Nippon Paint India Private Limited, Chennai) Nippon Paint, headquartered in Japan, has over 131 years of experience in the paint industry. Over years,

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1 Welcome to Green Co Summit-2016 Hyderabad Best Practices in Product Stewardship. Mr.Tushar Sinkar Mr.Arun S

2 Nippon Paint India Private Limited, Chennai) Nippon Paint, headquartered in Japan, has over 131 years of experience in the paint industry. Over years, Nippon has grown to be the number one paint manufacturer in Asia and among the leading paint manufacturers of the world. Nippon produces high-quality paints and coats for automotive, industrial and decorative sectors. Over the years, Nippon Paint has perfected its products by means of breakthrough paint technology, with an emphasis on innovation and ecofriendliness. After over five years in the Indian market, Nippon Paint is steadily becoming a household name. Apart from a range of interior, exterior and enamel finishes, Nippon has many specialty products that showcase its technological prowess. The Nippon Paint factory located at Sriperumbudur near Chennai caters to the decorative segment of Nippon Paint in India. Spanning across an area of acres of land, the plant is Nippon s first greenfield project in India. Nippon Paint, Chennai manufactures both water based paints and solvent based paints, with the water based paints taking nearly 85% of the product mix. Nippon s Lean for Growth (LFG) principle emphasizes the concepts of LEAN, sustainable growth and delivery of margin. It encompasses three other main concepts followed by Nippon which are Total Quality Management which is to do it right the first time, Strong Manufacturing Program which is a key enabler to deliver consistent and quality products and Productivity and Efficiency Reporting Tool which is productivity and efficiency data tools. Nippon Paint, Chennai has incorporated GreenCo in its LFG principle thereby imbibing concepts of GreenCo in its day-to-day operations. The unit was rated GreenCo Gold in April Nippon Paint, Chennai has the distinction of being the first paint manufacturing company in India to be GreenCo Rated and multiple products being GreenPro certified.

3 Green Co Journey

4 Manufacturing Process Process Flow B2 B4 B1 B3 B5 B6 Additives Latex Notes: 1 Color tinting and color matching excluded from this study

5 Mission. We will always explore new technologies and markets, to create paint innovations that respond to the ever-evolving needs of our customers. As colour artistry is part of our DNA, through our products and effort, we constantly aim to beautify our surroundings. We will always strive to ensure that our paint innovations are kind to the environment - protecting nature will always remain a priority. This means environmentally sustainable manufacturing processes and working to exacting standards.

6 AQUA ENAMEL SYSTEM

7 Project Background Consumption of water based products in today s market, especially in household segment has increased drastically up to 80%. When working in confined or poorly ventilated spaces, the evaporation of solvents can be uncomfortable for workers or even flat out hazardous to their health. For this reason, many projects have started demanding for low or no volatile organic compounds (VOC) products. Hence it was important to meet customer requirements by offering water based products with performance closely matching that of solvent based products. This would help in achieving low VOC content and reduce carbon footprint. Nippon s Aqua Enamel was launched to meet industrial requirement through water based paints providing performance of solvent based paints.

8 In many of our group countries, water based enamel was launched long time before. As a part of group we at NPI were also engaged in development of water based enamel from year Market Challenges Overall acceptance from market was not satisfactory. Price was major factor. Consumer was not ready to pay more for safe product. Habits some times become obstacles for change.

9 Management Support From day one of Nippon paint inception in India, we decided to focus more on water based products. Since we are the first to develop a water based coating for Auto industry, Top Management was very keen to see water based product with property close match to solvent based enamel. Top management wanted to extend benefit to maximum customer whether its trade use or General industrial use.

10 Trigger of the Project Nippon Paint India Private Limited, Chennai, being a GreenCo Gold rated and GreenPro certified company, considers it their responsibility to initiate new products with reduced VOC content and carbon footprint thereby making it eco-friendly. Use of low VOC paints should be extended to industrial use in addition to decorative segment.

11 Uniqueness of the Project Nippon aqua enamel is completely a water based system of low VOC content and will deliver the same output as that of a solvent based alkyd enamel. Nippon aqua enamel can be applied even on metal, wood and concrete system. The product has been accepted and approved by Godrej and Boyce Mfg. Co. Ltd. and many other companies are looking to use this product.

12 Development Aqua Anticorrosive Primer Low Voc Water Thinnable Apply overcoat after 2-3 Hrs. Good water resistance. Anticorrosive performance upto 150 hrs Salt Spray resistance.

13 Corrosion Commonly known as rust. Destroys luster and beauty of objects and shortens their life. Thenard Corrosion is an Electrochemical Pheonomenon Davy Sacrificial protection of iron by Zinc

14 Factors affecting Corrosion Concentration of dissolved O2 Conductivity of water at steel surface

15 Salt Spray Test The Salt Spray (Fog) ASTM B117 consists of atomizing a salt solution into uniform droplet on specimen supported between from vertical. 5% NaCl Solution. Exposure Zone of Salt Spray Chember maintained at 35 C. PH of Salt Solution in Between

16 Salt Spray Test Chamber

17 SST OF AQUA ANTICORROSIVE PRIMER Salt Sray Test results after 150 hrs

18 Voc Certification

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20 ROHS Certification

21 AQUA ENAMEL

22 Challenges in Development Gloss similar to Alkyd based enamel Good Flow and levelling Good Hardness Good Adhesion Good gloss in shades, normally colournat reduced the gloss. Very limited technology available Some technologies like alkyd emulsion are more expensive.

23 Product Features Low VOC Heavy Metal free Good Antifungal performance Water thinnable Fast drying Non Yellowing Good Gloss retention Technologies Alkyd Emulsion Polyurethane dispersions Normal Emulsions Pure Acrylic emulsion Silicone emulsions

24 Alkyd Emulsions Features Open time flow and leveling Gloss at 20 0 Adhesion on wood and metal Wood penetration Corrosion resistance Technologies tried Problem of yellowing Drying Issue Cost of product

25 Comparison of Acrylic v/s Alkyd Emulsion Properties WB alkyd emulsion WB Acrylic Physical drying slow Fast Yellowing Medium low Cost High medium Low temperature drying good bad Coalescence aid demand low high Penetration good bad Gloss level high gloss medium - high gloss Open time --> flow and leveling Good medium alkali resistance bad good Sustainable materials Partially No

26 Gloss Comparison Aquagloss on Acrylic Emulsion Aquagloss on Alkyd Emulsion Alkyd Enamel

27 Black White Golden Yellow Phirozi Blue Smoke Grey Beige Signal Red Jade Green Shades Developed

28 VOC Certification

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30 ROHS Certification

31 Further Development WE are in process of developing Bases to make shades through Point of sale.

32 Replication Potential The product and its characteristic is replicable by any paint industry.

33 Environmental Benefits Reduced risk of health hazards Exposure to solvents and other organic liquids is one of the most common chemical health risk at work places. Generally, organic solvents are combustible, often highly volatile and extremely flammable. Some solvents produce vapours that is heavier than air which may move on the floor or ground. A distant ignition source, such as a spark from welding or caused by static electricity is a prevalent hazard. Water based products eliminates such risks.

34 Energy conservation The raw material used for making resins is often natural oils and additives, resins needs to be synthesized and cooked at degree centigrade for several hours. The process, in addition to being a time-consuming one, requires huge amount of electrical energy. In contrast, water based emulsion used for making water based paints are made at a much lower temperature in a short duration, thereby conserving natural sources and reducing carbon footprint.

35 Nippon aqua enamel is a low VOC, heavy metal free, eco-friendly, high durability product. Its improved durability can also delay the painting cycle time.

36 Best Practices in Product Stewardship. Cost Economics Investment made: The product was a result of the Research and Development (R&D) efforts & continuous support of Nippon India Management

37 THANKS