkali resistant pigmentation because of the contact of Piaster Aftd `soap or detergents \ with the paint t!* ' v jv'.- * :f .' '`'C^. ; 'i v:;:-; m-r mrnmsmwmmmmmM......................... .}:< \W Xf. ';H:m m; . ...... \ * i r `- 'A. i.i y/1! Ltf, i . r::?. r ;. ' f: i>. : :i i:; H. ;l? U`! v v. - !(.V-. : '/.i lift 5 Vv'' i m ' A'r. . C , i > iMyjin UNIT FIVE - Exercise 7 - Cont 24. Tinting pigments must be non dry ' topcoats. bleeding for air Reference PTSP #25 (Use 392*092 as an example) 25* G-743 _______ JLL . Styrene butadiene, Latex, G. 7?8 and G-1117 Emulsion_____ are used as the vehicle in "Lucite" Wall Paint. 26, The two phases of !,LuciteH Wall Paint are 1. external or continuous. and 2. dispersed phases. 27, Match the ingredients in the first phase (above) with property's they impar c to the paint. (4) Ethylene Glycol 1. Mechanical Stability (5) Polypropylene Glycol 2. Dispersion (2) Non-ionic Surfactant (8) Cobalt Naphthenate 3. Pigment Wetting 4. Freeze thaw stflfbility (9) Methocell ,, (9) Sodium Polycarbbxylate Sol. 5. Anti foaming 6. Wetting (7) Triton X-100 (2) Soya Lecithin " 7. Dispersion | i , 8. To speed dry of Styrene Btitadiem ` Resin ; V* ' . (10)Phenol Mercury Oleate 9. Thickner (1) Ammonia 10. Prevent putrefaction 28. Odor less Mineral Spirits, H- 632 is added as a Anti bubbling agent when paint is applied by roller1. 29. The dispersed____________ phase includes Latexes and pigments 30. 31* Water based dispersions are made by .48- Process Show the use of the following ingredients in a "Lucide" Wall Paint. i 1. V-Gum 2. Titanium Dioxide (3) a Reduces Cost (5) b LowersGlossi DUP030049750 UNIT FIVE - Exercise 7 - Cont. 3. Calcium Carbonate (6) c Adds Color 4. Calcined Clay 5. "Celite" 6. 547 Line Dispersions 32. (2) d Produces Hiding (7) e Hydrates V-Gum (1) f Produces Thixotropy pigments are used to provide ____stability. 33. The maximum fineness allowed is 2.5-4 Mils. 34. Color pigments added as 547 Line ^47^Process dispersions or purchased dispersions. 35. V-Gum and water are added together in the first part of the "48 Process" grind. 36. Colored tintings should be mixed a minimum of 1 hours to affect satisfactory dispersion, as tested by the brush Sensitivity Test. 37. Care must be exercised in mixing to prevent foaming 38. ' 39. Trade Sales products containing over 0.65 .. % lead must j. carry a lead warning notice. I | A 37-5032 Green Dispersion is to be ground in the plant. The following type of Mills are available. 1. 227 Cu ft. Mill - 6* x 6* 2. 78 Cu ft. Mill - 5* x 48 3. 26 Cu ft. Mill - 5' x 1* ! j What Mill or MillA are required to grind sufficient 37 Line i dispersion to produce 1500 gals of 603-904 - two 544 Mils Calculate the most ecomonlcal batch size to makjL of 603-904. 40, 1700 gal. 41. Give the name for the following intermediates a. VD-5822 Lead Tallate ` Ji- '< . 1 ` f !! 1,, * L> /,* , ,' >>' -"1'1 y t... . ` " <'(' DUP030049751 UNIT FIVE - Exercise 7 - Cont b. 348-18323 Ammonium Stearate Solution' c. VH-7552 10% Inhibitor Solution; d. T-8629 #200 Thinner^ 42. RC-427 is added to the final stages of a steel Mill'grind with spins between each addition to prevent colloidal I shock. 43. In 32-6117, a 48 Process Grind, the final adds of resin and .i ghinner should be added so that maximum amperage dr< >p is 1 amp. every 2 mins. . 7 44. What two precautions must be observed in scheduling a batch of 60-360 in the plant? 1. No high acid resin in previous mill dispersion 2. No lead in previous mill dispersion 45. Give ratios of ingredients to; a Reduce gloss 32-6097/34-123 - 65/30 b. Increase gloss RC-539/34-123 - 95/30 .- < . ; of 60-360. 46. Give the chemical reaction between W-10 and H-555 ZNQ+2CIM (CHo) 6 C00H Zn(C00 CHoU CH* o +Ho0 47. In 392-013, the Latex & Thinner are added first, j J*/' `S, *" 48. Give the function of the following codes in 392-0131 Code a. H-506 b. H-454 Function 1. Reduce Viscosity 2. Fungicide f c. H-701 3. Odorant d. H-632 4. defoamer - coalescent agent e. H-542 f. H-284 8* H-658 5. drier 6. pH control 7. -Defoamer__________ DU P030049752 UNIT FIVE - Exercise 7 - Cont. ,/ 1 h. H-609 i. H-657 8. Wetting agent 9. Wetting agent . j- H-514 10. Freeze Thaw - lapping 49. How does the adjusting for viscosity of a water based paint differ from an alkyd type paint? In water based paint you add all H^O and increase viscosity with VM-5751, Methyl Cellulose.________________________________; In alkyd type paint you add thinner to reduce viscosity. "i 50. Streaking of 392 Line dispersions are caused by lump of colored pigment. 51. Water in "48 Process" grinds should be added at 70 to 90 F. 52. Why must W-1012 be added slowly (sifted) in a water dispersion? For proper hydration________________ 53. Name the S-4 and S-5 materials used in a batch of a 392 Line product. Ammonia and Potassium Pentachloropheno1 54. Hydration of V-Gum occurs faster in than in cold water. hotwater / 55. Thixotropy is produced by the hydration of V-gum_______. 56. Doping water based products is limited to 2_______% on total batch or 20 % on ingredient whichever is smaller 57. Occasional/Steam cleaning of equipment used for water based products should be done to sterilize the equipment. DUP030049753 UNIT SIX - EXERCISE I - Cont ! ~r ntji*.* cys .. . 1 : - ! - ' ' . . -, 1 9. 1 What properties are covered under the test for Film Properties. .N- / f; r *' : ' ' .color_____ gloss S -v y. - . - .. .-.v. ...i\ ' ' Wr -H-fs'V-!-' ---.f- := . '#;:r-* :'v : .10 Hardness Amearaoc&. AdjissloBi Match the gloss angle with the type of product controlled by that angle. . ' tOoo ' V > < ; ' b.' 60 1' " V.-"; l. ' i : * .C 75 ; (4 ) 1. "Lucite" Wall Paint ; (3 ) 2. Textured Auto. Lacquer (2 ) 3. Semi-Gloss Interiors o 00 WA A i. :;. mm mmm S.. HV; W-:- : 'd. . (1 ) 4. Refrigerator Whites 11., Give the TM's used in Color Matching Instrumentally. 1. TM-142-A TM-142-0 .12 2. TM-143-A 3. TM-143-B TM-142-M - , Name the stages of dry. (TM-219-A) 1. Dust free 2. Tack free _________________ ...' VVv>-Ti - i,;;y - : .'v 'ii 1 3. Hard dry 4. Set to touch ___________ 13. : 95 % Confidence Limits of the test is measure of t -. ?< 14. M. `4:;- i KgSlt'fl;: JO. :4. r the reliability of the test. . V TO. determine brushing timer as a function of dry time; TD- 508-R Brush Dry and Wet Edge time is used. This test should not be used as a control test:. '/ i \1 *1. V: Is- * ` 1 .. V . : : **/ ' DUP030049754 UNIT SIX - EXERCISE I The three types of test methods are: a._ -XDl Ls . h.. TT * S c. TH s Only of products. M 's are specified on formulas for control " J, The test methods describe a testprocedure. A Standard Testing Practice describes the way a line of products is tested If a product is controlled by an STP,_ no tests are generally shown on a formula . Most products are tested for: (show the TM number) a. 'Dry .. ' / TM-219-A b. Film properties , ' '_ c. Color d. Gal, wt. TM-340-A .' TM-350-A TM-13- . . '. '' ' ' i1 . * " ' /: .; ; Other generally applicable test methods are: (show TM number) a. Viscosity b. Bake TM-9 " TM -341-A ' ' ' ' ; ' ' <r. C. Gloss TM -204-F d. Solids TM -221 Name seven methods of application used in testing of products. a. Brush b. Spray - ________' _________ . ' ^ ' ' . ' ;. .v c. Doctor blade ' v ' d. _ Wire wound rod Silk Screen f._ Flow uglier., goafctag. !*r-w w w t DU P030049755 i <J t'- S < yl>r $ >& ljWi.;j %; UNIT SIX - EXERCISE I - Cont. i 15, You desire to control a product by TD-508-J. What must be done to get it issued for control purposes? Submit it tn H. A. Mray ....witA it ba Issued a s ....a..TM,;,,__________________ j-}1 i"i : i ` 16 . What is the purpose of a STP? To list all tests generally ... . applicable to a line in one place. This eliminates necessity for showing all tests on formulas and,it tends,to maintain the uniquality character of a uniquality line. ...................................................... 17. Color Standards are either vet .standards or drv plate standards. 18. Permanent Standards are given a 6 Digit Code, 19. The code indicates the general Color of the standard - * and the plant developing the color. 20. Instrumental Color Standards have an ' .'.vr the code and Sparger Standards an "X" !* in v .: Avy. I^ DUP030049756 4 u n it SIX ~ COLOR PROBLEMS 'j -' 1: 1. Determine the L, A and B ' : ' . \ Values using TM-143-A. values for the following G, R and B ' ' -j * , | a, G - 53.28 L - 76.60 R 56.94 a * 5.11 B 48.820 b - 4.65 b. G ** 3.040 L - 19.66 R ** 3.823 a - 2.32 B- .611 b - 24.11 2. The G, R, and B Values of a standard are: G* 22.64, R " 26.540, B * 14.550, the batch has values of G 23.240, R 27.360 and B 15.050. Is this batch a satisfactory batch, using zone G as the limits of acceptability? Plot results on Zone G Chart. No. AL * 0.61 Aa = .55 Ab * -0.10 j . 3. A pilot of a blue 42 line base, batch #5295672, was found to have a G value of 49.90. The G value of the standard is 51.25. The tinting strength of the batch is 18.225 '% when the tinting strength factor is 13.5. Calculate the pounds of adjustment resin to be added if the batch sifce lb 1,500 lbs. 173.38 lbs. . i ' "* ' r;,* V . ; 'V ;= ' 'V'- v 'V. J - A-:v ' ' '" ..... i: >V DUP030049757 -' ` '` ; ' . ' >, ^ ' L / i ' -- ; . ,r j-, ' UNIT SEVEN Exercise 1 LABORATORY - COMPANY PRACTICES . ` .' ' ' - -ir w, ' ?-j '' 'i , ' -* j 1. The official title of the Dunont Co. is k . t . du Pont i.- de.,Nemours and Ho.. Tnc.__'___________a________________________' . ' 2. When full name is used, de and du are always in `! 1 ower.... case except when all letters are in capitals ; .' : " ' . . t` r(f. t- .;> ; ' f l 'v!u :' * ; , 3. The Md,{> of du is capitalized when nn Pont .. i] ' . ' . ' .i)':* ):. / :]z.' * - :::.<i'r . ' . * ; t - is used alone.-' ' . '; \ j ' , ;f -- j' .. j ,, ; " 4. How is the word Incorporated or its abbreviation used? J. .. ' I. ' ' - __Used in.smaller print than the company name, under the> 'namp ; , =?7v,2,?; '' 'y't '"r *; _ _v't; j if possibleif not out in parenthesis._______________ Vi'j'j/.w' 1 i.f* -'Mr ' .*1 >; . _ 5. Show how you would address a letter to S. N. K ally in >, :1 - i: '| Toledo. ftk- - . i . ;/V'* ' f $v . ' r V -V J. W. Gkonos Toledo Paint Attn: S. N. Kelly '' - - ! i 5*. '. a ......:...,............. ' i .? > * 6. Show how you would sign this letter. Plant s 'M *V:- ' Chemical Groun and vour name. ..................... \ ;;" _ u.'':,' i% . .- \ ` '* .. '1 >. `'H-'X : -1' r -i ' .r iy ws$y vi-p;V*r f `V ' ... , i ' ...' 7. Show how you head a letter if the following isf the : subject of your letter. ;; The Divisional plants have had trouble with viscosity . | 1 | i stability of 60-215 Black Semi Gloss "bulux" Wall Paint and _ .j* *:. . . , you have corrected this '' and . you are now reporting '' on your solution. 60-215 Black Semi Gloss 'rDuluxM Wall Paint | > . ;| \ V`; - ' . ' ^' r-y-~ (. ' y :i Viscosity Stability -Divisional .............. .......... . ' . ... i'C l- '. & .v" ' |: ......................................... DU P030049758 UNIT SEVEN - Cont. )' 8. Generally one copy of a letter to WilndLngton y_ s1: Production office is sufficient. i-: Hv: ; i 9 * Your supervisor should visa all . letters - . i -___ ______________________ -VV&Side.... ...... ,..; of the pliant. ' V) ,rr.*- III!iVg: .. i .l;V< '' l,*- - *' 'i V*' '- `' '1 . . ''. ' * ' " v' - ' r>. ... ,3; ^ ... . .v ;k t' ,** * ^yr ;v-; v. iy . '"Vi V`,; *.<. ' i *' i- - ' ' i . * DU P030049759 UNIT SEVEN Exercise I 10. Copies of letters concerning prdduction technical subjects should be sent to e . T. Breuer .^ ' ' office.. of Wilmington Production . . . ' 11. Copies of all correspondence concerning Release Letters should be sent to t .. s . Raker ; concerning all Finishes Release Letters to h . r. Anderson . concerning Automotive Product 1 2, . Releases to e . p , Rwvnne and Household Specialties Releases to 'r' H.. J, Jehem4nn of Wilmington Production office. 12. As a chemist I have responsibility to:, V ' 'J ' - ; ___to the public___________;,i_________________________________________ .V; ,V-: 2. to mv science .......................... ......................................... .. i . . 3^ . fi : .*/' j.1 '''^* to mv profession __ to my employer .. 1 . >' _ , , : V1 V .'[ .''.5. to myself - - . . P to mv associates _________________________1 j i ; ' r: .. i: 13. We should recognize that information is valuable _______ " r -ir; ... ;v -/' . and we should be discrete . in its use., s . .. ; P ; 1 14.... Technical and trade. ' Secrets and confidential information are ah important ." i v Company. '' ' . asset - of thb Du Pont, . i -- \ 15.v All : - information relative to Du Pont company ' v; . should be considered as confidential by the employees, : 16. These types of information should be safe guarded: ^ . 1.. Research information ____________________ 2. Technical information and "know how1* on processes etc . - . .* J 3^,' Fields of endeavor of Du Pont i .C 4. ^:5. Information, bn eauipment used or not used by Du I ont. . - ' ' -I" Patents that: Du Pont uses or does not use. ____- ., -r- DU P030049760 UNIT SEVEN Exercise 1 6. Information on costs, sales forecasts etc. 7. Marketing strategies and advertising campaign_______ 8. Product quality and diversification programs _________ 9. Changes under consideration in wages, salaries, benefits 17. The two questions which should be asked when decisions regarding safeguarding information are required are: 1* Does the person have the right to know the information 2. Does the person need to know the information _ 18, Precautions should be taken when: 1. Discussing confidential matters in public places, etc. 2. Using phone where an employee may be overheard. 3. Leaving confidential papers where they may be seen by others. 4. Improper disposal of confidential informaltion . i' 5. Using telegrams and teletypes where persons other than addresse may see them. ! 19. What are the three items you agreed to when you signed the Employment agreement. 1. Not to disclose any secrets on information to which you may become informed. 2. Shall promptli^ inform employer f any inventions or discoveries and to assign all his " interests in some to the employer. 3. To promptly turn ] \ over to employer all secret documents in your! possession. 20. What are three things to be done if you shouljd be given an \ unsolicited suggestion by some one outside of the Company? 1. Never discuss an idea or suggestion 2. Suggest he write the Manager Patent Secti on F & F Dept. 3. If unsolicted idea received forward to abi Dve manager - ' DUP030049761  f: UNIT SEVEN Exercise 1 - 'Y:M; f-: : V: 21 . -w. .} - i* ' ... .j-.V ,4U. V-- ' What are the most important disadvantages in discussiiig in a publication or talk a patentable idea for which a patent application has been made? 1- In advent_a patent does not issue, information has beenMdisclosed .which ....we .may, ...want. to keep secret 2* Tf a patent issues and is litigated competition mav be gd^an^aaimunitionloi:,, its at tack,.an ..the ...s>.a.tsnt., 3. PnhliVat.inn may sfimnlate linriesireri competitive.._l................^ .' ) * ;/ ...activity in..the. sams area and may lead to interferante procedures. Confidential Documents include: ...... 'V'j/ I -v 'V'V;Y !> 1. ..Written ar print s,d..ma.t.tfi;c. .2 Drawing^- 3. _Photographs ; :(.i,; .vi; . *,' -ri ' ; ^ ii 4. Punch Cards 5. Magnetic tape .6 Any other physical object embodying Company information 23. ' :}4i; :Y.y 24. I _______ am responsible for safe guarding documents X originate. What are the two types of markings that are used for indicating .iYV' V ' Vis'-Y-V'-'-f t: Y'.v'-. the confidential nature of the document? ; ' i; - : y. I IV For company use only. ,.. . ... v Limited Distribution " / , . . ' . ' : ." " \ ; ': V 0. DU P030049762 UNIT SEVEN - Exercise 1 25. Circle the letter T or P designating whether the following statements are true or false. 1 1. There are some documents relative to the company which are not confidential. (^F1 2. Photographs are never confidential* i v T(f ) 3. ; Most of the Company's confidential documents require only the marking "For Company Use Only." .| . T (?) 4. "Limited Distribution" should be used sparingly. j (t ^F 5. The basic consideration for the type of distribution tp be given a document is the desire of the recipient. t (F), 6 *.V.r *v i-:r ' *S'...., 7. "Limited Distribution" should never be shown on the outside of an envelope. Ct )F "Confidential" should never be shown on any F & F correspondence* T () 8. "To be opened by addressee only" may be used on envelopes not containing any data marked with classified markings. (t ^)F 9. Confidential documents not needed by an employee should be sent to jfile or sender or otherwise properly disposed of, (t )f 10. Employees having need for confidential documents should have / suitable storage facilities to properly safeguard them. (t )F >1 tlP. 26.; ft ; nu.,.Ront-- .-.Confidential..........--Technical. '. , if information is used on all information transmitted to foreign affiliates. 27. 28. Mailing envelopes to foreign affiliates should not show! any *Confidential ' information markings. I | . * Define the term Trade Mark ' ' ! rade-mark. incl nries...any word- ,name.,.symbol or,, device...ad.apted...and , used, by a Manufacturer to identify Trig goods arid distinguish them from those maria by others. ) 29. Trade Marks are of.definite and tangible value 30. a. Define "Generic Usuage" ...is_dejined as_the use of a valid trademark ^a^;^dfeacrjj^tiveJ.tem for a general class.of goods. Be DUP030049763 ,f;' f . . UNIT SEVEN - Exercise 1 b.__Name three trade marks which have become generic by use, ____ ____Nylon-,.............. ............................ Aspirin Cellophane Dynamite 31* Give the proper generic term to be used with the following trade : marks, indicating by proper symbol their registration status. . . . ' 1. 2. *'T, - . . ' ' S-,;: .3.' "Duco" "Dulux" 7 Lacauer ............................................................. Enamel ...... ................................... .Chemical specialties____;_________________________ * . 4. * "^O" Outside Whitte________________________________:________________ 5. "Dulite" Enamel ' i ` "V.'- ;:" *' f . S-[ H. i 1f' i : .1 6. * "Dux" .Enamel______________________;_____________ 7. *"01d English" ___Paint Oil____________________________:__________ V 8. ^ `.'-l ; j-\; -> . ' : .. 9. "Leeton" ...Acrvlic Resin "Lucite" ....Wall Paint............. ........................................................ !J. 1 ; ; ;tfc:>' 7 >*;' :Vr K, * ; V`;s:-?'I1 ' . 1 / v' V i, ' 10. 11. 12. "Ovalite". Undercoater "Teflon" TFE - fluorocarbon Resin Finish "Preparakote" Primer Surfacer ___'_______ ' 32, Show by circling the T or F if the following statements are /. true or False. a. All correspondence having the trademark mentioned should carry . a footnote Registered Du Pont Trademark, T(f ) b. . Teflon enamel is the correct way to designate the trade mark for TFE paint products in a letter. ,t (j ?) c. All Trade Marks should have the first letter capitalized. (f) F d. The following markings in a letter indicates that it is a non ' ; registered ^trademark; "Tufcote"* . t (f ) *" ` .......................-------------------------------' ...J--------------J-- * .I..., ,r 7-7-- ..............-- - --TV nrji""'r >' ................ DUP030049764 UNIT SEVEN - Exercise 1 e*. When ever the first letters of other words in a sentence are , capitalized it is advisable to capitalize the whole Trade Mark. j (t )f f. The generic name need appear only once with the trade mark in ' any single document. # | j T (} ' ' ! g The generic name should follow immediately after ti:he trade mark ^' t with no punctuation or article between the trade Stark and generic name. F h. If the trade mark is registered then there should be a footnote on the page where the trade mark first appears stating ^Registered Du Pont Trade Mark. (t )f i. Unregistered trade marks need not refer to a footnote indicating the status of the trade mark. . t (f ) j. TM placed to the upper right of the trade mark indicates that it is a registered trade mark. \ T(F) k. We should apply our rules regarding Trade Marks to those of . other companies. j (T) F 1* The Du Pont oval with the single word Du Pont therein is the official trade mark of the Du Pont company. ... (J) F m. Trade Marks and Trade Names are synonymous* ; ' t () DU P030049765 UNIT SEVEN -Exercise 2 1. Absences should be reported to your Supervisor___________ by 9 A.M. of the first day of absence. 2. Give the seven items you should give when reporting an illness. a. Name in full'________________________________________________________ -' b. Payroll number or salary c. Home address________________________________________________!_ ' d. Name of hospital if hospitalized_____ e. If sick or injured, name of attending physician f. Nature of Illness or injury______________________________ g. Date expected to return to work 3. What should you do when reporting back to work aftel an illness. a. Report to Medical______________. \ b. T h...e...n....t..o.......P...e...r..s...o..n" n...e...l...--.. ........... .......... " '" --- ---------- ----------' : "3 - c. and finally your supervisor ____________________ ' 4. An identification pass-with your photograph on it must be shown when asked for to gain entrance to the plant. 5. An employee not having his pass when he is asked to show it will be required to wait at the gate for his supervisor to identify * him. 6. All cars must have a yellow bumper sticker on the car before they can be brought into the plant. 7. Pedestrian employees must enter at all times through the Main gate. ; 8. Automobiles being driven into the plant at 7:45 A.MJ must enter through the West gate. At 12:00 Noon they must ledve through the Main gate. 9. No material may be removed from the plant without ari written________ materials pass obtained from the supervisor responsible for the material. All personal property brought into the plant should DUP030049766 UNIT SEVEN - Exercise 2 10. be checked in by the guards Requests for Cash Sales of regular Trade Sales products or 0 and D : materials must be made on Tuesday ..... , Wednesday , Thursday ,, between the hours of 8 A.M. and io A.M. at g^nnH floor No. 3 Bldg.. 11. Employee will receive a fiarhnn copy of the Sales ticket / V- for sale from the rework maa. 12. He picks up his. paint from the ...guard iLQUSJL and presents his sales slip to the guard as he leaves the plant. J ' Circle the T or F to indicate whether the following statements ' are true or false. a. Common glass ware can be secured from the Store Room. Room 102 (T)F b. Orders for common vehicles and pigments must be made on Store. Room order ( Pink sheet). (%)F If- c. Orders for materials made at another plant should be placed with the Laboratory Purchasing section (John Kissel). d. Resins, Dispersion?and thinners will always be supplied1 within specifications. j ; ?( e. f. A chemist may order materials or equipment up to $25.00., , -- \ . ' -* D. S. Samples are samples of substandard finished products made by an F & F Plant. j ? g: A chemist can sign maintenance, repair or installation of T@) T f: laboratory equipment shop orders up to $50.00 beyond that the - orders must be signed by supervisor. . ** . . . ^ _. hf Orders for new raw materials should be routed through the T(?) ; Technical Investigator ( Harry Stauffer). : t (f ) i. Information on standard codes can be obtained from Dale Reinecker. >1' . pi DUP030049767 UNIT SEVEN - Exercise 2 j. "K"'coded materials are special high cost raw materials. T(] 14. Permanent codes are assigned at Philadelphia and ______ .Plants. ' ` " . . . 'U-- !. * v , 15. Indicate where the particular type of Finish*is exposed* ^ 5;. j- ' ! - UK:'" Exterior,,,1House,.Pftint, :.u .UK' 1. Delaware Industrial.Finishes Clears 1. Florida u'.";-:'--. i ;.v-1, Florida J'..: 'f-fiK, 2. Florida 3. Texas _ ' ^ ' . . 2. Delaware J Metal Protective Paints . . ' ii*' ' *.; v!r'. 1. Florida 1$. 2. Delaware ' ~~l ' ` .* In the dark__________ and in the light ' * exposures are used to determine color retention of finishes. . A finished product (60-170) has been made in the plant but for ' some reason satisfactory hardness and dry cannot be obtained even with doping. It is suspected that the wrong resin was used in preparation of the product. RC-539 is the resin required by the formula. Prepare an analytical request form to obtain information about the resin indicating the supplying of the pigmented finished product (60-170) to analytical section. RESULTS: . V ' ' . ';v .: i?. e i.j, /' ; >, ,;i: /`"f-.:*.;;fVl .:v '' '. ;; '; DUP030049768 UNIT SEVEN - Exercise 2 18. A problem exists regarding hardness of 942-97540 Red Lacquer. In your study of this problem you have made panels of a standard and 5 experimental products. Tukon Hardness readings are needed. Prepare a physical Testing Form requesting Tukon Hardness of these 6 panels. 19. Explain procedure for filing retain samples, indicating form to be filled in, sample sizes required, boxes to be used and records to be kept. Duplicate R S record storage cards are filled in,, stored in cans no larger than 1 qt. and these to be filled into quart containing cartons. Retains are stored for 2 yrs. and records should be kept by the chemist of what is in each box. Box should be labeled with formulators name and disposal date. 19-A. Retains should be kept on all samples of products made by you. 20. FP-08 is called Formula Writing Guide . 21. Write the name of the plant after its letter designation. / B Brazil L Tucker C Chicago M Fort Madison E Everett 0 Canada - Ajax * F Flint P Philadelphia J Parlin S South San Francisco 22. Formulas developed by Marshall Development Laboratory show the 23. responsibility for the formula as Phila. 1. ' What approvals are required before a formula is Supervisor______________________________________ ' _______ DL ; issued? 'i . - Simplification (W. P. Colio if necessary Formula Specialists DUP030049769 UNIT SEVEN - Exercise 2 24. Gloss of a product is now expressed as follows 60/45-55 25. Define ' | Volume Solids Percent of solids bv volume in finished.................. i product. ` 2. Pigment Volume ___________ . . Percent of pigment by volume in..a finished.... ;;. product. !; 3. Weight Solids Percent solids bv weight in. a finished ______ . i' product. ,. j ` ' ' ..................... ; 4. Pigment/Binder Ratio Ratio of the.. pigment to ..lQQ._lb.sJ of i binder in a finished product...................................................................................... 5. Binder Solids Percent of binder (resin solids)_Jay_Meight_____ : , ........in finished product, _;__________________________________________________________-- , 6. Square foot Coverage The number of square fooLa. gal Ion.-of:.. y ..' '. - ., ! \ paint will cover at 1 mil of solid film. 7. Volume Weight Solids The volume of solids in an intermediate Per 100 lbs. of intermediate < 8. Prime Pigment. is a hiding pigment, ______________ 26. What vehicles are Reactive with Zinc? Vehicles which have an acid number specifications of 10 or more. 27.. C.o.S, is now shown on the formula in space listed for ^Patent Markings. 28. Give the specifications of a Ball Mill Dispersions which are shown . 29. in "Initial Directions". 1. Cu ft factor, 2. Overall cycles & overall ratio Define Terminal Directions in a formula. Directions to fill and label the product. Also to show special accounting procedures. 30. The formula charge for finished Products is based on pounds per 100 . gallons '""I \ . 31. Thinner ingredient amounts are shown in pounds and ..gallons,.. DUP030049770 UNIT SEVEN - Exercise 2 32. Yield of resins is shown as the weight per 100 gallons . Losses include ..filter-----.--. ! reactions losses. __and ... polymerisation " 33/ What is the purpose of a Stop Notice? To stop production and/or 34. shipment of a finished product when necessary. ________________________ 60-160 Satin Sheen White formula appears to give off standard ^ vs' v material and you have decided that the formula should be stopped. if" What steps must be taken to stop this formula. Write necessary .if; stop notice form. ;llf f 35. 'Uf f! ' Give the nine reasons for obsoletions of a formula. x* -No manulacture.for-l year /Perm) 6 mo. (exp.l 2. No business anticipated bv Sales _________ 3* Production unsatisfactory__________ 4- .Faii.t.q, qoaffirqCt-9J?.e.s.t.f.Emulating..pr.agfcis.e_________U...,,' 5. Replaced bv another formula___________________ ;________ No longer required as an intermediate l ( v 7. Materials no longer available for product i/-y y li: Z;;f 36. 8. issued in error -. __________ ~ _______________i f - _- ' - 9. Sales withdrawn . ^ ............ ________ ' ' _____________ . . What is the function of an Experimental Request? i. . i. To request .. V-fl : ' :. experimental production of a finished product or intermediate. ff'f i r. ' OffSff : ' , 100-X-12345 is to be. made on an experimental request to get ' : ' '' ' i . factory experience;a 100 gal batch is to be made. 40-X-23456 is used in 100-X-12345 and is also to be made. Prepare an experimental Vr/t'J* request form and below trace the forms through the plant to manufacture of product.1 fiifl/ 38 * Indicate the cost code for the following work done by you :v. ;= o::- f':.; I., Plant Service work for Ft. Madison. 2280-M 2. :"47 Prpces's^fvfonDula; for.''a; SUW formula. 2600-G DUP030049771 UNIT SEVEN - Exercise 2 3. Preparation of an improved test method. 39. i ! 4. Training ____2TO-EL,...._____________________________ 3. Annual Inventory________gi 6. Service to Mexico Plant 2fr.QQ.-K Name and define the function of each of the testing procedures used by the P & F Department. : . L . ____ XM, -.;.QntXO,I.le,S,.S ,7___ ______--_____,;. _________ ' ; 2. .... STP -.Standard Testing.Practices to specify test for a line 40* 3 TM-400 series. Development or Sales Service tests. . Name the classifications of dangerous items by Interstate Commerce : Commission. ..' a. HVyp 1 OS lVfea --...-.......................- ----- ------------- b. _ Flammable liquids - 80 ................ c. Flammable solids...................................... d. .... Oxidizing materials ............... e. ..... Corrosive liquids.......... XT ......... '. f. ..... Compressed gases......................... ............... 'Y S* ......Poisonous substances .............. h. Combustible, liquids -?- 80 ............... ! i. . 41. i. ____Has.as.doas-a.rti,q.le.s--__________________ A raw material is a poison but It flashes at +80; i What ICC designation is shown on the formula. Pois. 42. Match designation of a code prefix with the product type code. 1. ' H : a. Lacquers and adhesives <V 2. VF 3. ; RC b. Semi Alkyd .- ` c. Varnish Flat ' i . <9> <2) :4.-V'HE,' d. Nitrocellulose Base (5) e. Duco Pigmented Lacquers (8) i, DUP030049772 UNIT SEVEN - Exercise 2 6., MG . Plasticizers (4> 7. No prefix 8. 200"Line S* Resins h. 49 Process Dispersions (3) (6) 9. 600-Line i. Synthetic Resin Pigmented Products (to) 10. 800-Line j. Liquids (1) 43. Color number assignments are made to each Plant _____!__________ '. 44. The new color number system uses and three . digits. two .--j -lettirs 45. ^ 46. The prefix to a line number indicates a baking band The number zero (0) preceding digits in a color number Indicates a single_______ pigmented lacquer or dispersion. 47. In formulating a new product, it was found that a solvent modification of RC-539 was the resin required. In this solvent modification. H-47 TM ~ was substituted for H-632 on a pound for pound basis. * What is the flash range for this new resin solution? -80L . 48. Give the 3 classes of pigments according to their bleejding. characteristics. - 1. 2. Non-bleeder Bleeder 3. Slight bleeder 49. What Bleeding notations are shown on formulas containing a slight 1: Y: Bleeding Pigments? Why? ____________ ______________. . i Initial.. Directions slight. b,lfiedar,..,,lls.fi-xlean .nflnhbleeding_______ ..equipment... ----,--------------------------;------------;--------------------------------- ------------- Terminal-Direct,iona...,iClean .equipment.., before...loading,a,.nonrhl-aeder" .To prevent,.subsequent contamination in .non.Tb.1.ending .equipments... DUP030049773 UNIT SEVEN - Exercise 3 T. Give the five purposes of the Release Letter System* av -Prapoae. new or significantly changed items for test or sale. b* --Propose important..changes in Manufacturing processes _________ c. .PPrreesseenntt. information on previously released production afecting , Marrkkeettiini g. Withdraw or otherwise modify another release. e. Transfer responsibility from one organization to another. 2. When should a Release Letter be written? < *!} ; . a. Important new products or processes. __________________________ : 1C< b. Revision or modification of existing products_______ rl - ' i; -. V I c* Finished products for resale.. .............................................. d. Products or processes which may create manufacturing problems. e* Products that raav involve new or unusual toxicity hazards /_ : f Developments that present air pollution problems 3. List items to be included in Release Letters. a. Proposal and extent" of Release b. Management decision requested l d. . e. f g.; h. i. jk. . r. m. n. Description of produfct or process. Reproducibility Continuing laboratory work Cost information Manufacturing problems Toxicity or other hazards Label information Simplification Patent information Conformanceto APC Directive 44. DUP030049774 ' ; . '/ . ;-s l ' : I -: . < . UNIT SEVEN - Exercise 3 * JEormula Cards________ _____ _ P* .-Approvals.________,________________ 4. What items should be included under Manufacturing problems? ' a* __Maw...raw.materials.............................. ............. ................ ,................ b. ....Effeet on consumption of raw materials c" prosisififeion capacity _ _ d` Need for new or special equipment e* Special precautions necessary f* Unusual control tests_____________ S- special containers required h. New intermediat ea_ required 5. Release Letter comment Letters issued by Plants Chemical Group ' r' ' - -'i shall be addressed to L. s. Baker a. h . J. Jenemann or E. P. Gwvnne b. Writer of Release with copies to 0 ......-....... c. Your supervisor ..' ...... . .._ ` `i>- : >v1 * ' 1;* - v . . ' . List the items to be covered in a Laboratory Report. a. Introduction.... ..... ' ! . 'i"! . s b. 'n c. Objectives Summary and conclusions .. ' ::i ' '!*< - '.7 ...V ' V d. - e," f. Action taken or proposed Patent Situation Publication Status : i ; - } /-V g. W . Acknowledgements Discussion ` Experimental Details 'j--' .. ... DU P030049775 UNIT SEVEN - Exercise 3 :* '' ; J :^ . . Ribliography.,... ,,......--.......................................... Charts and graphs________________.. 1: i ,' ii ; m. n. ; L Jr' . ', ;. o. p. ' j : q* ApPfittdlX. Rlossarv Abstract . ........ * !................................ j ', !................. Table of Contents . . . ...........L. 1 ___standard larm of .title page___________________________i; ) ..... }.-/ 7. Define the following : >\ ,-V ? ; ' .,1; `i ' . - 3. -- ^ ' a. b. Master Standards are Du Pont.stds... which are reference stds for working stds. Operating Standard* a\ standard used to control production >:V ' ; c. Official Standard Customer stds used as basis for color matching by . Dtrf'onc.---------------------:-- -----------------------------:-------------------- -- d. Temporary Color Standard A Wet std or DPS coded with code of prod : -.f "' *, ' irVi.- ' . ' )' . ' ; ` ; ; `y* ` > ' 8. e. Permanent Dry Plate Standard a drv plate standard used to control one or more products coded with a 6 digit code f. Porcelain Standard A standard made of porcelain g. S. R. Standard A standard supplied by customer 'f . ' h. Quality Standard ___A wet standard tn check quality of product-i on i. All property Standard properties and color A wet standard used to check film - 1 What is Metamerism? How can it be prevented? a colored product: . ..a ;'t ' which can be matched to a standard under one light source but not - under another.' It can be prevented by using same pigmentations as in standard. .- f - DUP030049776 UNIT SEVEN - Exercise 3 9. Match the following standard codes with the name for their type. 1. W-752-67852-P a. Sparger Standard <3; 2. 4-0123-6 3. 4-S135-6 4. DPS-860-78523 b. Wet Standard c. Permanent Color Std. d. Tinting Strength Std. (i: <2: (5; 10. 5. 4-X012-3 e. Temporary Color Std. Flint Plant Laboratory prepares the majority of Dry Plate (4; Standards. 11, Give the source for Fed. Standard No. 595 General Services Adm. 12. Business Service Center Region 3,_____________ What is meant by the term "Offset Standard Values"? The standard Colorimeter values of a product when a Colorimeter is calibrated to a porcelain standard. production. These values are then used to control future 13. Form FF-4745 Rev. is used to request standards. 14. Form FF-7182 is used to request Flint to prepare a permanent std. 155 Indicate by the plant designation (1) Plant originating standard and (2) Code of the standard, Plant Color a. 2-1234-6 Flint Black b. 3-X125-3 ' Toledo' ` Red c. 1-2516-4d. 7-2015-1 * Ft. Madison Pariin White Green e. 5-S025-7 Philadelphia Blue 16. SR Coded Standards are not to be shown on formulas. 17. Define Color Tie-in Certain lines are in "color tie-in lines" in which the same color number is used in each line for the same color 18. In the following group of codes indicate with a "Y" or "N" whether they are proper tie in codes. I a. 93-123 and 246-123 j (N) DUP030049777 UNIT SEVEN - Exercise 3 b. 84 - 5869 and 85 - 5869 (Y) c. 726 - 78562 and 797 - 78562 (Y) d. 884 - 97652 and 885 - 97652 (N) e. 707 - 5896 and 246 - 5896 (N) 19. Explain the purpose of the "Color Classification System". to_______ find an active product and color for product desired by customer. 20. Give the codes of all the products controlled by color standard. No. 2-2001-7 84-24675, 93 - ___________8904_______________ : ___________________________________246 - 890-67114 _____________ 701 '890 -__________________________________________________________i ___________________ 21. You have a request for an 895-Line product having similar color to 93-95896, determine the standard code controlling 93-95896 and then whether there is an active product of this colbr in 895-Line. .| Standard Code 3-0080-6 _______ . 895- None__________________ . fwj- . DUP030049778 UNIT SEVEN - Exercise 3 .22 S R-12345 was received from Sales with a request to develop a 780-Line product having the color of the S R. Determine if we have a product with the color of the SR. . 1. Select segment plate nearest color of S.R. 2^ Check color chips filed under segment plate color for color match. 3. c If a color match is available check standard index for products, available for a 780 Line product. 23. Describe what you should do,if you revise a Automotive product with an increase of y$0.05 per gallon. ' 5 :\r> Send a notice of this o the Sales Department on form FF- 7694 _ '. .. ' ' W-7784 . .. ' . .. . `. ' . . * ' - . ! , ' . 24. You have formulated a revised "47 Process" Mill base for 93-97625 <32-9762,6). You desire to make a semi works batch of the finished <-'r "" irt ' - : .( . product to test plant production. Prepare the necessary papers to produce a 100 gal. batch in the plant. - ' V:';; ''-E3pr ;;_; '/'-vv .v;y:. / ' . ! r DUP030049779 : UNIT SEVEN - Exercise 3 25' Prepare a flow chart for the handling of these papers f It r >; DUP030049780 ' . .fc-XHl-bV-T XL., '! - CmCU\-kT\0M FOR A'PPROVMG- AN\> ACCESS\VlG- EXPER\MEHTAL. TKOT^Ct io y \ ^QUESTS j OTU&\NACT-o'K E?R S/T?/ MASTER MARSHALL. LA3. 'KECc pb.DE'^ 4 EPT. PTre.wYO LA SPECIALIST 4- EPS. w 5" "E/ tD AG- 11 EPR SUPERVI CcfR j ' 3 EPpJ, 4-'f T COWLS 1 OW Pl a n n in g - Lo c a l l u g n i.m-l t Su p e r v i s o r 3T-5 "REGULAR FORTOtA / 3>vs-rRVTav>-v\oN. l EVP] TROD. AREA SUPERSUSoR i \EPR : :d a <s* j CHE.VUST 'EFR COPY. # Mr 3 EVP. N TRcTD. Pl a y u n l Or SUPERVISOR 3s STOCK CONTROL. s ec t io n 3 EPS l CBATC R CARD Ee c t io m V^QRVCS Su p p l y $e p r ,, LABEL ? t?CTUW 3EPR s ' STOCK Tl a n t Co n t r o l . -------15 FILS 2.EPR ' e p k c o p y **& "?R0T>v)C~r\O t\l A'RPA- ^1 EPR A* "SC CONTROL LAb >1 EPK A-T&C V 'pRo^LOriovU Su p s -r n is o r k / pfs i -Y-T3C. ( MARSHALL, LA'S, | ,, RgCOTysgia. raepK' 2PX9. OUVCrlKATOR / Ma r s h a l l Fil e . l as T>R6DUC.Tie>YV AREA CLERK. 3c .1 EPR J, 33C COPIES AccOuKiTmfii t >e p t . c o n t r o l l AS SUPERS'tScTR, <*| Ey>p. X/3"C COPIES Lo c a l Au g n ia s o t SUPE.RV/ISO'R, l EPS. v 33C CdPtes *> A <3* ' . SOPRU\GR *&1 EPR 33C copiss V . DAGC HEAT'ST **l SPR s.Jpl k v pe LAS I CBC C(JP^ FILE ' CPU. CatV 1 DUP030049781  UNIT SEVEN - Exercise 3 26. The Divisional Alignment Group serves as the central clearing point for gp^-iai ________ alignments involving mnrp _______ than one plant and for coordinating all special alignments. 27. The Plant Alignment chemist is responsible for handling routine alignments. ' 28, List 5 types of situation which would require "Special" Alignment. 1. Initial manufacture of new quality lines .2 All new dispersions or significant modifications 3. All new resins- or significant modifications 4. All formulas involving new processes or process modifications. ....................... anticipated 5. All formulas where manufacture at more than one plant is 29 The responsibility for testing stability samples lies with the Development chemist. 30, An Alignment program may consist of the following. 1. Anticipated time table for alignment __________________ .2 Establishment of preferred location for alignment r3. Periodic review meetings with sales, development and production 4. 5. 6. 7. 8. 9. 10. Participation of alignment chemist in experimental prod, batches Pre-alignment of formulas in semi-works Review of formulas during development with DAG Participation of P. E. Group Review of simplification aspects Coordination with other Plants Technical Activities Arrangement for adequate stability studies of alignment batches.------------- ------------- DUP030049782 UNIT SEVEN - Exercise 3 (Cont.) 31. The Divisional_______ Alignment_____________ Group will maintain a Special Alignment History ______________ File. j 32. It is the responsibility of the Divisional Alignment Group to . determine at which point Development j end Production . are satisfied with performance of a formula. 'j 33. The following persons should be advised of satisfactory completion of alignment of a formula. j 3-* Sales Product Manager................ 2. Development Supervisor_______, 3. Technical Supervisors________ 4. Production Planning Manager 5 Release Letter Coordination DUP030049783 UNIT SEVEN - Exercise 4 RULES - GENERAL PLANT AND SAFETY j REFERENCES .' : ' a. Employees Handbook b. Safety in Laboratory . ,i c. PTSP #28 Identification of Fire Hazards of Materials 1. Notify your snr of any change in your home address or ..phone. number. 2. Employees found smoking in other than designated areas ate subject to dismissal.- . I 3. Gambling in any form is strickly forbidden. r- . . 4. Any injury no matter how small should be reported to Medical ' and must be treated at., plant_________ dispensary as soon as possible. 5. Circle the mT" or "F" indicate whether the following statements are true or false; " ' !r a. All unsafe practices should be reported to your supervisor. (t )f b. Horseplay and practical jokes help maintain morale of the employees. c. Materials should be stored more than 12' below a sprinkler T ' - head. v . ' .................... . . '' d. You should lift with your legs and not your back. TQ? . F e. Safety glasses are required in all operating areas of the plant with certain exceptions such as smoke houses and cafeteria. f. Head protection is required in all operating areas. g.: Safety shoes must be worn by all employees. F T T h. No person shall enter a roped area without approval of supervision. , ^ . . . . F I ' "" " '' '' i.' Occasionally it is permissable to use a tool for which it is not :^.^..'':iatended.'-V `- ^ ' ' DU P030049784 UNIT SEVEN - Exercise 4 RULES - GENERAL PLANT AND SAFETY j. No one is to operate elevators unless properly instructed and authorized. (t ) F 6. Circle "T" or "F" to indicate whether the following statements are true or false; , . a. Stand in front of a disconnect switch when operating it. T(F) b. No one is to work on any electrical equipment except an . employee.authorized to do so. j (t )F c. Use only machines you are authorized and know how ! to operate. (t )f d. No equipment is to be operated with guards removed. (t )f e. Get janitor to clean up all spills. 4: ' " ,* 1 f. Fire alarm boxes are painted Green. , . . T(j5) T(|> j g. Safety is a personal responsibility. , (t )F ,,V.' h. Asbestos gloves are worn to protect you against corrosive chemicals. , t (f i. In a laboratory try to keep a fire under control ^d.th available fire fighting equipment, @E j. Ground wires must be,attached when transferring solvent from one ' container to another. . 7. Marshall laboratory must be evacuated when signals A2_ anc* rV are sounded. ! 8. Name the type of fire referred to by the following class codes, . Class A Class B- Class C Wood. paper textiles .and rags .............................4-- -- Flamg^bi,g_ljhquid^-..........-......................................................;____________ Electrical Fires ................................................................ Class D Metallic..powder JEires ~'i:- 9. Indicate the Glass Of fires upon which the following fire extinguisher : DU P 03004 97 8 5 UNIT SEVEN - Exercise 4 RULES - GENERAL PLANT AND SAFETY cl * Water Class A b. Foamite Class A & B ; i c. Carbon Dioxide Class B & C d. Dry Chemical e. Met-L-X Class A. B & C D Class i S 10. Indicate where the nearest safety equipment is located. a. Fire alarm 3rd floor west corridor___________ < ' b. Class A Fire Extinquisher __________________________'.' . c. CO 2 ~ Fire Extinquisher __________________________' ' d. Shower _________________________________________________________________ 11. What are the three things you should do in an emergency? a. Keep calm___________Get to safety__________________'_________ b. Send out alarms__________________________________________________ c. Bring situation under control_________________________ 12. How should you sound the alarm in the laboratory? a. Phone guards 222 or pull alarm box _______________ ' 13. What are the three precautions to be observed in preventing fires? . a. Control flames or sparks____________. b. Safe handling and storage of flaramables. c. GoodHousekeeping 14. Give five rules for proper and safe operation of electrical equipment. a- Do not operate any electrical equipment of questionable ___ ) condition. 5 ` Do,..not -use..any^equipment..not equipped -.with..proper ground cord attached. DUP030049786 UNIT SEVEN - Exercise 4 RULES - GENERAL PLANT AND SAFETY c. Do not make connections between non mating plugs. _______________ d. Use only explosion proof equipment in hazardous areas e. Do not use equipment which gives a noticeable shock. 15 > What are the safety rules for operating "bl/hS"' Process Equipment, , SUW and PLW Mill and Rejuvenators. !. 47/48 Process Equipment a* ....Make sure glass disks are tight and_in good conditions............ b* -Make $ure a^l fastenings and, adjustments, are..tight before starting unit. .. , c. Keep hands away from chuck d. Low boiling or toxic solvents should be avoided. ' - J* ` . SUW And PLW Mills . - , a. Proper gaskets must be used and tightly secured. ______________ b. Damaged lids not to be used__________._______________________________. c. 1 Lift mills close to body and lift using knees for leverage d. Lock out switch before adding or removing mills to rack ; e. Put mills on head to foot. _____________________ _________ Rejuvenators - . a. Cans should be properly closed. ' ______, ' b. Use adapters where necessary for small cans' ' c. . Lock out switch before opening gate_______, d. Check for leaks before leaving rejuvenator________________________ 16. Name the types of oxidizing agents which are used in the Laboratory.* Give one example of each* a. Peroxides b. Metallic peroxides solid oxidants . - i d. Liauid oxidants e. Volatile oxidants 1. 1. 1. ' 1. 1. Benzoyl peroxide ___ Sodium peroxide . Potassium chlorate................................................. .Percholoric acid...... ' . Chromic.oxide _______ .' DUP030049787 UNIT SEVEN - Exercise 4 RULES - GENERAL PLANT AND SAFETY ! .I 17. What precautions must be used in handling orgainc peroxides? 1. Store at low temperatures 1 ________ 2. Store limited quantities ; 3. Use protective equipment, especially eye protection j 4. Work back o a shield______________________________________ j 5. Keep away from organic material ___________I _______ < 6. Clean up spills immediately ________ ? 18. Describe the hazards involved in Chlorinated hydrocarbons. Symptoms of excessive exposure are __________________________ 1. Headache 2. undue fatigue, excitement and nasuea CCL6. produces cumulative effects on the liver. Keep from breathing vapors or skin absorption. 19. Describe the procedure for disposing broken glass. Glass must be disposed in special containers provided for purpose..___________________________;__________________________________________________ 20. Describe the procedure for disposing toxic or explosive waste material. These must be packed in separate metal containers, tagged with a red tag (name of chemist and contents) . The tag must also give specific disposal directions and delivered to store______ room for transfer to experimental station. ______________________ DUP030049788 UNIT SEVEN - Exercise 4 RULES - GENERAL PLANT AND SAFETY 21. Colored diamond shaped diagrams on tanks indicate that they contain materials which are ha^ardnns. 22. These are classed as. i. . ' 1* Health_____________ . ________________________________________ 2* - -Flammability ..........................;..................................................... ...... ___________ - Reactivity . _________.............- . -- _________________I_ Special._____________________________________________________________!................ hazards. - '' * 23. The higher the number the more . . '! hazardous is the j 1 . ; material.' . '' ". .... DUP030049789