e.g. Ingredients for exterior coating

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CONCLUSION
•The 4 Rules * Keep formulation pure & simple (i.e. the ingredients) Manufacturing process should always be “Slow in - Fast out” *The result over–rules the formula *Never, never memorise formula
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RULE 2. PROCESS MUST BE SLOW IN TO GET FAST OUT
•Lean and mean system. Rather have issues in plant than out in the market • The Formulation process must be strictly controlled.
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Four Cardinal Rules
* Keep formulation pure & simple (i.e. the ingredients) *Manufacturing process should always be “Slow in - Fast out” *The result over–rules the formula *Never, never memorise formula
•The formula must be so detailed that the production staff have absolutely no latitude.
•It should be so detailed that an unskilled hand could successfully follow the process.
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e.g. Ingredients for exterior coating
•Water •Biocide • RESIN (Binder) H2O In Can & Dry Film Tg 18-22 Pure Acr, WAM,Surfactant Lean
•Defoamer •Coalescent Texanol, Butyl Icinol •Propylene Glycol Wet Edge Extension •TI02 or other in dispersion •Matting Agent (optional) •Thickener Urethane, ASE for In Can Stability •Depending on the binders surfactant package or lack thereof, some addition of surfactant may be necessary for colour acceptance
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RULE 3. RESULTS OVERULE FORMULA
•Scones •Definition of Manufacturing: transitive verb to produce something in the manner of a machine, without creativity. •Production staff should only follow the process. • The Formulator must always check the result. Measure touch, taste, smell. Does it look like a coating. • It must be User Friendly
I love Yoos all
References
•Encarta Encyclopaedia •Protective Coatings by Clive H Hare (1994)
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• The end result determines the ingredients.
• What is its use . •E.g. High Quality, Very User Friendly Exterior Coating (Tintable Base) Guaranteed for 10 Years for over non Timber surfaces, i.e. Metal Masonry etc. Roll,Brush app.
Performance Progress & Prospects
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Formulation & Manufacturing - Pure and Simple
Presented by Mark Slater LTSC SCAA Meglomaniac, Managing Director, Chief Formulator, and Bottle Washer Shieldcoat Pty Ltd
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e.g. Ingredients for exterior coating
• RESIN Water Based- Low VOC, Pure Acrylic- Industry Benchmark;
WAM Modified- Sticks like crazy; : Tg of 18-22- Hard- Low Dirt Pick Up; Surfactant Lean-Low Water Sensitivity
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RULE 2. PROCESS MUST BE SLOW IN TO GET FAST OUT (cont.)
Formula should always include: • the order of addition the timing between additions, •the timing of addition, •the length of final mixing the equipment used, its speed(s) and direction •the packaging size •the formulator must formulate for every different batch size. A simple Timer and plastic pails with holes drilled in the bottom for trickle feeding would suffice.
•Different variables such as pigments and their loading levels etc. will affect the outcome.
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RULE 4. NEVER NEVER MEMORISE
•The Pie Van factor •Formulators must capture every detail in formula for production no matter how simple.
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BARRIERS TO SLOW IN –FAST OUT
•Human Nature or the 2nd Law of Thermodynamics –Entropy •Essentially Decay or Chaos comes from Order Unless Order is sustained and the larger the system the faster and greater the decay or chaos.
The caring Resin manufacturer must tell you the type and % per resin solids of coalescent and recommend the de-foamer, biocide, and thickener. If they are an agent for all these they’ll try and flog you the lot, including the pigments. You the Formulator
The manufacturing process is intrinsically connected.
Thus a list of ingredients is not a formula •E.g. Packet Cake Mixes & Noodles
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RULE 1. KEEP INGREDIENTS PURE AND SIMPLE (Lean & Mean)
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BARRIERS TO SLOW IN –FAST OUT (cont.)
•Production staff will always get faster and faster, especially if they are conscientious. •Even if they have a detailed list they are supposed to check off one at time, when you are not looking they’ll tick it all off in one go. •They will memorise, they will break the timer and lose the pail with the hole in it and not tell you. •They don’t understand why they shouldn’t go faster
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What is a formula?
• One definition says it is a “process or modus operandi” •Encarta says it is a ”prescribed and more or less invariable way of doing something to achieve a particular end”.