With the widespread use of wall putty many paint manufacturers have entered the production of wall putty. It is now a mature market with a market capitalization of over Rs 3,000 crores.
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As you might very well know, wall putty is used as a protective base on interior and exterior walls for expensive paints. It is also used for levelling of wall surfaces to fill cracks and surface imperfections. The momentous growth in infrastructure development projects along with residential and commercial projects in both developed and developing regions is a leading factor which that will boost the demand for wall putty in near future.
If you are planning to make a fortune out of this booming Putty Manufacturing Industry, read the guide below to understand the basics of the Putty Manufacturing Process.
Putty Manufacturing Process:
The main ingredients of Putty are white cement & dolomite in ideal proportion. Normally, the recipe proportion is 1:4 of white cement to dolomite. For example, 5 Tonnes of Putty will have 1 ton of white cement (BD ' Kg/m3) & 4 tonnes of dolomite (BD ' 950 Kg/m3) along with other minor ingredients.
The basic manufacturing workflow is divided into 4 parts
1] Raw material unloading & storage:
Generally raw material comes in sizes ranging from small bags of 25 kg & 50 kg to big bags weighing kg. Unloading of these bags and feeding of raw material to conveying system shall be achieved by bag slitting machines for small bags and with electric hoist & bag massager system in case of big bags.
Depending upon the finished product, the quantity of raw material can be decided. First, the bulk quantity of raw material (white cement & dolomite) is transferred to storage silos. For transferring the material to silos, pneumatic conveying system is preferred as it is economical and robust, both in operation as well as maintenance. The capacity of these silos depends on how much raw material we want to carry as the stock. Usually, it may be in between 3 to 6 days. To avoid the jamming of raw material inside the silo, cones need to be fluidized. Moreover, for extra precaution, bin activators are also used.
2] Weighing/batching of the ingredients:
The ingredients should be added in exact proportions (determined by formula) to ensure producing premium quality Putty powder. So, a hopper with weighing cells must be located below the storage silos. Metering of the raw material from silo to weigh hopper should be performed by screw conveyors. After getting the right quantity of material in the weighing hopper, it will be dosed to charge hopper by conveying line via rotary airlock valves.
3] Conveying of raw material to charge hoppers:
The raw material must now be conveyed to charge hoppers as per requirement. Selection of charge hoppers is done with the help of diverters in the conveying line. Conveying capacity is decided by the blender batch cycle time. Based on capacity requirement & distance, conveying air is calculated & a blower is selected. Average conveying air velocity ranges between 25 ' 30 m/s.
4] Blending & mixing:
After the material is charged in a charge hopper, it gets dosed in a blender/ mixer with the help of a screw conveyor. The average blender mixing time is between 15- 30 minutes. The material is then transferred to the packing machine where it is duly packed. The final product is then moved to finished good storage area.
All the system operations can be controlled through a PLC panel.
Using PLC programming, the system measures the accuracy of various raw materials mixed in the ingredients, thus delivering a superior quality Putty powder. Consequently, it also reduces labour intensity in addition to environmental pollution. Hence, making it a win-win for all.
We hope that this article helped you get an idea about the Putty manufacturing process and realize how the lean phase pneumatic conveying system makes the whole Putty manufacturing process hassle-free and automated.
Hydroxypropyl methyl cellulose (HPMC) is a natural polymer materials as raw materials,through a series of chemical processing and prepared non-ionic cellulose. It contains almost methyl cellulose(MC) of all the performance, your first choice for production of high quality building materials additives.
To meet the needs of environmental protection, Our product with high water retention, dispersion, good fineness, good work ability, easy dissolution characteristics.It suitable for dry mortar building, both inside and outside wall putty powder milk (cream), adhesives, caulks, interface agents, coatings, self-leveling agent of new building materials.
1. Water Retention: The water retention will be enhanced, which is helpful with such problems as cement or gypsum construction material drying too fast and poor hardening or cracking due to insufficient hydration.
2. Operationality: It can enhance the plasticity of mortar and improve the coating efficiency in construction projects.
3. Adhesivity: It can make mortar attach to base material better since the plasticity of mortar is enhanced.
4. Slip Resistance: It can prevent slipping problem between mortar and the base material in construction project as a result of its thickening effect.
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Building gypsum powder is the main material of gypsum putty and is the basic material to ensure the bond strength and impact strength, therefore there are strict requirements on its quality.
Physical properties
Fineness: all passed through 120 mesh sieve.
Initial setting time: not less than 6min
Final setting time: less than 30min
2h flexural strength: greater than 2.1MPa
2h compressive strength: more than 4.9MPa
Whiteness: greater than 85 when used directly in the production of decorative layer plaster putty; and higher than that used in the production of paint or wallpaper base.
In the ingredients of gypsum putty, although CMC has a certain viscosity, it can have damaging effects of varying degrees on the strength of gypsum, especially the surface strength. So a small amount of binder should be added, making it migrate to the surface during the drying process of gypsum putty and increase the surface strength of gypsum putty.
Otherwise, there will appear surface dusting phenomena for the gypsum putty scraped onto the walls, because of not spraying coatings for a long time. But using MC, HPMC or HEC instead, we will not need to add binders, because they are different from CMC, can be used as powdery binders and will cause no or little decrease on the gypsum strength. The commonly used binders of gypsum putty are gelatinized starch, starch, oxidized starch, water-soluble polyvinyl alcohol at room temperature and redispersible polymer powder, etc.
A very small amount of penetrant is added to make the gypsum putty bond better to the substrate. Commonly used penetrants include anionic and non-ionic types.
Talcum powder in the gypsum putty is mainly to improve the applicability of the paste, to facilitate scraping and to increase the surface finish. Fineness: all pass through 325 mesh sieve; Na2O content: less than 0.10%; K2O content: less than 0.30%.
For Wall Putty/Plaster
The blade coating performance of gypsum putty slurry is mainly ensured by water retention agent, which can ensure the compatibility of plaster putty slurry, so that the water in the gypsum putty layer will not be absorbed by the wall too quickly, and avoid the dusting and peeling phenomena caused by insufficient water required for hydration of plaster. Water retention agents are mainly derivatives of cellulose ethers, such as methyl cellulose (MC), hydroxyethyl cellulose (HEC), hydroxypropyl methyl cellulose (HPMC) and carboxymethyl cellulose (CMC).
The hardened gypsum is inherently soft and brittle. Once the gypsum putty layer is too thick, the interfacial layer can easily flake off, so adding a certain amount of flexibiliser and penetrant can increase the degree of flexibility of the gypsum putty and can further improve the operational performance of the gypsum putty slurry. Commonly used softening agents include a variety of sulphonates and lignin fibres.
Although some cellulose ethers and binders have a retarding effect on gypsum, the retarding effect does not meet the time requirements of gypsum putty, so a certain amount of retarder is also required.
For further technical information talk with our specialist or visit our website https://www.hpmcfactory.com. We can help you to identify the best solution for your application.
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