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TECHNICAL REPORT

ON

STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

WITH

MAUNCHEL CHEMICAL INDUSTRY LIMITED

(MAUNCHEL INDUSTRY LIMITED)

BY

OKEKE DAVID SOCHUKWUKAIMA

MATRIC NUMBER :2023214070

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF ENGINEERING

NNAMDI AZIKIWE UNIVERSITY, AWKA

ANAMBRA STATE, NIGERIA

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD

OF BACHELOR OF ENGINEERING ([Link])

CHEMICAL ENGINEERING

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ACKNOWLEDGEMENT

I express heartfelt gratitude to God for His unwavering grace and strength
throughout my SWIES program. His faithfulness sustained me during challenging
times, both in preparation and during my industrial attachment.

Special thanks to my parents, whose unwavering support, spiritual, financial, mental

and moral has been invaluable.

I extend my sincere gratitude to the Head of Department and the entire staff of the
chemical engineering department, Nnamdi Azikiwe University, for Providing me
with this invaluable opportunity to Gain practical experience and deepen my
knowledge in engineering.

Special thanks to the team in the production section, particularly my supervisor,

[Link] chukwuma For ensuring a smooth and stress free
experience. I also appreciate the support and encouragement from the
entire Maunchel staff. Their intellectual contributions significantly enriched my time
here.

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ABSTRACT

I did my training at Maunchel chemical limited in Nnewi for three months. This
report is about what I learned and experience during that time. In the production
department, during this period I was actively involved in various stages of the
manufacturing process, including mixing, grinding, tinting and packaging of paints.
I learned about raw material used in producing different types of paints such as
emulsion, gross, and textured paints. I also observed how machines like mixers, and
filling machines are used in production. Safety procedures and quality control
measures were also emphasized to ensure that the final products meet required
standards. This report highlights my experience, the knowledge I gained, and the
practical skills I developed during the training. It also includes some challenges I
faced suggestions for improving the training process for future students. The aim is
to help other better understand the paint production process and prepare them for
industrial work environments.

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TABLE OF CONTENTS

Acknowledgement
Abstract
Table of Contents
List of Figures
List of Tables

CHAPTER ONE: INTRODUCTION

1.1 Background of the Study

1.2 Objectives of the Industrial Training
1.3 Scope of the Training
1.4 Significance of the Training
1.5 Company Profile
1.6 Organizational Structure

CHAPTER TWO: COMPANY OVERVIEW & OPERATIONS

2.1 History of the Company

2.2 Vision and Mission Statement
2.3 Departments in the Company
2.4 Roles and Responsibilities in Each Department
2.5 Safety Rules and Regulations

CHAPTER THREE: PAINT PRODUCTION PROCESSES

3.1 Introduction to Paint Manufacturing

3.2 Raw Materials Used
3.3 Process Flow Diagram
3.4 Dispersion and Mixing Operations
3.5 Grinding and Milling Process
3.6 Tinting and Colour Matching
3.7 Quality Control Procedures

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CHAPTER FOUR: INDUSTRIAL TRAINING EXPERIENCE

4.1 Tasks Assigned During the Training

4.2 Practical Activities Carried Out
4.3 Machines and Equipment Operated (e.g., High-Speed Disperser, Mixer, Filter Press)
4.4 Challenges Encountered
4.5 Skills Acquired

CHAPTER FIVE: OBSERVATIONS & RECOMMENDATIONS

5.1 Observations
5.2 Problems Identified in the Company
5.3 Recommendations
5.4 Conclusion

References

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CHAPTER ONE

History of SIWES (Student Industrial Work Experience Scheme)

The Student Industrial Work Experience Scheme (SIWES) was established in 1973
by the Industrial Training Fund (ITF) in Nigeria. It was created in response to the
growing concern among employers that graduates of higher institutions lacked
practical experience and adequate skills for employment in industries.

Initially, SIWES was targeted at engineering, technology, and science-based

students in universities, polytechnics, and colleges of education. Over time, it has
expanded to include more disciplines.

Today, SIWES remains a compulsory part of many academic programs in Nigeria.

Objectives of SIWES (Student Industrial Work Experience Scheme):

1. Bridge the gap between theoretical classroom learning and real industrial practice.

2. Expose students to modern techniques, tools, and work methods in their field.
3. Develop practical skills relevant to their course of study.
4. Enhance students’ employability through hands-on experience.
5. Promote industrial involvement in academic training.
6. Prepare students for future work environments and challenges.
7. Foster student confidence in applying their knowledge to real problems.
8. Encourage industry-academic collaboration for national development.

Industrial Training Fund (ITF) is a Nigerian government agency established in

1971 with the aim to promote and encourage skills acquisition in industry and
commerce to enhance productivity and employability.

Functions of ITF:
1. Provide training programs for workers in industries and organizations.

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2. Supportthe implementation of SIWES (Student Industrial Work Experience

Scheme).
3. Develop human resources for various sectors of the economy.
4. Conduct research on training needs in industries.
5. Organize workshops, seminars, and conferences to improve workforce efficiency.
6. Assistemployers in setting up training systems and evaluating employee
performance.

The ITF plays a key role in Nigeria’s workforce development by aligning education
with industry needs.

HISTORY OF MAUNCHEL CHEMICAL INDUSTRY LIMITED

Maunchel chemical Nigeria Ltd. is a Nigerian-based paint manufacturing company established to meet the
growing demand for high-quality decorative and industrial coatings in the construction and maintenance
sectors. Since its inception, the company has expanded from a small-scale mixing outfit to a fully structured
manufacturing operation with modern production facilities, quality-control laboratories, and an extensive
distribution network.

Founding and Early Development (Establishment Years)

Maunchel chemical Nigeria Ltd. was founded by a group of local entrepreneurs with backgrounds in
chemical engineering, building technology, and business management. The company was
officially incorporated with the aim of producing affordable, durable, and climate-resistant paints
suitable for the Nigerian environment.

During its early years, production was carried out in a small workshop equipped with basic
machinery such as:

 Manual and semi-manual mixers

 Small dispersion tanks
 Weighing scales
 Hand-operated filling systems

The company initially produced emulsion paint, gloss paint, primer, and undercoat, targeting
local builders, hardware shops, and small contractors.

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CHAPTER TWO

PAINT

DEFINITION AND HISTROY OF PAINT

Paint is a coloured liquid or mixture applied to surfaces such as walls, wood, or

metal to protect, decorate, or preserve them.
It comes in various types and colours, and is typically made up of pigments (for
colour), resin or binder (to hold the particles together and help them stick), solvents
(to make it spreadable), and additives (to enhance performance).

The History of Paint

Ancient coloured walls of Egypt were exposed for years to the element still possess
their brilliant colour as vivid as when they were painted about 2000 years ago. The
Egyptians mixed their colour with a gummy substance and applied them separately
from each other without any blending of mixture. They appear to have used six
colours: White, black, blue, red, yellow, and green.
They first covered the area entirely with white then traced the design in black leaving
out the right of the ground colour, they used minimum for red and generally of dark
tinge. Paint was made with York of eggs, the substance would harden and adhere to
the surface. It was applied to. Pigment was made from plants, sand and different
soils. Most paints used either water or oil as a base.
At 17th Century house oil painting where a primer was used along with several
undercoat and an elaborate decorative overcoat the pigment and oil mixture would
have been grounded into a paste with a mortar and pestle. The process was done by
hand by the painter.
In 1718 Marshall Smith invented a machine or engine for the grinding of colours. It
was a device that increases the efficiency of pigments dramatically. The 19th century
progressed, both the decorative reasons and because the paint was effective in
preventing the watt totting from damp. Linseed oil was also increasingly used as an
inexpensive binder.

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Components of Paint
1. Pigment: Provides colour and opacity (e.g., titanium dioxide for white, iron oxide
for red).

2. Binder (Resin): Holds the pigment particles together and helps the paint stick to
surfaces (e.g., acrylic, alkyd, epoxy).

3. Solvent (Thinner): Makes the paint fluid for easy application and controls drying
time (e.g., water for water-based paints, turpentine for oil-based).

4. Additives: Improve specific properties like drying time, mold resistance, flow,
and durability (e.g., antifungal agents, UV stabilizers, anti-settling agents).

These components work together to give paint its colour, texture, performance, and
protective qualities.

Raw Materials Used in Paint Production

Hundreds of different pigments both natural and synthetic exist.

1. Titanium di oxide (TiO2): is a prime pigment which provides
whiteness and colours, and is the main source of hiding capability.
Colour pigment either inorganic or organic like synthetic iron
oxide (red, yellow, blue, black etc.) are used to provide colour and
to make paint opaque thus protecting the substrate from the harmful
effects of ultraviolet light.
Kerosene or fuel: Are a solvent and the liquid portion the glass
paint. It serves the purposes of water in gloss paints.
Water (H2O): Are a solvent and the liquid portion paint (also
referred to as the “carries”) which provide desired consistency
and makes it possible to the surface being painted. It is also used

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to dissolve the pigment before being added and is used in all

paints production except gloss paints.

2. They natural resin; which includes;

Poly vinyl acetate (PVA) or Acrylic: is a synthetic resin
which provides adhesion integrity and toughness the dry
paint film by binding the pigment together
Alkyd: is a synthetic resins binder which provides
adhesion, integrity and toughness to the dried paint film
by binding the pigments together. It is only used in gloss
or oil paints.
3. Additives serves many purposes: Calciumtrioxocarbonate (caco3): it gives the
paint body and substance without changing its properties, and also improves the
coverage of the paint. It is an essential additive that is used in the production of
emulsion, texcote, and screeding paint. It also impacts properties like been
sheen, scrub resistance and exterior colour retention to the paint.
Thickening agent e.g. hydroxyl ethyl cellulose, is a
thickener which provide adequate viscosity (thickness). It
impacts how thick the paint goes on and how well it flows
out when applied.
Deformer is used to break bubble as they are formed in the paint.
Vinkocide is a preservative that helps to keep the paint as
much long as needed. It also can also be referred to as an
anti-fungicidal agent.
Marble dust is a fine quartz that is needed in texcote or
texture paint that makes it to have rough appearance on the
wall when applied.

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Ammonia (NH3) serves as preservatives for the paint and

fights the growth of living organisms on the walls e.g.
mushroom and spirogyra.

Paint Manufacturing Process (General Steps):

1. Weighing and Pre-Mixing: All raw materials (pigments, binders, solvents,

additives) are measured accurately. They are mixed in a large mixer to form a
uniform slurry or paste.

2. Grinding/Dispersion: This breaks pigment particles into smaller sizes and ensures
even dispersion.

3. Let Down (Final Mixing): Additional binders, solvents, and additives are added to
adjust viscosity, colour, and properties. The mixture is stirred until uniform.

4. Filtration: The paint is filtered to remove impurities or undispersed particles.

5. Quality Control Testing: Samples are tested for colour, viscosity, pH, drying time,
and coverage.

6. Packaging: The finished paint is filled into containers (e.g., tins, drums, buckets),
labelled, and sealed for storage or distribution.

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CHAPTER THREE

Classification /Process in paint production

Paints can be classified based on their base, finish, or application:

1. Based on Paint Medium/Base:

- Oil-Based Paints: Durable, water-resistant; used for wood and metal.

- Water-Based Paints (Latex): Easy to clean, low odour; used for walls and ceilings.
- Emulsion Paints: Water-based with plastic binders; quick-drying and washable.
- Enamel Paints: Oil-based with glossy finish; used for furniture, doors, etc.
- Cement Paints: Water-based; used for external walls.
- Bituminous Paints: Made from asphalt/bitumen; used for waterproofing and metal
protection.

2. Based on Finish:

- Matte Finish – Non-reflective, hides surface flaws.

- Eggshell/Satin Finish – Slight shine, easy to clean.
- Semi-Gloss Finish – Durable with more shine; good for kitchens/bathrooms. -
Glossy Finish – High shine; used for trim, furniture, and metal.

3. Based on Application:

- Primer Paints – Prepare surface before painting.

- Undercoat Paints – Applied after primer for better coverage.

- - Topcoat Paints – Final decorative and protective layer.

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Some Kind of Paint and Their Uses: There are different kinds of paint
which includes;

EMULSION PAINT
This is an acrylic and water based copolymer emulsion paint for interior
paint. It has good coverage and opacity depending on the quality of the
paint. Quality latex paints that have 100% acrylic binder are especially
durable and highly flexible. They tend to adhere extremely well to a variety
of exterior surfaces, which means they have greater resistance to
troublesome paint failures like blistering, flaking and peeling compared
with other types of paint.

GLOSS PAINT
This is alkyd resin enamel paint for used on a wide variety of application including
wood, steel, plaster, and clipboard. Hard board etc. it is suitable for both interior and
exterior use easy cleaning when stained. Top quality oil based paints have excellent
adhesion characteristics which mean they get a tight grip on the surface being
painted.
However, oil based coating does tend to oxidize and get brittle over time which can
lead to cracking problems in exterior applications, yellowing and clipping problems
in interior applications.

TEX-COAT OR TEXTURED PAINT

This is a highly quality textured acrylic copolymer emulsion paint reinforced with
fine quartz and suitable for interior and exterior use. Textured paint has sheen and
textured finish with 70% wash ability, scrub ability and 100% opacity .it has a long

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life span for over ten years on the wall. They are paints with water soluble thinner
and they include calcimines in which the thinner is glue.

SILK PAINT
This is a highly acrylic based paint with fine material. They are shiny in nature when
apply on wall surface. They require binder or resin component such as acrylic,
polyvinyl acetate, texanoletc. they are highly costly and quantity in nature

Process Involved in Paint Production

1. Measuring the Chemicals
This is an importance aspect in paint production. Chemicals are being measured
before used in paint production to meet the required standard in paint. Weighing
balance is the equipment used to weigh different components for accurate
measurement .it is measured in kilogram

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Plate:1(Diagram of a weighing balance)

2. Hand Scoop : this is a plastic or steel fabricated tool, a utensil with a

short rounded sides, used for shovelling handle and deep or ladling in the paints
factory for fetching solutes of measurable volumes or weight when need, it is
often used for fetching colour pigments or other dry or semisolid substances
as well as any type of powdered chemical additives for the production of paints
as required, the coloured ones are used for fetching colour pigments while the
steal scoops are for chemical additives.

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FIGURE 2: COLOR PIGMENTS AND ADDITIVES SCOOP

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4.1.3 Dispersing the Pigment:

The paste mixture for most industrial and some consumer paint is now routed into a sand mill. A
large cylinder that agitate tiny particles of sand or silica to grand the pigment particles, making
them smaller and dispersing them throughout the mixture. The mixture is then filtered to remove
the sand particles. There, the premixed paste is subjected to high speed agitation by a circular
toothed blade attached to a rotating shaft. This process blends the pigment into the solvent.

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Plate:4.3(Diagram for dispersion mixer tank)

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Production of 400 litre of White Emulsion Paint

Step 1: Measurement of Chemicals

All materials were accurately weighed based on the production formula.

Step 2: Preparation of Titanium Dioxide Paste

6 kg of Titanium Dioxide was dissolved in a small quantity of water and stirred to form a uniform
white paste.

Step 3: Main Mixing Process

- 200 litres of water were poured into a rapid mixer.
- 250 kg of Calcium Carbonate was added gradually while stirring to avoid clumping.
- Theprepared Titanium Dioxide paste was added and mixing continued until a smooth slurry was
formed.
- 50 kg of Acrylic binder was introduced to improve paint adhesion and durability.
-2 kg of Defoamer was added to eliminate foam and air bubbles.
-2 kg of Vinkocide was added to prevent microbial growth.
-5 kg of dissolved Natrosol (in water) was introduced to increase viscosity and consistency.
-2 kg of Ammonia was added last to stabilize the pH and help coalescence.

Step 4: Final Mixing and Packaging

The entire mixture was allowed to mix thoroughly for 10–15 minutes to ensure homogeneity. The
paint was then ready for packaging and labelling.

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Quality Control/Assurance Measures in Paint Production

1. Raw Material Inspection

- Verify quality and specifications of pigments, binders, solvents, and additives
before use.

- Check for contamination or expiry.

2. Batch Formula Verification

- Ensure accurate weighing and proportioning of raw materials as per formulation.

3. In-Process Testing
- Monitor pH, viscosity, and consistency during
mixing.

- Observe colour uniformity and dispersion.

4. Finished Product Testing

- Colour Matching: Compare with standard colour charts.
- Viscosity Test: Using viscometer to ensure flow is within standard range.
- Drying Time Test: Confirm the paint dries within the required time.
- Adhesion Test: Check how well paint sticks to surfaces.
- Opacity/Spreading Rate Test: Ensure proper coverage.
- Gloss Level Test (if applicable): Check surface shine.
- Resistance Tests: Water, scrub, chemical, and weather resistance.

5. Packaging Inspection
- Check for proper sealing, labelling, and container integrity.

6. Storage Conditions
- Ensure finished paint is stored under appropriate temperature and humidity to maintain quality.

7. Retention Samples- Keep samples of each batch for future reference or customer complaint
resolution.
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Common Defects in Paint and Their Causes

1. Blistering
- Cause: Trapped moisture or solvent under the paint film
- Effect: Bubbles or blisters on surface

2. Cracking/Flaking
- Cause: Poor surface preparation or over-thinning
- Effect: Paint film splits or peels off

3. Chalking
- Cause: Degradation of binder by UV light
- Effect: Powdery residue on surface

4. Peeling
- Cause: Poor adhesion to substrate
- Effect: Paint film detaches in layers

5. Sagging
- Cause: Over-application or poor viscosity control
- Effect: Paint runs down, forming uneven layers

6. Fading
- Cause: Exposure to sunlight or poor-quality pigment
- Effect: Loss of colour intensity over time

7. Wrinkling
- Cause: Thick application or drying too quickly
- Effect: Paint surface forms skin with wrinkled texture

8. Efflorescence
- Cause: Moisture drawing salts through masonry
- Effect: White, powdery deposits on painted surfaces

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Relevance of Industrial Training (SIWES):

[Link] Experience:
- Bridges the gap between theoretical classroom knowledge and real-world industrial practices.

2. Skill Development:
- Enhances technical skills, teamwork, communication, and problem-solving abilities.

3. Familiarity with Equipment & Processes:

- Exposes students to modern tools, machinery, and industrial workflows.

4. Career Orientation:
- Helps students discover their strengths, interests, and preferred career paths.

5. Workplace Ethics & Discipline:

- Instils professionalism, punctuality, accountability, and safety awareness.

6. Industry Exposure:
- Provides understanding of company structure, production processes, and quality control
systems.

7. Networking:
- Creates opportunities to build professional contacts and references for future employment.

8. Academic Relevance:
- Supports final year projects and improves academic performance through applied learning.

9. Employment Advantage:
- Gives students an edge in the job market through prior industry experience.

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Problems and Challenges Encountered During SIWES:

1. Limited Practical Exposure:

- Some companies assign students to only observe instead of participating in real tasks.

2. Inadequate Supervision:
- Poor guidance from industrial or academic supervisors can affect learning outcomes.

3. Lack of Equipment/Facilities:
- Some organizations lack modern tools or functional machines for proper training.

4. Unrelated Job Assignments:

- Students are sometimes posted to departments not relevant to their course of study.

5. Financial Constraints:
- Inadequate stipends or no financial support for transport, feeding, and accommodation.

6. Time Constraints:
- Short duration of training limits in-depth learning of complex processes.

7. Poor Documentation Support:

- Difficulty accessing training materials or company information for reports/logbooks.
8. Communication Barriers:
- Difficulty understanding technical language or relating with staff due to lack of orientation.

9. Health and Safety Risks:

- Exposure to industrial hazards without proper safety training or equipment.

10. Weather or Environmental Challenges:

- Harsh working conditions in outdoor or poorly ventilated environments.

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Suggestions for Improvement in SIWES Program:

1. Better Placement Matching:

- Students should be placed in industries relevant to their field of study.

2. Longer Training Duration:

- Extend the training period to allow deeper understanding and hands-on experience.

3. Increased Supervision:
- Regular visits and monitoring by both school and ITF supervisors to ensure proper learning.

4. Adequate Orientation:
- Pre-training seminars should prepare students on expectations, ethics, and safety.

5. Provision of Stipends:
- Timely and adequate financial support should be provided to cover expenses.

REFERENCE
1. Aigbodion, A. I. (2018). Principles of Paint Technology. Lagos: Chemical Technology Press.

2. Hassan, M. A. (2020). “Modern Paint Manufacturing Techniques.” Journal of Industrial Chemistry, 12(3),

44–58.

3. Raw Materials Research and Development Council (RMRDC). (2019). Paint and Coating Production

Manual. Abuja: RMRDC Publications.

4. Ogunyemi, K. T. (2021). Industrial Training Report Writing Guide. Ibadan: TechPublishers.

5. Company Internal Documents (2025). Paint Production Department Manuals, Safety Guidelines, and

Process Sheets.

6. ISO 9001:2015 Standards on Quality Management Systems.

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