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Iowa Paint Manufacturing Co. Viscosity Analysis. Presented By: Ruchi Patnaik Co-Author: Piyanka Roy. Iowa Paint Manufacturing Co. Since 1933, Iowa Paint has been making quality paint and coatings More than 1400 colors available

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iowa paint manufacturing co viscosity analysis

Iowa Paint Manufacturing Co.Viscosity Analysis

Presented By:

Ruchi Patnaik

Co-Author:

Piyanka Roy

iowa paint manufacturing co
Iowa Paint Manufacturing Co.
  • Since 1933, Iowa Paint has been making quality paint and coatings
  • More than 1400 colors available
  • The choice of professional painting contractors for quality paints
  • Paints and coatings meet and/or exceed U.S.Government paint specifications
satin acrylic house paint
Satin Acrylic House Paint
  • Very durable for interior walls and ceilings
  • Good color retention
  • Easy water clean-up
  • Low odor
  • Dries to tough finish
  • Rooms can be used almost immediately
objective
Objective
  • Improve viscosity for batches of paint
    • Determine precision of viscosity measurements (and identify removable sources of imprecision)
    • Find the appropriate quantity of Hydroxyethyl Cellulose (HEC also known as A44) to be added for various desired adjustments of viscosity
viscosity
Viscosity
  • Viscosity of paint is increased or decreased by addition or removal of the following three elements
  • A44 (Hydroxyethyl cellulose)
  • T49 (Water)
  • Resin
current situation
Current Situation
  • Low initial incoming viscosity
  • Final viscosity requirement: 95-100 Krebs
  • Use of A44 to increase viscosity
  • Paint produced in 2000 or 4000 gallon tanks
  • Use of trial and error to get to desired viscosity
why a44
Why A44?
  • High thickness efficiency
  • Low water solubility
  • Excellent color development and color acceptance
  • Compatibility with a broad range of paint ingredients
  • Batch-to-batch uniformity
  • Good brush and roller application
  • Non-sagging properties
analysis
Analysis
  • Gage R&R study for lab measurement precision
  • Homogeneity test for within vat sampling variance
  • Regression Analysis
gage r r
Gage R&R
  • Repeatability is variation typical of that seen in repeat measurements for a particular operator on a particular specimen
  • Reproducibility is variation that can be attributed to differences between operators
gage r r10
Gage R&R
  • Two different batches of paint
  • Two measurements by each of 4 group members for each batch
  • Use of viscometer and stop watch to measure viscosity
  • Viscosity measured at 77Fahrenheit
r r calculations
R&R Calculations

^

^

Equations for repeatability and reproducibility:

Source DF SS MS

Parts 1 52.5625 52.5625 MSA

Operators 3 0.6875 0.2292 MSB

Interactions 3 0.6875 0.2292 MSAB

Error 8 0.5000 0.0625 MSE

Total 15 54.4375

I (parts) = 2 J (Operators) = 4 m = 2

within vat sampling
Within-Vat Sampling
  • Five samples from one batch of paint
  • Two measurements by each of 4 group members for every sample
  • Use of viscometer and stop watch to measure viscosity
  • Viscosity measured at 77° Fahrenheit
within vat calculations
Within-vat Calculations

^

Equations for locations:

Source DF SS MS

Locations 4 30.850 7.713 MSA

Operator 3 0.275 0.092 MSB

Interaction 12 2.350 0.196 MSAB

Error 20 7.500 0.375 MSE

Total 39 40.975

results of measurement precision studies
Results of Measurement Precision Studies
  • Gage R&R Calculations
  • repeatability = 0.250 Krebs
  • reproducibility = 0.327 Krebs
  • To combat reproducibility variation, keep operator fixed

^

^

results of measurement precision studies17
Results of Measurement Precision Studies

Within-Vat Calculations

  • repeatability = 0.612 Krebs
  • locations = 0.922 Krebs

To account for location variation, sample from several locations and either physically mix, or average measurements

^

^

historical data19
Historical Data
  • Plot of all nine samples in order to examine the slope
regression analysis
Regression Analysis
  • Use of Minitab software to find relationship between amount of A44 added and mean viscosity increase
  • Equation found is in terms of:
    • Add ‘x’ pounds of A44 in every 1000 gallons of paint to increase viscosity by ‘y’ Krebs
  • Minitab output for regression analysis gave 1.19 lbs. of A44 additive to be added to 1000 gallon tank for 1 Kreb increase
regression output
Regression Output

The regression equation is:

visc = 87.3 + 1.19added + 5.51 z1 + 5.01 z2 + 6.25 z3 + 3.51 z4 - 2.21 z5 + 1.38 z6 - 0.21 z7 + 0.77 z8

derived equations
Derived Equations

Equations were derived for each size of tank used by Iowa Paint, where

y = pounds of A44 & x = desired viscosity increase (Krebs)

  • For 1000-gallon tank: y = 1.19 * x
  • For 2000-gallon tank: y = 1.19 * 2x
  • For 3000-gallon tank: y = 1.19 * 3x
  • For 4000-gallon tank: y = 1.19 * 4x
viscosity table
Viscosity Table

Table for the amount of additive appropriate for various tank sizes

viscosity plot
Viscosity Plot

Plot of viscosity increase versus A44 addition for the 1000-gallon tank

Viscosity Increase (Krebs)

conclusions
Conclusions
  • Several factors play a role in viscosity measurements
    • One source of variation relates to measurements done by different people
    • Another relates to tank location of the sample obtained
  • Historical data provides quantitative guidance for viscosity adjustment
recommendations
Recommendations
  • Make sure that only one person handles the viscosity measurement
  • Samples for measurement of viscosity may be taken from different areas of paint tank and mixed or measurements averaged
  • Use the equations, table and chart derived from historical data to eliminate trial and error (and get correct viscosity)
aftermath
Aftermath
  • Company is willing to try it out!
  • Able to give the company an acceptable solution to implement
  • Derived accurate amounts of Hydroxyethyl Cellulose to add to achieve desired viscosity level
  • Graphical and tabular representation of solution for easy reference
acknowledgements
Acknowledgements
  • Dr. Stephen Vardeman

Professor

Iowa State University

  • Mr. Mark Angerer

Technical Director

Iowa Paint Manufacturing Co.