CHAPTER ONE: INTRODUCTION

1.1 BACKGROUND STUDY

First, let's start with the basics. A paint processing factory is a facility that manufactures

and distributes paint products. These products can be used for a variety of purposes,

including home improvement, industrial applications, and automotive applications. The

factory will typically have a variety of equipment and machinery that is used to mix,

package, and distribute the paint products. The factory will also likely have a quality control

department to ensure that the paint products meet the required standards.

A Paint Factory is an industrial site, usually consisting of buildings and machinery, or

more commonly a complex having several buildings, where workers process raw materials

into paint. Factories arose with the introduction of machinery during the industrial revolution

when the capital and space requirements became too great for cottage industry and

workshops. Paint is a subdivision of surface coating. It is a relatively opaque solid coating

applied as thin layer whose films are usually formed by polymerization of polyunsaturated

oil. However, other subdivisions of surface coating include: varnishes (clear coating),

enamels (pigmented varnishes), lacquers (film formed by evaporation only), printing inks

and polishes. Paints generally have very low thermal conductivity, electrically inert and can

be washed and cleaned. The various raw materials for making paints include pigments,

vehicle, alkyd resins, surfactants, solvents (thinners) and coloring matters.

Paint Factory or plant is an industrial site, usually consisting of buildings and machinery, or

more commonly a complex having several buildings, where workers process raw materials

into paint.
 Factories arose with the introduction of machinery during the industrial revolution

when the capital and space requirements became too great for cottage industry and

workshops.

Paint is a subdivision of surface coating. It is a relatively opaque solid coating applied

as thin layer whose films are usually formed by polymerization of polyunsaturated oil.

However, other subdivisions of surface coating include: varnishes (clear coating), enamels

(pigmented varnishes), lacquers (film formed by evaporation only), printing inks and

polishes. Paints generally have very low thermal conductivity, electrically inert and can be

washed and cleaned. The various raw materials for making paints include pigments, vehicle,

alkyd resins, surfactants, solvents (thinners) and colouring matters.

Paints are classified into two principal types:

1. Resin based paints (Gloss finishes)

2. Latex based paints (Emulsion paints).

The major difference between the two is only in the types of vehicle used and cost.

1. Resin based paints are used for exterior and interior surfaces and are dry to a lustrous or

shinny finish.

2. Emulsion (Latex) paint involves the emulsion of 2-phases one of which is water and any

other phase.

Classically, emulsion is a suspension of one phase in another. Latex paints have as their

major film forming constituent synthetic resin latex with or without other film forming

constituents added in an oil-water emulsion type system. The continuous phase consists of

an alkali – dispersed hydropholic colloid in water and contains two more different types of

particles in suspension, styrene – butadeux (SBR) copolymer which was the original quality
 film former in emulsion paint. Polyvinyl acetate (PVA), acrylic and PVA acrylics

copolymers have largely replaced SBR as film former.

From these, resins and latex are made objects with a wide range of colours and texture

found in household wares, building materials, electrical and electronic appliances,

automobile and aeronautics, clothing, building structures etc. in short it s difficult to imagine

contemporary society without painting (colours).

Paints are the material employed as finishing for other materials. They are used to

protect metals, timber and plastered surface from the effect of weather, heat, moisture, gases

etc., thereby improving their appearance. Paints are classified into oil, water and cement and

bituminom paints. There are also special paints used for special purpose e.g. heat resisting,

fire proofing, chlorinated rubber paint etc.

Paint factory is regarded as an important or essential industry in many country

because of it effect and function in the environment. Finally, this project (paint factory) will

help in improving on the face lift of Makurdi as the capital of Benue State as well as the job

opportunities which our teeming youths desire.

1.2 PROBLEM STATEMENT.

The problem statement of a paint processing factory is the issue of paint defects. These

defects can occur during the mixing, packaging, or distribution process, and they can result

in a range of problems for the factory and its customers. Defects can include clumping,

separation, discoloration, and odor. They can also cause the paint to not adhere properly to

surfaces or to be difficult to apply. These defects can result in wasted materials, unhappy

customers, and lost profits for the factory. To combat this problem, paint processing

factories must have a robust quality control process in place to detect and correct any
 defects. Another problem that paint processing factories faced. One of these is the issue of

waste management. Paint factories generate a significant amount of waste, including

solvents, pigments, and other materials. This waste must be disposed of in a responsible and

safe manner, in accordance with environmental regulations. Another common problem is

that of safety. Paint factories use a variety of hazardous materials, and there is always the

potential for accidents or injuries. The factory must have strict safety protocols in place to

protect its workers and the environment.

Another challenge for paint processing factories is the issue of global competition. The

paint manufacturing industry is highly competitive, and factories must constantly strive to

improve their products and processes in order to remain competitive. In addition, the global

economy is always changing, and this can create additional challenges for the industry. For

example, fluctuations in the price of raw materials can impact the cost of producing paint,

and changes in currency exchange rates can affect the profitability of the industry.

1.3 AIM AND OBJECTIVES

1.3.1 AIM

The primary aim of a paint processing factory is to produce high-quality paint products

that meet the needs of its customers.

1.3.2 OBJECTIVES

1. To reduce costs and increase efficiency, in order to remain competitive and profitable.

2. To improve its environmental performance, by reducing waste and emissions

3. To improve its quality management system. This system is used to track and measure

the factory's performance, and to ensure that it is meeting its objectives.

 4. To achieve continuous improvement. This means that the factory is constantly

looking for ways to improve its processes and products.

1.4 JUSTIFICATION OF THE STUDY

A paint processing factory must be able to justify its existence in order to remain successful.

There are a number of ways that a factory can justify its existence, including:

a) Delivering products that meet the needs of the market.

b) Being competitive in terms of price and quality.

c) Delivering products on time and to specification.

d) Having good customer service and support.

e) Maintaining good relationships with suppliers and customers.

f) Staying up-to-date with technology and innovation.

g) Focusing on continuous improvement.

1.5 SCOPE OF THE STUDY

The factory will typically be responsible for a number of different processes, including:

1. Raw material procurement and storage: Raw material procurement and storage is an

important part of a paint processing factory. This is because the raw materials used in the

paint production process must be of the highest quality, in order to ensure that the

finished product is of a high standard. The raw materials must also be stored in a way

that prevents them from being contaminated or degraded. The most common raw

materials used in paint production include pigments, resins, solvents, and fillers. These

materials must be sourced from reliable suppliers, and they must be stored in a way that

protects them from moisture, heat, and light.

2. Paint mixing and blending: This process involves mixing the raw materials together in

the correct proportions, in order to create a homogenous paint product. The paint must be

mixed and blended to a very high level of accuracy, in order to ensure that the finished

product is consistent in color, texture, and quality. This process typically takes place in a

mixing tank, which is equipped with mixers and agitators to ensure a thorough and even

blend. The paint is then stored in barrels or drums for further processing.

3. Paint packaging and storage: After the paint has been mixed and blended, it is then

ready for packaging and storage. This process involves transferring the paint from the

mixing tank into drums or cans, and then sealing and labeling the containers. The paint is

then stored in a temperature-controlled environment, in order to ensure that it retains its

quality and properties. This process is very important, as it ensures that the paint is ready

to be shipped to the end user. In some cases, the paint may also be stored in a warehouse

for a period of time, before being shipped to the customer.

4. Distribution and logistics: Once the paint has been packaged and stored, it is then ready

for distribution and logistics. This involves transporting the paint from the factory to the

customer. In most cases, this will involve shipping the paint by truck or rail. The paint

must be transported in a way that protects it from damage or contamination. The paint

may also need to be transported to a distribution center, where it will be stored until it is

ready to be shipped to the end user. Once the paint reaches the end user, it must be stored

and handled correctly in order to maintain its quality.

5. Customer service and support: Customer service and support is an important part of the

process of manufacturing and distributing paint. This involves providing information and

assistance to customers, and resolving any issues that may arise. The paint manufacturer
 will typically have a customer service department that is responsible for handling

customer inquiries, processing orders, and providing technical support. They may also

provide training and education to customers, in order to ensure that the paint is being

used correctly. This support is important in maintaining customer satisfaction and

building a positive reputation for the company.

6. Quality control and assurance: Quality control and assurance is a process that is used to

ensure that the paint being produced is of the highest possible quality. This process

involves testing and inspecting the paint at every stage of production, from the raw

materials to the finished product. Quality control checks are performed on a regular

basis, and any issues that are found are corrected. This ensures that the paint meets all of

the required standards and specifications. Quality assurance is also important, as it helps

to identify and address any potential problems before they become a serious issue.

7. Environmental management: Environmental management is a key component of paint

manufacturing. This involves ensuring that the paint is produced in a way that minimizes

the impact on the environment. This includes using raw materials that are

environmentally friendly, and using processes that are efficient and reduce waste. It also

includes managing the disposal of any hazardous materials or byproducts. In addition,

many paint manufacturers are committed to reducing their carbon footprint and

promoting sustainability. This is done through a variety of initiatives, such as using

renewable energy and recycling materials.

8. Health and safety: Health and safety is another important aspect of paint manufacturing.

This involves taking steps to protect the health and safety of workers, as well as the

public. This includes using personal protective equipment, such as gloves and masks, to
protect workers from exposure to harmful chemicals. It also includes regular safety

training, and following proper procedures for handling hazardous materials. In addition,

paint manufacturers must follow all relevant regulations and laws regarding health and

safety. By taking these steps, paint manufacturers can help to create a safe and healthy

environment for their workers and the public.

 CHAPTER TWO: LITERATURE REVIEW

DEFINITION OF A PAINT PROCESSING FACTORY:

Paint Factory or plant is an industrial site, usually consisting of buildings and machinery, or

more commonly a complex having several buildings, where workers process raw materials into

paint. Factories arose with the introduction of machinery during the industrial revolution when

the capital and space requirements became too great for cottage industry and workshops. Paint is

a subdivision of surface coating. It is a relatively opaque solid coating applied as thin layer

whose films are usually formed by polymerization of polyunsaturated oil. However, other

subdivisions of surface coating include: varnishes (clear coating), enamels (pigmented

varnishes), lacquers (film formed by evaporation only), printing inks and polishes. Paints

generally have very low thermal conductivity, electrically inert and can be washed and cleaned.

The various raw materials for making paints include pigments, vehicle, alkyd resins, surfactants,

solvents (thinners) and coloring matters.

2.2 HISTORY OF A PAINT PROCESSING FACTORY

The history of paint processing factories goes back to the Industrial Revolution, when the first

factories were established to mass-produce paint. These early factories were relatively small, and

they used simple machines to mix and produce paint. As technology and knowledge advanced,

paint factories became larger and more sophisticated. They began to use machines such as rollers

and mixers to produce paint more efficiently. In the 20th century, factories began to use

computerized systems to control the production process, and this led to even greater efficiency

and quality control. Today, paint factories are highly automated and can produce a wide range of

paints at a high volume. More recently, there have been a number of developments in the paint
industry that have helped to improve the quality and efficiency of paint processing factories. For

example, the development of water-based paints has reduced the amount of volatile organic

compounds (VOCs) released into the environment. In addition, new technologies such as

ultraviolet light curing have made it possible to produce paints with improved durability and

performance. These advances have helped to make paint processing factories more sustainable

and more efficient. As a result, they are able to produce a high-quality product while also

protecting the environment.

Another aspect of the history of paint processing factories is the development of different

types of paint. In the early days of paint manufacturing, there were only a few types of paint

available, such as oil-based paints and enamels. However, over time, new types of paint have

been developed to meet the needs of different industries. For example, automotive paints have

been developed to provide durability and a high-quality finish, while water-resistant paints have

been developed for use in bathrooms and kitchens. The evolution of paint technology has been a

key part of the history of paint processing factories. There are many different types of paint

processing factories, each with its own unique focus. For example, there are factories that

specialize in the production of automotive paints, architectural paints, industrial paints, or marine

paints. Each type of paint has its own specific requirements and uses. Automotive paints, for

example, must be able to withstand the harsh conditions of the road, while architectural paints

need to be durable and fade-resistant. Industrial paints may need to be able to withstand high

temperatures or corrosive environments. Marine paints are designed to resist the harsh conditions

of the ocean environment. Another way that paint processing factories are divided is by the size

of their operations. There are large, multinational corporations that produce paints on a massive

scale, and there are also small, family-owned businesses that produce paint in smaller quantities.
In addition, there are specialty paint companies that produce custom paints for specific

applications. The size and scope of a paint processing factory can vary greatly, and this can

affect the way the factory operates and the types of paints it produces.

There are two main types of manufacturing processes: batch and continuous. In a batch process,

the paint is mixed in small batches and then stored in tanks or drums for later use. In a

continuous process, the paint is mixed continuously and then transferred to storage containers or

directly to a packaging line. The type of process used will depend on the type of paint being

produced and the needs of the company.

Another interesting aspect of paint processing factory is the different types of equipment used.

Some of the most common pieces of equipment include:

a) Mixing tanks, which are used to combine the ingredients of the paint.

b) Mills, which grind the pigments and other solid ingredients into smaller particles.

c) Dispensers, which measure and dispense the different ingredients of the paint.

d) Filling machines, which fill the containers with the paint.

e) Labeling machines, which apply labels to the containers.

f) Packaging machines, which put the filled and labeled containers into boxes or other shipping

containers.

2.3 TYPES OF PAINT PROCESSING FACTORY

There are several different types of paint processing factories, including:

1. Solvent-based paint factories: These factories use solvents to mix and process the paint.

2. Water-based paint factories: These factories use water as the main ingredient in their

paint formulations.
3. Powder coatings factories: These factories produce powder coatings, which are applied

to surfaces using electrostatic charge.

4. UV-cured paint factories: These factories produce paints that are cured using ultraviolet

light.

5. Epoxy paint factories: These factories produce epoxy paints, which are used in industrial

and marine applications.

6. Industrial paint factories: Industrial paint factories are a special type of paint processing

factory that is designed to meet the specific needs of industrial customers. Industrial

paints are often used in harsh environments, such as in factories, power plants, and other

industrial settings. These paints must be able to withstand high temperatures, exposure

to chemicals, and other harsh conditions. Industrial paint factories use specialized

equipment and processes to produce these paints.

7. Powder coatings factory: Powder coatings factories produce paints that are applied to

surfaces using a process called electrostatic spraying. These paints are applied as a dry

powder and then heated to form a tough, durable coating. Epoxy paint factories produce

paints that contain epoxy resins. These paints are used in industrial and marine

environments because they are resistant to corrosion and chemical damage. Automotive

paint factories produce paints that are specifically designed for use on automobiles. They

are formulated to provide a durable, glossy finish that is resistant to fading and

scratching.

8. Wood coatings factory: Wood coatings factories produce paints and stains that are used

on wood surfaces. These products are designed to protect the wood from moisture and

UV damage, and they can also enhance the appearance of the wood. Metal coatings
 factories produce paints that are designed to protect metal surfaces from corrosion and

abrasion. These paints can also provide a decorative finish to the metal surface. There

are also a number of other specialized paint factories, such as marine coatings factories

and aerospace coatings factories. These factories produce paints that are specifically

designed for use in marine and aerospace environments.

2.4 CASE STUDY

INTRODUCTION

In the previous chapter’s discussions have been on the production process for the manufacture

of different paint products, and the factory design criteria. All these are channeled towards the

eventual realization of the project; a paint factory, Makurdi. However, still with the same

purpose, this chapter will analyze the various existing paint factories based on the following:

a. Background information/location

b. Products

c. The factory layout

d. Analysis of various components

e. Factory processes/production processes

f. Raw materials

g. Plants and machinery

h. Lighting

i. Services

j. Materials of construction

k. Landscape - Appraisal/Assessment.
 Based on these, the following case studies were analyzed;

i. International paints West African Limited, Ikeja, Lagos.

ii. Mater – Piece Chemical Company limited, Oji River.

iii. Haymes Paint Factory, Ballarat, Victoria Australia

2.4.1 CASE-STUDY 1: INTERNATIONAL PAINTS WEST AFRICA LIMITED, IKEJA

LAGOS.

2.4.1.1 BACKGROUND INFORMATION/LOCATION: The factory is located at Oba Akran

Avenue Ikeja, Lagos State. At this same avenue, there are other existing paint factories of the

same standard which include; Berger paints and Dulux paints. One can also find the following

other companies; Guinness bottling company and many others.

2.4.1.2 PRODUCTS

International Paint West Africa Limited manufactures the following vast products;

i. Nigerlux gloss paint

ii. Niger wood, finishes and ancillary products for furniture and plywood factories.

iii. Glamour Emulsion paint

iv. Leader gloss

v. Packaging coating for most of the large food and drinking canning and bottling industries is

Nigeria.

vi. Industrial coating for automotive, aviation agriculture, etc.

vii. Protective coating for steel, concrete structures etc.

viii. Nigertex (textured coating)

ix. Marine coating for small vessels for above and below the waterline.

Different types of Finished and canned Products are shown above.

The Factory Layout

FLOOR PLAN OF PRODUCTION HALL

SECTION OF THE PRODUCTION HALL

PRODUCTION HALL

FACTORY PROCESS

The factory process comes in the following phases;

i. Dispersion stage (Ball mill section)

ii. Weighing section

iii. Mixing and Tinting (Bead mill section)

iv. Sieving (cowls mill section).

2.4.1.3 PRODUCTION PROCESS

Raw materials are brought into the production hall from the warehouse and later charged into

a high speed (high quality) dispersion machine – Ball mill. This machine reduces the raw

materials into smaller, fine aggregates and they are weighed and their qualities determined before

they are moved into the third stage. This stage entails the mixing and addition of some additives.

When the raw materials are mixed and thinned at the bead mill machine until a reasonable level

is achieved, the quality control laboratory tests the quality, viscosity, mix and fineness of the

present paint paste. When the quality and the physical properties of the paint are confirmed, it is

transferred to the cowls mill machine. Obviously, the machine sieves out the unused

agglomerates and pure paint paste is transferred to the tinting section for color matching.

The tinting section takes care of the various final colors of the paint products. However, at the

Tinting machine, the quality control laboratory checks and tests the various colors that is to be

applied. After this, the paint is charged into the canning machines where they are canned in

gallons and transferred into the final storage area for packaging, dispatching and sales.

2.4.1.4 PLANT AND MACHINERY

The plant and machinery for processing, mixing, blending and production of paint include;

Ball mill machine, weighing machine, Bead mill machine, cowls mill machine, tinting

machine/tanks, canning machine.

2.4.1.5 LIGHTING
 Natural lighting is admitted into the production halls and warehouse through roof lighting and

high-level glazing. In the offices adequate daylight is encouraged by the use and installation of

wide range of Louvre windows.

2.4.1.6 SERVICES

Sufficient water from the Municipal water supply can be provided and stored at the overhead

tank for use in the factory. Electricity supply is from the Power Holding Company supplemented

with a high voltage supply from the factory generator.

2.4.1.7 MATERIALS OF CONSTRUCTION

- Walls: Sandcrete bocks are utilized at the offices, restaurants (Jnr), Maintenance block,

Security department etc. and Aluminium Cladding materials on sandcrete blocks at the

warehouses, production halls etc.

- Roofing: Aluminium roofing sheet over simple wooden and steel roofing structures.

- Floors: Reinforced concrete mezzanine and upper floors and reinforced concretes ground floor

for production spaces and normal mass concrete ground floor and reinforced concrete upper

floors for Administrative, Sales, Personnel and Maintenance Units.

LANDSCAPE

The entire factory is fairly landscaped due to over utilization of the available space and little

set-back from the main road. However, almost all external spaces are paved except the parking

and entrance areas which are finished with chipping.

 E

XTERNAL LAYOUT OF THE FACTOR

APPRAISAL/ASSESSMENT

The factory is planned on a separate building planning layout and based on some considerations.

The assessments are as follows:

i. The factory has a standard scope with the following components: administration,

production, warehousing, welfare, and research, etc.

ii. The separate buildings help in isolating the noisy zones from the quiet zones, but the

functional relationship of these various units is weak. However, the relationship between

the production areas is direct and efficient.

iii. There is no defined, strong, covered connection between the various separate blocks.

iv. The overall planning of the layout has no expansion possibility due to over utilization of

the spaces and poor external planning of the different blocks.

v. Due to the incorporation of double loaded corridor in office planning, there is poor cross

ventilation, however, this is supplemented with adequate artificial ventilation system (air
 condition). But, adequate natural ventilation is obtained in personnel department and

other units with single loaded corridor.

vi. Lighting in both the production areas and offices is relatively adequate. In the production

areas, it is admitted through roof lighting and high level glazing. But in the mezzanine

floors maximum artificial lighting is utilized.

vii. There is a good control of noise and vibration generated in the production hall.

viii. The production line of the factory is good in terms of the in-flow and out-flows of raw

materials and finished products respectively.

2.4.2 CASE-STUDY II: MASTER-PIECE CHEMICAL COMPANY LIMITED, OJI

RIVER.

2.4.2.1 BACKGROUND INFORMATIONS/LOCATION

The factory is located at Mile 2 Oji-River, off the old road from Enugu to Awka. The actual

place is the masterpiece village, after the police college.

2.4.2.2 PRODUCTS

Master-piece Company with full production capacity of 7500 gallons per week manufactures the

following products;

i. Decorative paints (Galaxy paints)

ii. Allied paint products (glue)

2.4.2.3 THE FACTORY LAYOUT

The factory layout consists of the following;

1 Offices (administrative Units)

2 Welfare (Canteen, Clinic)

3 Showroom

4 Raw Materials and finished good storage Unite

5 Production Hall Security House.

Note: All these are contained in separate buildings.

THE FACTORY LAYOUT

1. OFFICES

This block is easily seen while approaching form the main gate. It contains offices for; Board of

directors (Chairman/Managing Director), Assistant to General Manager and office spaces for

Accounts department, Marketing and Commercial departments, Store, Transport division etc.

2. SHOWROOM
 This is at the opposite side of the office units and could be easily seen while approaching from

the main gate. In this space, the products are exhibited are displayed and even sold to interested

visitors.

SHOWROOM AND FINISHED PRODUCT STORE SECTION H-H

3. WELFARE

The staff welfare comprises of the staff canteen and medicare.

Canteen: this is at the rear of the factory buildings, nearer to the Giant warehouse and the

production hall. It shares the same open court with these units.

Medicare: this is off the factory premises, outside and close to the security house. The factory

hospital delivers the required drugs to this unit for onward utilization by workers.

4. WAREHOUSE

There are different types of storage spaces, the general storage area, the finished goods

storage area, the raw material storage area and the giant warehouse.
 The general storage area is located at the same building with the showroom, divided by a

partition wall. It is used for the storage of stationaries, or general goods. The raw material

storage area is beside the showroom and it has its delivery yard at the entrance to the factory (the

open court). This court is common to the offices and the showroom.

The giant warehouse for the storage of finished products, maintenance equipment and repair

of vehicles, is located at the rear and close to the staff canteen.

As previously mentioned, it shares a common open court with the production hall and staff

canteen, and this usually serves as the service yard.

FINISHED PRODUCT STORE

5. PRODUCTION HALL

This is where the production process takes place and it is located behind the general storage

and showroom and has an open court as mentioned above.

 PRODUC

TION SECTION

PRODUCTION HALL

6. SECURITY HOUSE

This is at the main entrance gate to the factory and has an area for 3 security men and a

waiting space.
 2.4.2.4 FACTORY PROCESS

This include:

i. Weighing

ii. Mixing

iii. Sieving

iv. Packaging/Canning.

2.4.2.5 PRODUCTION PROCESS

From the storage area, raw materials are weighed and transferred to the mixing machine in the

production hall. Different raw materials are thoroughly mixed to a reasonable level and quality.

The physical properties are usually tested and controlled during this stage.

The paint paste eventually goes to the sieving machine from where they are charged into the

storage tank for the final stage of the manufacturing process – Canning. The finished products

are packaged, stored and dispatched to various depots.

2.4.2.6 RAW MATERIALS

The basic raw materials are:

i. High grade pigment

ii. Solvents and vehicles

iii. Water

iv. Synthetic resins.

 2.4.2.7 PLANT AND MACHINERY

i. Weighing machine

ii. Medium size mixing machine

iii. Mixing and storage tanks

iv. Canning Machine.

2.4.2.8 LIGHTING

The introduction of daylighting into the production hall, storage spaces, giant warehouse,

etc. is through high level (600mm) window opening, vertically protected with metal rods.

However, the interiors of the above spaces are daily lit, due to the amount of light admitted and

the lack of roof lighting.

Natural lighting is introduced into the office and staff welfare blocks through a wide Louvre

window opening.

SERVICES

Obviously, the supply of electricity is not a problem due to the location of the Oji River Power

generating station close to the factory village. Water supply comes from the water Board, while

as River water supply comes from Dodo River and Oji River.

MATERIALS OF CONSTRUCTION

FLOORS: Reinforced mass concrete floor with reinforced strip foundation at production areas

and normal mass concrete floor at other spaces.

WALLS: Sandcrete block walls.

 ROOFING: The roofing system is the normal pitch roof with wooden roof structures and zinc

roofing sheets

LANDSCAPE

The entire factory and open courts are still bare without grasses, trees or shrubs. There are

no defined walkways, driveways and the parking spaces are not sufficiently landscaped.

EX

TERNAL LAYOUT OF THE FACTORY

APPRAISALS/ASSESSMENTS

i. The facilities are not adequate for a standard paint factory but, the existing ones are

enough for smooth and effective functioning of the factory. However, there is no research

unit, standard sales, accounts, administrative or commercial department.

ii. The adoption of separate building blocks is not well articulated and it is not efficient in

terms of the smooth and direct functional relationship between various facilities.

However, this concept really separates the noisy zones from the quite or private zones.
 iii. From the concept of separate building, there is a high expansion possibilities. All the

facilities can expand as much as necessary. However, this idea was not considered

thoroughly during the initial design and layout.

iv. The separate buildings encouraged adequate cross ventilation except in the administrative

offices due to the use of double loaded corridor.

v. The lighting of production spaces through high level windows is not sufficient and

effective at work places and worktops.

vi. The entire landscape of the factory needs to be redesign and improved based on the

existing facilities.

vii. The factory does not reflect itself and it does not exhibit a good aesthetic façade.

viii. The production line of the factory is not direct and it conflicts with other facilities.

2.4.3 CASE STUDY THREE: HAYMES PAINT FACTORY

2.4.3.1 LOCATION: BALLARAT, VICTORIA AUSTRAILIA

2.4.3.2 BRIEF HISTORY

The Haymes Paint complex sited outside Ballarat on an industrial estate was designed in

response to the brief of a local private paint production company to provide a socially aware

environment that balanced the needs of staff and community groups with normal business

aspirations.

The intrinsic nature of paint and its potential to affect environments was a strong element in

the shaping of buildings and their surrounding spaces. The expressed structure and planar

elements of the buildings celebrate the notion of as a persuasive pscho-responsive medium that

embellish elements in a colour field experiences.

 Haymes Paint has built an enviable reputation for one thing, a single-minded dedication to

quality. A fourth-generation family company Haymes now supplies premium quality products

around Australia through the paint specialist network.

When David Haymes says “Paint runs in my veins”, he really means it. Haymes Paint,

started by his father Henry. It isn’t just a business to David, it’s an obsession.

Haymes Paints is also a signature to the Australian Packaging conevant and understand the

fragility of our environment and climate. Therefore, Haymes Paints is working towards a goal of

zero waste. Reducing out water usage, energy consumption and emissions are examples of areas

Haymes are targeting to improve sustainability and protect our environment for future

generation.

2.4.3.3 PRODUCTS

Haymes Interior Expression

Haymes Interior Expression is quite simply the first interior paint, offering the most

advanced way to bring colour and style into life. Using Haymes enables passion to craft the best

paint, the interior Expression range brings you discernibly richer, true colours to impress.

Haymes Ultra-Premium Prepcoats

Haymes Ultra-Premium Preparation coats offers a complete range of primers, sealers and the

best possible results. Preparation is vital in achieving the best possible finish which is why

Haymes have an extensive range of specialist preparation products to cater for every substrate to

ensure the right foundation for every finishing coat.

 The Haymes Newlife interior wall finish range offers a premium quality finish that is easy to

achieve. Available in a wide variety of finishes suitable for every area of the home the new life

wall finish range is an acrylic formulation making it a washable and durable finish. It provides

great coverage and is easy to apply.

Haymes Designer finishes Suede

It is a rich, ultra-premium paint that dries to a soft matt finish, delivering a textured,

sophisticated look. This water-based is suitable for use on both exterior and interior surface.

i. Easy to apply

ii. Wash up in water

iii. Interior and exterior durable.

Haymes Solashield

Self-priming with superior UV protection and durability, Haymes solashield is reinforced

with a 15 year protection guarantee. It resists cracking, fading and is easy to apply.

Haymes Ultratrium

Is the next generation water based enamel ideal for doors, windows and trims. It advanced

low odour formulation goes beyond the Green building requirements which mean that now you

have a green alternative and can say no to those smelly solvent based enamels.
FACTORY EXTERNAL LAYOUT

TINTING TANK PRODUCTION

HALL
AN INTERNAL LAYOUT OF ONE OF THE PRODUCTION HALLS

INTERNAL LAYOUT OF OTHER PRODUCTION HALL

ENTIRE FACTORY LAYOUT

EXTERNAL FACTORY LAYOUT

 FINISH AND PACKAGE PRODUCTS

2.4.3.4 APPRAISALS

i. The elevations of the Administration building is very impressive

ii. The planning of the site is wonderful according to the information given by the website –

it falls in concordance with the nature of the Ballarat Town.

2.4.3.5 GENERAL DEDUCTIONS/LESSON FROM CASE STUDY

LOCATION: All the factories are sited in the industrial district of the town in which they are

located.

SITTING FACTORS: Proximity of supply to raw materials and market transport access,

availability of labour and the general topography have all been given attention in all the case

studies made.

WATER SOURCES: Water availability is given some measures of prominence in all the

industries visited and should therefore constitute a vital element of any plastic industry. A

borehole is a necessity.
 PLANNING: The layout of independent units did not observe the zoning principle as the

administration units is almost glued to the factory building. Major prominent areas identified

include:

i. Administrative block

ii. Production hall

iii. Technical area

iv. Staff welfare.

ORIENTATION: East-West oriented sites do not have problems with ventilation and cross

ventilation for the production is well disposed.

2.5 DESIGN CONSIDERATIONS

MATERIALS AND CONSTRUCTION

1. FOUNDATION

The recommended type of foundation for the Paint Factory is pile foundation, and it is based

on ground water content of the soil. The depth of the pile foundation will vary depending on the

function under consideration. Recommended Foundation.

2. FLOORS

A. Ground floors: for all types of ground floors supporting heavy machine, there will be the

need for:

i. Adequate strength to support the machines and equipment.

ii. Adequate resistant to shock, abrasion, vibration and heat conduction.

iii. An easily moved and replaced large floor section.

iv. A surface that does not suffer from temperature and humidity changes or sudden contact

with oil, acids and other solvents.

v. A noiseless, sound absorbing, non-slippery surface under any condition.

vi. A surface where machine and equipment can easily be fastened.

From the above analysis, reinforced concrete is recommended. For other ground floors like:

administrative areas, welfare unit, ceramic floor tiles are recommended.

B. Upper Floor: The upper floor of some areas and the mezzanine floors of the production units

are to be constructed with reinforced concrete. For spaces with exceptional span, special floor

construction like waffle grid could be used as an alternative.

C. WALLS AND COLUMNS

The structural systems applied to the construction of factory are:

I. Load bearing wall system; in this system adequate natural ventilation, lighting and views are

sacrifice because of the existence of small openings on heavy and costly load bearing walls.

II. Frame construction system; in this system effective and maneuverable wall surface is

achieved with sufficient ventilation and lighting due to wide fenestrations. This system also

suffers from a high noise and heat penetration.

From the above analysis, the frame construction system will be adopted for the factory with

the incorporation of plastic panels on this block walls with an insulation gap between them. The

block wall prevents fire noise penetration while the panels prevent heat penetration and the

insulation gap traps air and prevents the ease of heat absorption (solar radiation) and noise.
 D. ROOFS AND CEILINGS

Roofs due to their large surface are the chief sources of heat inside the building from the sun

through convention and radiation. Roofs should exclude unfavourable weather, have adequate

height and allow sufficient daylight without glare or shadow. Therefore, heat-reflective

aluminium sheets material with adequate insulation will be adopted. Besides, the ceiling will

have a good reflective property. Some of the considerations on the types of roof structure are the

ceiling height and usefulness of overhead. For example, in the production hall, warehouses etc.

there will be considerations of materials handling machine, machine height stacking system,

overhead service etc. The following ceiling heights are recommended:

Administration block - 3m

Entrance Hall - 4m

Conference Hall - 4m

Board room - 4m

Staff induction room - 4m

Staff cafeteria - 4m

Laboratory and Library - 3m

For the production section the following standards are adopted where necessary.

S/n Types of Production Without Overhead With Overhead

1 Small product assembly on benches, offices 3 - 5m 3.5 - 6m

2 Large product assembly on floor or floor Maximum height of product + Maximum height of product

features 75%
 + 75%

3 Small product forming Height of machine + 100% Height of machine + 125%

4 Large product forming Height of machine + 125% Height of machine + 150%

For these spaces, roof light, head expellers, overhead lighting and services will be adopted.

E. DOORS AND WINDOW Doors: for safety against fire and burglary, folding doors and

recommended for the following spaces; Production Hall, warehouses, Maintenance Units,

Storage etc.

For Entrance Hall, Restaurant, Induction room, Conference Hall, Boardroom, Library etc.

revolving doors with heat reflective glazing are recommended. Fire escape doors will also be

located at different areas.

Windows: All windows will be made of metal frame and louvre with heat absorptive glazing,

free from heat, fire, noise, dust etc, effects. Windows in the production Hall and warehouse can

be double glazed.

FIRE AND NOISE CONTROLS

A. FIRE CONTROL

Fire is a chemical reaction which occurs when the chemical structure of a fuel is broken by

heat energy. This reaction usually occurs in the presence of oxygen with the release of heat and

light. Fire control is an effective measure towards industrial safety because most of the materials

found in an industrial environment are always disposed towards fire hazards. Therefore, this

should be considered in the design of this paint factory.

Fire control involves the following safety measures:

 i. Prevention of fire by eliminating oxygen or isolating fuel from the source of heat.

ii. Extinguishing fire by reduction or removal of the heat by cooling below the ignition

temperature, removal of fuel or by the use of dry chemical extinguishers, removal of

oxygen by smothering with carbon dioxide (CO2) and a combination of more than one

method. Therefore, for fire control in the entire system, the following devices will be

used:

1. The active and passive measures include the use of firefighting equipment, fire alarm,

automatic sprinkler, water tanks etc. use of hood and stair venting to remove heat and smoke and

installation of smoke and heat detectors.

2. Choice and treatment of building materials; use of enough concrete cover on reinforced

concrete structures, use of plastic panels of lower-class flame spread, use of adequate timber

dimensions, use of flame-retardant surface coating, insulatory steel and aluminium materials, etc.

3. General Design Measures Provision of an alternative means of escape in various components

of the factory, use of fire-resisting construction in staircases, self-closing doors, etc; provision of

access route for firefighting department, prevention of air cavities between walls and

combustible linings.

NOISE CONTROL

Control of noise pollution will be based on two sources; from outside and inside the factory.

However, the following devices will be used.

i. Use of landscape features to shield noise pollution from traffic and other external sources.

ii. Use of acoustic panels to prevent noise from production areas and warehouse.
iii. Use of discontinues floor units to prevent noise or vibration transmission from one floor

to the other.

iv. Use of resilient materials as machine pads to absorb vibrations.

v. Avoid transmission of vibration from floors to walls by separating both units.

vi. Isolate noise sources; group noisy equipment in one compartment.

ENVIRONMENTAL/CLIMATIC CONTROL

Climatic control is an important element of factory design. It influences the disposition of

buildings, process layout, orientation of building, the selection of materials and the detailing of

building elements. The means of control of climatic factors analyzed as follow.

RAINFALL

i. Use of water-resistant materials for construction and surface finishing

ii. Effective water drainage by sloping roofs and floors, drains, roof gutters etc.

iii. External ground covers and landscaping to prevent water erosion.

iv. Overhanging caves and other means of countering the effects of wind drives rain.

ii. TEMPERATURE

i. Use of heat insulating material and devices.

ii. External ground covers and landscaping to absorb heat from the sun.

iii. Use of heat absorbent and heat reflective glazing.

iv. Adequate cross ventilation through efficient design.

v. Use of building materials and structures that will tolerate large temperature variations.
 SOLAR RADIATION

i. Use of vegetation and landscaping to prevent glare and intensive sun rays.

ii. Use of sun shading devices to cut off sun rays like; deep overhangs, sun breaking

horizontal and vertical fins.

iii. Efficient orientation of building to achieve good sun incident angle (diffuse lighting).

WINDS

i. Use of good materials, construction and building structures that can withstand excessive

wind effects.

ii. Good orientation of building relative to wind direction will ensure good ventilation and

prevent wind draught.

HUMIDITY

i. Utilize good ventilation for effective air changes which will reduce the level of internal

humidity.

ii. Use of moisture-resistant building materials on walls and floors.

iii. Use of mechanical and chemical dehumifiers and air expellers in warehouses and

production hall.

ENVIRONMENTAL CONTROL

The following solutions to different environmental problems are to be adopted; viz:

VENTILATION
 In a warm humid climate like that of Makurdi, irrespective of the quantity of fresh air

required, in busy manufacturing areas, it is always essential to ensure adequate but not excessive

air movement in working zones. This prevent stagnation and avoid a built up of odour or

contamination. This air movement does not depend on volume of air in rooms but on the volume

of air handled, the velocity and temperature at which it is introduced and the characteristics and

location of air supply ventilators, louvers or other means of cooling the working zones.

To provide pleasant comfort condition in the entire system, natural air movement will be

induced by the use of the following:

STACK EFFECT

This can be achieved by the installation of heat expellers, use of roof vents or adjustable roof

lights, etc. that will enhance the flow of air current. In other words, warm air generated by

machines and workers is made to rise up and escape through the roof openings while cool air

from outside replaces its position.

PRESSURE DIFFERENCES

This could be possible by placing air outlet directly opposite air inlet as much as possible to

provide cross ventilation which aids rapid air changes without any change of direction which

reduces wind speed in its journey from the pressure to the suction area.  Use of adjustable

windows example louvres, landscaping, courtyard, use of single loaded corridors, use of

mechanical ventilation.

TOPOGRAPHY

i. Use of land covers and landscaping to check erosion.

 ii. Use of ramps and steps to provide access from one level to another.

iii. Use of embankments, retaining walls to exploit height differences.

VEGETATION

Utilize good natural vegetation to provide effective surface cover and landscape against and

radiation, wind, noise pollution etc.

ORIENTATION

This involves the placement of building on site to satisfy the demand for adequate ventilation,

view, reduction in amount of solar radiation, etc. In other words, this is influenced by wind, and

sun directions. However, the best orientation based on sun path, is East-West, facing this

direction. Similarly, the best orientation based on wind direction is SE-NW, with the longer side

of the building facing the direction. Based on the above, the best orientation is a compromise

between the two and in satisfaction of visual requirement on site.

LIGHTING

The provision of lighting to work places is a valuable contribution to people’s working

condition. The quality and quantity of light affects people’s productivity, accuracy and

psychological attitude towards the work. The basic aim of lighting is to achieve a specific high

standard of visual efficiency for a task, which requires a systematic approach to the working

environment. Interior lighting in this factory must fulfill two functions:

Illuminating the interior and its contents.

Illuminating the manufacturing processes to an extent that allows visual efficiency.

 Natural and artificial lighting are the means of achieving good lighting and they have

significantly different characteristics and their effects must be considered.

NATURAL LIGHTING: This can be achieved by using the following:

i. Fenestration – use of window, doors glazing and void.

ii. Roof lighting – for this to be adequate they must be large enough to give the required

daylight factor and spaced to provide an even spread of light over the work place. They

should also control disability glare and make provisions for maintenance.

ARTIFICIAL LIGHTING: The availability of daylight is such that the majority of building

cannot be adequately lit by daylight alone through normal working hours and mostly during the

night. This is, however, supplemented with artificial light.

Different types of lamps are good solutions to the problem but, fluorescent lamps are suitable

and cheap solution for the majority of all. The following table gives the types of lamps to be

installed in some stated sections.

COLOURING

Use of complementary harmonious colours has an effect on performance, efficiency and

productivity. It also promotes safety by identifying dangerous areas and escape routes. Coloured

lighting can also be used to emphasis working and circulation zones and for identifying services

and machinery.
 The basic functions of colour are to aid vision, psychological effects, aesthetic effects, and

to develop a pleasant and orderly appearance. The proposals for colour application are as

follows:

(a) Brightness contrasts shall be greater within the confines of the work in hand.

(b) Brightness contrast shall be less between work in hand and its background.

(c) That is contrast farther away shall be permitted to interfere with the first two relationship

mother words, effective illumination upon the object in work is required, slightly less upon the

background against which the object is seen, and successive small contrast against the floor,

walls or other surfaces within view.

FLOORS: This should be light in colour in order to minimize brightness contrast. The

specification of lighter colours is based on the fact that less light falls open the floor than upon

the machine. The colour of the floor will approach neutral as a concession to maintenance and as

a common denominator between other colours.

WALLS: Slight brightness contrast is required between the walls, the machine and their colour

value depends on their distance, height, orientation and illumination. Upper part of walls shall be

in white and lower parts in colours that will achieve the above effect.

CEILINGS: These should be handled with care because they are situated above the horizontal

field of vision and usually reflects all possible light from sky or interior sources. In most cases

they should be white and maintained by repainting at reasonable intervals.

MACHINES:

I. Mechanical Equipment - Neutral

 II. Maintenance Equipment – Yellow

III. First aid Equipment - Green Cross on white background

OFFICES: White ceilings, walls with colours of not less than 50% reflectance and provision of

architectural light sources above and left of the officers left shoulder.

ENTRANCE LOBBBY: This space where public is admitted should obviously exemplify in

colour, the quality, function, character, etc. of the paint factory it represents. Here, different kind

of painting can be used to exhibit the products, create free expansion, imagination, drama and

fancy. Fortunately, the necessity of observing rules for good seeing is not present, since people

spend on a few moments here.

Therefore, the visitor’s first impression is important and then lobby should be designed with

features that will influence him favourably towards the factory. Painting in colour will be an

integral part of the attack upon his emotions. The following colours are recommended:

i. BLUE: This is definitely calming, welcoming and cool colour.

ii. YELLOW (LIGHT): Brings good cheer.

iii. RED: Excites to courageous endeavour and feels warm.

iv. ORANGE: Powerful stimulant of all

ROAD AND PATHS

i. The existing roads in the industrial layout close to the proposed site will be used for the

service, staff and visitors’ routs.

ii. Landscaped foot paths will be used for the pedestrian walkway.

iii. Additionally, covered walkways will be used where necessary.

iv. Provision will be made for disabled circulation, if necessary, with the use of ramps etc.

CHAPTER THREE

3.1 RESEARCH METHODOLOGY

The purpose of this research is to really collect important information towards the

realization of this project and to make an important contribution to Architecture, some research

activities had been carried out and data collected through;

1. Visits to existing paint factories site of the projects to determine their production processes,

organizational chart and determine the requirement and conditions to be fulfilled in the setting up

of such factory.

2. Use of libraries, research institute, books, journals and unpublished manuscript of thesis

reports.

3. Visits to relevant Government establishment like the ministry of commerce and industry, for

collection of data, byelaws, history and other important information.

4. Personal interview of some people.

5. Internet.

3.2 LIMITATION OF RESEARCH

 Due to the limitation of standard paint factories in Nigeria, one is limited to researching

with only the small-scale private paint factories. In researching with the private factories, it was

discovered that the factories were over protective of their setting. They feared that their

competitors might get hold of information given out for the research and have a hold over them.

Some of them that co-operated discourage photographs.

CHAPTER FOUR

DESIGN

4.1 STUDY AREA/ LOCATION

Akinlalu is a locality in Ife north, osun state. Akinlalu is situated nearby to the

localities Idiroko and Oloji.

Fig 4.1. Location map showing streets and landmarks.

Source: Google Map

Fig 4.2. Location map showing streets and landmarks in satellite view.

Source. Google Earth

4.2 SITE SELECTION AND ANALYSIS

To a large degree the site has a direct influence on the ultimate efficiency and performance

of the plant through the effects of site factors on plant design and construction. Subsequently, the

selection of a site is necessary to understand the kind of plant to be built. Therefore, for the paint

factory to be efficient there must be considerations towards suitable site selection.

4.2.1 CRITERIA FOR SITE SELECTION

Industrial location decisions involve the determination of all factors that will afford the

establishment, the greatest advantage to be obtained by virtue of location. The determination will

be whether the site will be away from congested city areas, away from any industrial slums or

whether the site will tend to be in a country area. Subsequently, there will be determination

towards the size of the site, immediate community and other general conditions. Perhaps the

most important reason for a large site is flexibility for expansion. The design must be such that

the plant can be extended on any of its four sides, so that extension is feasible without reshuffling

the entire layouts. Additionally, there is nothing quite conducive to contented working as a

pleasant, landscaped, park-like setting. Then there will be other considerations like market,

utilities, transport, labour and perhaps publicity value if the site is near a main highway. To a

great extent, the site has a direct influence on the ultimate performance of the plant.
4.2.1.1 GENERAL INDUSTRIAL LOCATION FACTORS (Ryan Abramson 2023)

Some of the general determinations of a site’s value are:

1. Geographical location

2. Market location

3. Proximity of competitors

4. Relation to suppliers of components, accessories etc.

5. Local climate (prevailing winds, sun heat load, humidity – does the process required dust-free

atmosphere? High or low operating temperature.

6. Sources and availability of raw materials –

(a) Locate plant at raw material source or at market or between them when materials used are

without weight loss.

(b) Locate plant at raw material source when weight losing materials are used.

(c) Locate plant close to market, when materials are universally available.

(d) Locate plant at the market, when material increases in weight alter operation.

7. Local power and fuel sources.

8. Industrial and fire protection water.

9. Sewage and waste disposal possibilities.

10. Tax rates.

11. Labour force and cost of skilled and unskilled labour.

12. Transport facilities.

13. Land contours (existing or easily modified contours may actually simplify solution of traffic,

loading dock, multi-level processing problems).

14. Site size, available land and comparative cost.

15. Possible residential facilities for employees.

16. Soil strength.

17. Spring or potential flood conditions, and natural disaster.

18. Laws and working condition.

4.2.2 SITE LOCATION AND DESCRIPTION

Plate 4.1: Image showing Africa on the world map Plate 4.2: Image showing Nigeria in Africa

Source: Google Source: Wikipedia

 Plate 4.3: Image showing Ogun State in Nigeria

Source: Osun State Ministry of Lands and Physical Planning, Osogbo (2010).