FORM 2 THE PATENTS ACT 1970
(39 of 1970)
COMPLETE SPECIFICATION (SECTION 10)
Rule. 13
AN IMPROVED DEVICE FOR INSTANT MANUFACTURE OF CUSTOMIZED
PAINT, A CONTROL SYSTEM FOR USE IN THE SATD DEVICE AND A
PROCESS FOR MAKING THE PAINT USING THE DEVICE
PIDILITE INDUSTRIES LTD., A COMPANY REGISTERED UNDER THE
INDIAN COMPANIES ACT 1956 HAVING ITS REGISTERED OFFICE
LOCATED AT REGENT CHAMBERS, NARIMAN POINT,
MUMBAI - 400021, MAHARASHTRA, INDIA.
THE FOLLOWING DESCRIPTION PARTICULARLY DESCRIBES AND ASCERTAINS THE NATURE AND THE MANNER IN WHICH THE INVENTION IS TO BE PERFORMED.


Field of the Invention:
This invention relates to an improved device for instant manufacture of customized paint, a control system for use in the said device and a process for making the paint using the device. The device of the present invention is useful for the manufacture of the desired paint at the point of sale (retailer or stockist). The device of the present invention facilitates not only instant manufacture of paint of desired quality and colour, but also in desired quantity at an affordable cost to the customer. Further, by employing the device of the present invention, the customer can manufacture paint nearest to his/her choice at a cost, which is in the desired range by mixing and matching properties of different grades of paints available in the market. For example, a particular paint available in market is very good in hiding, but less in wet scrub than desired. Using the present invention, customer can retain the hiding property, as well as increase the wet scrub by accepting a slightly higher cost or compromise slightly on hiding and get higher wet scrub at same cost. Thus the customer can adjust the properties like the contrast ratio (hiding), whiteness, wet scrub, colour depth, gloss, stain resistance, etc. using the above menu-driven machine. Further it can be tinted as per the shade required by the customer using 16 or more colorants. In other words, the device of the present invention is useful for manufacture of all types of paints with infinite combinations of properties & colours and is a unique one.
The invention also relates to a Control system useful in the above mentioned device and a process for making the paint using the device.
The paint manufactured using the device of the present invention can be applied on surfaces such as interior or exterior surfaces of any building, or structure.
Background of Invention:
There are, currently, a variety of paints and protective coatings available in the market, which are useful for applying onto surfaces of buildings and structures. Presently these paints and coatings are manufactured in factories and supplied in several pack sizes and

grades. The customer has to be content by selecting the readymade paints or coatings from the limited choice of pack sizes, quality and price range available in the market. The customer cannot select the precise quantity required or the precise price range based on his/her own preferences.
Presently paints and coatings are manufactured in bulk in plants and are distributed in different size packs through distributors and retailers. For a particular grade of paint, a minimum bulk batch size has to be made. Inventory of different grades of readymade paints has to be maintained. Sometimes, non-moving stock may lead to dead stock & expiry of shelf life.
Till we developed a device which is the subject matter of our co pending application no 917 MUM 2002 filed on 21.10.02, there was no system - apparatus or process - by which a customer can select the ingredients and manufacture the desired quality and colour of the paint of his/her choice at a cost, which he/she can afford.
Earlier the customization is limited to the selection of colours for standard quality / grade of Base Paint. Base paint of few standard types is manufactured in a factory and it is used for colouring. It is not possible to alter the properties of the base paint at retailers outlet through this tinting / colouring device. Customer can choose a particular shade from thousands of shades of colour as shown on the displayed shade card. This chosen colour is entered into Automatic Colourant Dispensing Machine, which dispenses colourants into pre-filled base paint containers to create the desired colour. Colourant quantity for particular base paint and shade is stored in the computer.
If a customer's paint colour needs to match a particular sample colour, then this sample colour is read by spectrophotometer and colour value is determined. This colour value is then converted by colour matching programme of machine to produce a recipe of colourants to achieve this colour for the Base Paint. These colourants are dispensed by machine into the base paint to create the desired colour.

The applicants being in the field of manufacture of paints and coatings, thought about the
advantages of providing a system - apparatus / process - which will facilitate manufacture
of paint having customer's choice of properties & colour and at affordable cost, at the
point of sale, (such as the shop of the retailer or stockist).
In our co pending application no 917 MUM 2002 we have described and claimed
A system for the manufacture of customized paint with infinitely variable combination of
properties for a desired colour of Paint was not possible using the device claimed in our
above said application Therefore, we continued our R & D in that direction and have
succeeded in developing an invention for meeting the above requirement
In other words, the improved system as per the present invention, to the one described and claimed in our co pending application no 917 MUM 2002 system, will facilitate instant manufacturing of customized paint of desired colour at the point of purchase, the customer will be placed in an advantageous position, because, such a system will help the customer to select a combination of functional parameters of the paint, colour, price range for the paint and quantity of paint whereby the device with the help of embedded control system will determine the exact proportion in which the ingredients and colourants are to be mixed and dispensed, and carry out the mixing process.
Accordingly the present invention is an improvement in or relating to the Invention disclosed and claimed in our co pending application no 917 MUM 2002. Recognizing the importance of such a system namely, a device/process, the applicants took up research & development work to develop a device/process for instant manufacture of customized paint with colour option.
Therefore, the main objective of the present invention is to provide an improved device for instant manufacture of customized paint by choosing from infinitely variable combination of properties / shades.

Another objective of the present invention is to provide an improved device is to provide an improved device for instant manufacture of customized paint at the point of purchase overcoming the limitations of the present day paints.
Still another objective of the present invention is to provide an improved device for the instant manufacture of customized paint, which allows the customer to select the paint quality parameters, required by him/her and at a cost, which he/she can afford.
Yet another objective of the present invention is to provide an improved device for instant manufacture of customized paint, which helps in the possibility of infinitely varying combinations of the ingredients, used to get a variety of paints.
Another objective of the present invention is to provide an improved device for instant manufacture of customized paint by which the customer pays for exactly what he/she wants and is not charged an average/general cost, which is the case with prior art, thereby giving him/her the best value for money.
Still another objective of the present invention is to provide an improved device for instant manufacture of customized paint in which the customer can select and incorporate in the paint, in a cost effective manner, properties required for specific applications such as various interior areas of his / her house, which need painting like, ceiling, walls of living room, bedrooms, kitchen, bathroom, etc., which need different properties of paint. For example, the paint for coating the ceiling may require veryjiigh whiteness, low to medium wet scrub, lower colour depth and high opacity at a lower cost. The paint required for walls of the drawing room & bedroom may require medium wet scrub, lower colour depth, etc. The paint required for kitchen may require high stain resistance and wet scrub for easy cleaning of food stains, etc.
Yet another objective of the present invention is to provide an improved device for instant manufacture of customized paint which facilitates the customer to select a paint

such as white base suitable for his / her choice of colour depth, etc. which can later be coloured using required stainers to achieve, higher colour depth capability for deeper shades, etc.
Another objective of the present invention is to provide an improved device for instant manufacture of customized paint, which allows the customer to select the paint quality parameters and colour, required by him/her and at a cost, which he/she can afford.
Yet another objective of the present invention is to provide an improved device for instant manufacture of customized paint having a compact design, which can be easily assembled at the desired site such as distributor's site.
Another objective of the present invention is to provide an improved device for instant manufacture of customized paint, which can be operated by a layman without any skill.
Yet another objective of the present invention is to provide an embedded control system, control logic to translate the wish of the customer to sequence of operation of various components of the device with the help of the software for instant manufacture of customized paint.
The invention has been developed on the basis of our findings, on sustained R&D, that if a device is fabricated and provided with a control system driven which (i) will calculate ingredients to manufacture paint within the budget while keeping in view the desired properties / requirements / applications (ii) will convert desired properties / requirements of customer into proportion and quantity of each paint ingredients, (iii) will dispense the paint ingredients used in the manufacture of paints automatically at defined quantities and proportions (iv) will convert desired colour into proportion of Colorants required to achieve colour for the selected Base Paint and (v) mixing of the selected and dispensed paint ingredient and Colorants quantities and proportions at the

site, to achieve the final Paint satisfying all the desired requirements of customer and giving desired colour, the above mentioned objectives can be achieved.
The invention is described with reference to the figures shown in the drawings accompanying this specification as an illustration. Invention can, however, be used for manufacture of paints with broader selection of performance parameters than described in the illustration. In the drawings
Fig. 1 shows an embodiment of the device of the present invention, representing a plan view of the device (having three cans).
Fig. 2 represents the plan view of another embodiment of the device of the present invention (having four cans).
Fig. 3 represents the electronic connections of the Control system of the device of the present invention.
Fig.. 4 A represents the flow chart showing the operation of the device without the Internet module
Fig 4 B represents the flow chart showing the operation of the device with the Internet module
Fig 5 A represents the flow chart of the software used for the operation of the device Fig 5 B represents the flow chart of the maintenance component of the device of the present invention
Accordingly, the present invention provides an improved device for instant manufacture of customized paint which comprises a housing (1) incorporating at least three cans (2) for holding ingredients useful for preparing the desired paint, each can being provided with top openings for the ingredients to be filled and bottom openings for connecting to the individual pumps (3) through the pipes (4) the pumps being provided for pumping the ingredients from the said cans (2) into the paint container (6) through flexible pipe (5), the pumps (3) being provided with individual variable frequency drive (VFD) (7) for varying the flow rate of the said ingredients from the said cans (2) to the container(6), the paint container (6) being removable placed on a weighing platform (8), for weighing

the paint formed in the paint container (6), the weight signal from the weighing platform being transmitted to a control system (9), the control system comprising an embedded controller having a LCD (liquid crystal display) (10), the control system also being provided with a central processing unit (11) and an interface ( 18 ) for connecting to a server for facilitating internet connection , the output of weighing platform (8) being connected to the central processing unit (11), one terminal of the central processing unit being connected to the LCD (liquid crystal display) (10), second terminal of the central processing unit (11) being connected to a smart card reader ( 12 ), the third terminal of the central processing unit interacting with the memory ( 13 ), the fourth terminal of the central processing unit being connected to the input of the digital input/output device (14), the fifth terminal of the central processing unit being connected to a tinting unit (17), the output of the digital input /output device
( 14) being connected to a relay board (15 ) and the output of the relay board (15) being connected to the variable frequency drive ( 7 ), and a membrane keyboard ( 16 ) is provided for human interface. Colorants being dispensed from the tinting unit (17) to get the desired color.
According to another embodiment of the present invention there is provided an improved control system ( 9 ) for use in a device as defined above which comprises an embedded controller having a LCD (liquid crystal display) ( 10 ) provided with a central processing unit ( 11 ), and an interface ( 18 ) for connecting to a server for facilitating internet connection, one terminal of the central processing unit being connected to the LCD (liquid crystal display) ( 10 ), second terminal of the central processing unit ( 11 ) being connected to a smart card (12 ), the third terminal of the central processing unit interacting with the memory (13 ), the fourth terminal of the central processing unit being connected to the input of the digital input/output device (14 ), the fifth terminal of the central processing unit is capable of being connected to the tinting unit (17), the output of the digital input /output device ( 14 ) being connected to a relay board ( 15 ) and the output of the relay board (15 ) being connected to the variable frequency drive ( 7 ) and membrane keyboard ( 16 ) for human interface.

According to another embodiment of the present invention it is provided with a method for instant manufacturing of customized paint using the device as defined above.
In a preferred embodiment of the invention, the main container housing ( 1 ) may be partly closed as shown in Fig. 1. It may also be provided with openings ( 19 ) connected to the ingredient cans with pipe to refill the base as shown in Fig. 2r
Though the invention has been described with reference to three cans for holding the ingredients, it is to be noted that it can have more than three cans depending upon the choices of ingredients required for the manufacture of the paints. The bottom of the cans are connected by means of a pipes (4) which may be made of PVC, rubber, plastic, stainless steel being provided with isolation valves, the ingredient from can (2) being pumped through an electric driven pump preferably a screw pump (3) with variable speed drive VFD (7), considering the accuracy at which the paint ingredients are dispensed. At high speed the pump dispenses around 80% of the paint ingredients and the remaining 20 % is dispensed at low speed for accurate cut off
The cans (2 ) used for holding the ingredients may be of suitable sizes, such as 50 litres, 100 litres or bigger size drums and the like, based on the appropriate use of the device at the Point of Sale (Retailer or Stockist or Depot).
The ingredients used in the cans ( 2 ) incorporated in the device of the present invention may be selected from the following : Filler base comprising blends of extenders like talc, china clay, calcite, etc., Ti02 base comprising Titanium Dioxide, Emulsion base comprising a high binding emulsion polymer along with rheological modifiers, etc. Each can (2 ) will contain the individual ingredients. These 3 cans are preferred arrangement. Additional cans be used for separate emulsion polymer for exterior paint additives.

The pumps are controlled by the control system. The control system selects one ingredient for dispensing at a time & sequentially dispenses all the other ingredients. The speed of the motor does the coarse and fine feed arrangement. The motor speed is regulated to dispense around 80% of the required quantity at high speed and for balance 20%, motor runs at a lower speed. It also measures the paint container weight through the load cell (8) & controls the pump speed through (VFD) variable frequency drive (7).
After addition of all the above ingredients, if tinted paint option is selected, then Tint system is activated to dispense required colourants. Tinting system used is standard package commonly available in the market.
The filled paint container (6) is closed and taken out from the device and mixed thoroughly. The mixing can be effected preferably by keeping the container kept inside a gyro-shaker for sufficient period say about 3 minutes for thorough mixing of the ingredients.
The data used in the device of the present invention is based on empirical data, derived from various combinations of paint ingredients. For example, the data incorporated in the device of the present invention may consist of the following information:
Database # 1: Data for Base White Paint

S.No Serial Number
F.B Filler Base - Paint ingredient comprising mainly of blend of extender pigments
like Talc, China clay, Calcite, etc.
T B Titanium Dioxide Base - Paint ingredient comprising mainly of Titanium
dioxide.
EB Emulsion Base - Paint ingredient mainly comprising high binding Emulsion
Polymer along with rheological modifiers.
Hiding : Contrast Ratio
WPL Weight per litre in Kg's.
The above data has been arrived at based on the accepted and recognized standards for the purpose. Accordingly the following standards have been utilized for preparing the
data:
1. Paint Opacity or hiding measured as Contrast Ratio as per ASTM 2805. Paint opacity will determine the covering capacity, higher the contrast ratio better will be the covering capacity.
2. Whiteness measured as Whiteness Index as per ASTM D2244
3. Wet Scrub measured as No. of strokes of brush on Wet Abrasion Tester before failure as per ASTM D 2486 - 96 using 1% soap solution instead of scrub media.
4. Colour strength or depth of colour, which can be achieved on addition of stainers, measured as Reflectance index (ASTM D 5326 - 94), higher the reflectance index, lower will be the colour depth.
5. Cost / Litre of paint in Indian rupees or any other currency of choice.
6. Stain resistance measured as loss of whiteness in dE value, which is the colour difference between painted panel before staining and after washing off the stain as per ASTMD3258-73.
7. Gloss measured on Gloss-meter at 85° angle.

8. Covering Capacity measured as sq. mt. / litre of Paint, which is empirically arrived at by applying the Paint and measuring the spreading rate for giving good coverage of the surface. Every possible combination of the above ingredients is characterized for these 8 paint properties by experimentation. This matrix correlating various possible combinations of these ingredients to its 8 properties are taken into consideration. This information will be upgraded continuously. Database # 2 : This database lists all possible shades and its recipe required to get 1
litre of "Coloured Standard Base Paint"

All the Bases in Database # 1, is divided into 6 types of Bases
1. White
2. Tinted White
3. Pastel
4. Midtone
5. Deeptone
6. Masstone
In each of above types of Bases, 1 Base in middle range is selected as "Standard Base Paint". All shades are linked to one of these 6 "Standard Base Paint" and amount & type

of Colourant required is empirically arrived for 1 ltr of Paint, using a standard Colour matching software. This data is listed in Database # 2
Database # 3 : This database lists all Base White Paint in Database # 1, with a correction factor for each of 16 Colourants with reference point of" Standard Base Paint" Database # 3:

against corresponding "Standard Base Paint". Reducing strength is measured as per ASTM # 2745 using standard Colour Matching software package.
The device has been fabricated in such a way that it is possible to translate/convert/produce/suit the customer's requirements of the paint properties. After the selection and desired proportions of the ingredients are determined, commands are given through the control system to prepare the desired paint.
The control system is a device, which can be an embedded control or a personal computer or a programmable logic controller. The control system used is fabricated specially for use in the device of the present invention. As stated above, the system is shown in Fig. 3. The system should have essentially the following controller features:
1. It should have user interface in the form of display and keyboard
2. It should be able to take input from one load-cell
3. It should have adequate memory or data storage for storing recipes
4. It should be able to control the electrically operated drives, valves and pumps through relay outputs.

5. It should have an interface for connecting to a Server for Internet access.
6. It should be compact
7. It should have expansion possibility for future requirements
The system should also have basic functional inputs for the following :
1. The controller to take the weight as input and activate drives & pumps to dispense desired quantities.
2. The controller to take inputs from the user and determine the recipe.
3. The controller to dispense each ingredient as per recipe
Based on above requirements, a control system has been fabricated comprising
(a) Display Driver
Display driver drives the human interface. Functionally the controller needs only text interface. For better presentation, the LCD with display of 256 colours and a resolution of 640 x 480 (256 colour) TFT LCD pixels is considered.
(b) Keyboard Interface
The keyboard used may be a dust and water-resistant with Membrane keypad. User interacts with paint dispensing system using this keyboard.
(c) Data storage and calculation
Since the number of paint grades can be infinite, the data related to corresponding properties and quantity of ingredients is stored at very small intervals of combination of ingredients. Data can be for infinite combinations, but build up of data will be on a continuous basis and will be appended periodically on the machine by replacing the smart card.
(d) Memory
The system will have 2 types of memory. First will be flash memory to store programmes and data that does not need to be secured. There will be also RAM (random access memory) to store dynamic data that will be needed during programme execution.

(e) Digital I/O
The central processing unit interacts with valves and pump through digital I/O card. The pumps and valves operate from 230 V AC supply. This I/O is isolated from CPU using opto-coupler output.
(f) Relays
Optically isolated relays are provided for isolation between I/O and the field components like valves, drives and motor to avoid accidental high voltage short circuit damage to the control system.
While fabricating the control system, other considerations such as real time clock for date and time, Switched Mode Power Supply are considered, based on actual requirements.
• Description of the software for operating of the improved Paint Dispensing Device
The description of the software for operating the paint-dispensing device of the present invention is given with reference to Fig. 5A and 5B. This consists of following components, namely, Security Component (A), Paint Selection Component (B), Paint Dispensing Component (C), Tint Dispensing component (T), Maintenance Component (D), Smart card Component (S), Internet Component (I), Pump check/Tint Purge Component (PT). The paint-dispensing device is booted by switching on the power supply. The Login Security Component of the software performs authorization using login numeric Password (pin code). The user has to enter a pin code via a keypad (Fig. 3, #16). The Security Component of the software validates the pin code. Upon successful authorization, the Paint Selection Component (B) displays the Main Screen (Bl) that allows the user to either choose from designing his / her own desired paint or select a market equivalent paint as the case may be.
If the user chooses to design his / her own paint, the Design Own Paints screen (B2) will be displayed. All the respective parameters or properties for the desired paint will have to

be entered into this screen (B2). The Paint Selection Component (B) will then query the Paint Database (B3) that is stored in the flash in binary format, and display the resulting paint parameters, price and required volume onto the Design Own Paint screen (B2). If the user modifies any of the paint properties and parameters, the new price and quantity are subsequently displayed onto the Design Own Paint screen (B2). By selecting the confirmation button on the Design Own Paint screen (B2), the Paint Selection Component (B) stores the selected paint parameters (B4) into the control system memory (Fig. 3, #13). The Paint Dispensing Component (C) subsequently reads the selected paint parameters from memory.
If the user chooses to select a market equivalent paint, the market equivalent paints screen (B5) will be displayed. The Paint Selection Component (B) will subsequently retrieve the list of all the available market equivalent paints from the market equivalent paint Database (B6) stored in the flash in binary format. After the user selects the desired market equivalent paint, the resulting price of the paint and the required volume are displayed on the market equivalent paint screen (B5). If the user modifies the market equivalent paint properties and parameters, the new price and quantity are subsequently displayed on the market equivalent paints Screen (B5). After confirmation, the selected paint parameters (B7) are sent to the Paint Dispensing Component (C).
The Paint Dispensing Component (C) calculates the required quantity of each paint ingredient required for the final desired paint mixture. It, then, starts to dispense each paint ingredient sequentially into a container (Fig. 1, #7) by operating the valves (Fig. 1, #4) and pump (Fig. 1, #6). Once the final required quantity of the desired paint mixture is achieved, the paint dispensing process stops and then the Paint Selection Component (B) displays the Main Screen (Bl).
The Tint Dispensing Component (T) is used to dispense tint which is subpart of Paint Selection Component (B) the appropriate base would be selected as per the Tint database (T2). It, then, starts to dispense each paint ingredient sequentially into a container (Fig. 1,

#6) by operating the pump (Fig. 1, #3), followed by Colourants by Tint dispensing system. Once the final required quantity of the desired paint & Tint mixture is achieved, the paint dispensing process stops and then the Paint Selection Component (B) displays the Main Screen (Bl).
Upon pressing a pincode through the keyboard (Fig. 3, #16), on the Login Screen (Bl), the Paint Selection Component (B) will validate the key. If it is the maintenance pin code, the Maintenance Component (D) will display the Maintenance Screen (Dl) that will consist of various maintenance options. Based on the selection of the user, the Maintenance Component (D) will process the respective maintenance request. If the logout button on the Maintenance Screen (Dl) is selected, the Main Screen (Bl) will be displayed.
Upon pressing a pincode through the keyboard (Fig. 3, #16), on the Login Screen (Bl), the Paint Selection Component (B) will validate the key. If it is the Smartcard pin code, the Smartcard Component (S) will display the Smartcard Screen (SI) that will consist of various Smartcard operations. If the logout button on the Smartcard Screen (SI) is selected, the Main Screen (Bl) will be displayed.
Upon pressing a pincode through the keyboard (Fig. 3, #16), on the Login Screen (Bl), the Paint Selection Component (B) will validate the key. If it is the Internet pin code, the Internet Component (I) will display the Internet Screen (II) that will consist of various Internet options. Based on the selection of the user, the Internet Component (I) will process the respective Internet request. If the logout button on the Internet Screen (II) is selected, the Main Screen (Bl) will be displayed.
Upon pressing a pincode through the keyboard (Fig. 3, #16), on the Login Screen (Bl), the Paint Selection Component (B) will validate the key. If it is the Pump check/Tint purge pin code, the Pump check/Tint purge Component (PT) will display the Pump check/Tint purge Screen (PT1) that will consist of various Pump check/Tint purge

options. Based on the selection of the user, the Pump check/Tint purge Component (PTl) will process the respective Pump check/Tint purge request. If the logout button on the Pump check/Tint purge Screen (Dl) is selected, the Main Screen (Bl) will be displayed.
• Sequential Operation of Dispensing Device : The details of sequence of operation of the device of invention as described in the sequential operation below which are given only for illustration purposes and therefore should not be construed to limit the scope of present invention. The sequential operation of the dispensing process is described below:
1. The level of the ingredients in the tank is checked.
2. The total required volume of the desired paint to be dispensed in each paint container is calculated.
3. Repeat steps mentioned below for each paint container.
4. The required weights of the desired ingredients are calculated.
5. The weight of the each ingredient which is to be dispensed is also calculated
6. Operate the pump 1 at coarse speed for dispensing the filler base.
7. Get the load cell reading.
8. If the load cell reading doesn't increase by 0.5 kg in 80 iteration, it indicates a pump error, which has to be rectified. If increased, proceed further.
9. The weight of the ingredients so far dispensed is calculated.
10. If the weight dispensed so far is equal to the 80% of filler base quantity then change the pump speed to fine speed.

11. If the weight dispensed so far is equal to the weight to be dispensed from Filler base then stop pump.
12. Open the pump 2 at coarse speed for dispensing the Ti02 base.
13. Get the reading of the load cell.
14. If the load cell reading doesn't increase by 0.5kg in 80 iterations, it indicates a pump error, which has to be rectified.
15. The weight dispensed so far is calculated.
16. If the weight dispensed so far is equal to the 80%of weight to be dispensed for titanium base then change the pump speed to fine speed.

17. If the weight dispensed so far is equal to the weight to be dispensed from titanium base then stop pump.
18. Open the pump 3 at coarse speed of the emulsion base.
19. Get the reading of the load cell.
20. If the load cell reading doesn't increase by 0.5kg in 80 iterations, it indicates a pump error, which has to be rectified, otherwise proceed further.
21. The weight of the ingredients dispensed so far from the emulsion base is calculated.
22. If the weight dispensed so far is equal to the 80% weight to be dispensed for emulsion base then change the pump speed to fine speed.
23. If the weight dispensed so far is equal to the weight to be dispensed from Emulsion base then stop pump.
24. Open the pump 4 at coarse speed of the Emulsion base exterior.
25. Get the reading of the load cell.
26. If the load cell reading doesn't increase by 0.5kg in 80 iterations, it indicates a pump error, which has to be rectified, otherwise proceed further.
27. The weight dispensed so far from the Emulsion base exterior is calculated.
28. If the weight dispensed so far is equal to the 80% of emulsion base exterior then change the pump speed to fine speed.
29. If the weight dispensed so far is equal to the weight to be dispensed from Emulsion base exterior then stop pump.
30. Check the tint machine & dispense the required Colourants. Give Error if problem in tint machine.
31. Store the record of the dispensing process in the database.
32. Go back to the first screen.

Working of the device:
The following sequential operations have to be effected as shown in Fig. 4 :
Step I: Selecting of the desired Paint
In the first step for the manufacturing process of the paint using the device of the present
invention, the operator starts the sequence by pressing the 'START' key. User has to
select the paint category i.e., design one's own paint (Step I) or any equivalent paint
available in the market (Step D). After the selection, the related screen will be shown in
the display screen.
Step I: In design one's own Paint selection, User has to select for Interior or Exterior use.
For Interior or Exterior Paints, user has to enter details like for Interior - room type or
Exterior area type, total area to be painted, Budget range and User desires "Base White
Paint" (Step la) or Tinted Paint (Step lb) for Users colour choice
Step la(i) : For selection of "Base White Paint", user has to enter desired 'Colour depth'
i.e. whether he / she desires a White paint or tinted white or Pastel shade or Midtone
shade or Deeptone shade or Masstone shade.
Step la(ii) : As per the User's selection in Stepl a(i), he/she will get a set of default
parameter as per budget range selected in Step 1.
Default parameter values are set :
For Interior use - Cost/litre, Hiding, Gloss, Washability, Stain resistance
For Exterior use - Cost/litre, UV resistance, Algal/Fungal resistance, Rain resistance, dirt
resistance, Gloss, Elasticity.
If the user wants to modify the default parameter values, User can iterate using slider
scale.
If changed parameter value is not possible in selected Budget range, user has to go back
to Step 1 and reset for new Budget range.
User can again filter the selected 'Base White Paint' by iterating the required parameter
values.
If the User is satisfied with his selection, then he can click NEXT button, which will take
him to confirmation Step III

Step lb : For selection of 'Tinted Paint', User can have two options :
Step lb(i) : Select colour /shade from "Standard shade card". For this selected shade,
default Base Paint is selected as per Budget range of Step 1.
This 'Base Paint' can be modified by iteration as done in Step la(ii). If the User is
satisfied with his/her selection, then User can click NEXT button, to take him to Step in.
'Base Paint' can be modified by iteration as done in Step I a(ii). If the customer is
satisfied with his / her selection, then he/she can click NEXT button, to take him to Step
III.
Step II: If User selects 'Equivalent paint available in Market'
User is asked to select Brand & sub-brand and if required the desired colour /shade. For
selected brand product, default 'Base White Paint' or 'Base Paint for desired colour' is
selected and parameters are displayed as in Step I a (ii).
User can modify above Base Paints as done in Step 1 a( ii).
If User is satisfied with his selection, User clicks on NEXT button, which will take him to
confirmation Step HI.
Step HI: Confirmation of Paint selected.
After the customer has set the desired parameters he / she comes to this step where he /
she has to confirm his / her selection. Here he / she has to select the package quantity and
pack size that he / she wants. After selecting the package quantity the cost per litre is
shown and the total cost. If the customer is sure of his / her selection and the package
quantity he / she can submit the paint combination by clicking the SUBMIT button. This
will take him / her to the process page where the preparation process of the selected paint
begins
Step IV: Starting the paint making process
The device is installed at an outlet such as the retailer's outlet. The customer can select
the required paint through a Menu Driven system. After selection of the process data by
the customer, the ingredient quantity will be downloaded to the device for the following
sequential operation :

1. The customer starts the sequence by pressing a single membrane key. Then the first ingredient pump starts automatically.
2. The variable frequency drive (VFD) connected to the pump will have few sets of I/O contacts for pre-defined speed. Speed is decided based on the weight range (two speeds for each recipe definable range up to say 4 Kg, 8 Kg & above) and not on the type of the ingredient.
3. First the pump will run at higher speed. After dispensing around 80% of required quantity, based on load cell indication, the speed will be reduced to second set value.
4. The pump will stop after addition of required quantity of the first ingredient.
5. The same procedure (1 to 3) is to be followed for the 2nd, 3rd & 4th ingredient, dispensing sequentially.
6. After dispensing of above Paint ingredients, if required, Colourants are added through Tinting system.
7. For thorough homogenous mixing of the ingredients, the filled paint container is closed, removed and mixed. The mixing may preferably be done by keeping it inside a gyroshaker for a period of say, about 3 minutes.
8. After dispensing the required number of paint containers, the pump outlet discharge tube end are plugged to avoid air ingress
Internet Option: User/ Customer has the option to use the device through remote site by connecting through internet as shown in Fig 4 B. Users login to Company website and come to "Design your own Paint" web page. This web page will take the customer / user through same menu driven sequential process for selection of desired Base Paint and colour as shown above in Step I to Step HI. After confirmation of mode of payment, this order is taken for execution by downloading this order from the Web server to the Improved device through internet port (18) and actual dispensing of Paint happens as shown above in Step IV.

The details of using the device of the invention is described in the Examples given below which are given only for illustration purposes and therefore should not be construed to limit the scope of the present invention.
Example 1.
A customer comes to a Point of Sale (retailer's shop), for his requirement of paint for
coating interior room walls of his house measuring 500 sq. mtr. in pastel (light) colour.
His budget for the paint is for 1st quality Emulsion Paint of about Rs. 160 / litre or Rs. 10 /
sq. mtr. The customer feeds his inputs into the human machine interface available in the
form of membrane keyboard in an embedded control system or a computer, and menu
driven process starts as shown in flow chart Fig. 4 as detailed below :
Step 1: Select - Design your own paint.
Step 2: Select - Interior Room Walls.
Step 3: Enter area to be painted as 500 sq. mtr.
Step 4: Select budget range as 1st quality or enter value as Rs. 160 / litre.
Step 5: Select colour depth - Pastels.
Step 6: Select highest priority property - Wet Scrub.
Step 7: Default options of paint with highest wet scrub possible in given cost of
Rs.160 / litre and with which, pastel shade can be achieved. These options
are picked up based on inputs given in Steps 1 to 6.
Step 8: Iterate other properties i.e. opacity, whiteness, stain resistance & gloss on
a slider scale. This iteration automatically revises the option.
Step 9: Select best option. If still not satisfied, go back to Step 8 for further
iteration of properties.
Step 10: Final option selected.
Step 11: Display of selected paint properties, quantity required, cost / litre and cost
/ sq. mtr. and total material cost.
If satisfied, select - 'Submit'.
Step 12: Ingredients are computed from database, which match the selected paint

properties.
Step 13: Commands are given to the device, which starts the pump and opens the
valve to dispense computed quantity of each ingredient to make the required total quantity of paint in multiples of biggest pack sizes.
Step 14: Filled pack is closed and taken out and kept inside a gyroshaker or (any
other type of mixing device) and mixed for 3 minutes to give final paint having the customer defined and designed properties.
At the end of the above operation, the paint designed by the customer having the desired properties and the cost is produced, to the customer's satisfaction.
Example 2
A customer comes to a point of sale (Retailer's shop), for his requirement of a paint
equivalent to some branded paint "Brand X" for his house measuring 500 sq. mtr. in
pastel colour. The customer gives his inputs into the human machine interface available
in the form of membrane keypad of embedded control system or a computer, and menu
driven process starts as shown in flow chart shown in Fig. 4 as detailed below :
Step 1: Select - Equivalent to some branded paint "Brand X" available in market.
Step 2: Select Colour depth - Pastels.
Step 3: Default option of paint with equivalent parameters to "Brand X" is derived
for pastel shade.
Step 4: Iterate other properties i.e., opacity, whiteness, wet scrub & gloss on a
slider scale to mix & max the desired parameters to be changed. This
iteration automatically revises the option.
Step 5: Select best option. If still not satisfied, go back to Step 8 for further
iteration of properties.
Step 6: Final option selected.
Step 7. Display of selected paint properties, quantity required, cost / litre and cost
/ sq. mtr. and total material cost.
If satisfied, select - 'Submit'.
Step 8: Ingredients are computed from database, which match the selected paint

properties.
Step 9: Commands are given to the device which starts the pump and opens the
valve to dispense computed quantity of each ingredient to make the
required total quantity of paint in multiples of biggest pack sizes.
Step 10: Filled pack is closed and taken out and kept inside a gyroshaker and mixed
for 3 minutes to give final paint having the customer defined and designed
properties. At the end of the above operation the paint designed by the customer having the desired properties and the cost is produced.
Example - 3 A customer comes to a point of sale (Retailer's shop), for his requirement of paint for painting kitchen room walls of his house measuring 100 sq. mtr. in pastel colour. His budget for the paint is for emulsion paint of about Rs. 160 / litre or Rs. 10 / sq. mtr. The customer gives his inputs into the human machine interface available in the form of membrane keypad of embedded control system or a computer, and menu driven process starts as shown in flow chart shown in Fig. 4 as detailed below :
Step 1: Select - Design your own paint (emulsion paint).
Step 2: Select - kitchen room walls.
Step 3: Enter area to be painted as 100 sq. mtr.
Step 4: Select budget range, enter value as Rs. 160 / litre.
Step 5: Select colour depth - Pastels.
Step 6: Select highest priority property - Stain resistance.
Step 7: Default options of paint with highest stain resistance possible in given cost
of Rs.160 / litre and with which, pastel shade can be achieved. These
options are picked up based on inputs given in Step 1 to Step 6.
Step 8: Iterate other properties i.e., opacity, whiteness, wet scrub & gloss on a
slider scale. This iteration automatically revises the option.
Step 9: Select best option. If still not satisfied, go back to Step 8 for further
iteration of properties.

Step 10: Final option selected.
Step 11: Display of selected paint properties, quantity required, cost / litre and cost
/ sq. mtr. and total material cost.
If satisfied, select - 'Submit'.
Step 12: Ingredients are computed from database, which match the selected paint
properties.
Step 13: Commands are given to the device, which starts the pump and opens the
valve to dispense computed quantity of each ingredient to make the
required total quantity of paint in multiples of biggest pack sizes.
Step 14: Filled pack is closed and taken out and kept inside a gyroshaker and mixed
for 3 minutes to give final paint having the customer defined and designed
properties. At the end of the above operation the paint designed by the customer having the desired properties and the cost is produced.
Example - 4
Stepl Step 2 Step 3 Step 4 Step 5 Step 6
A customer comes to a point of sale (Retailer's shop), for his requirement of paint for painting Interior room walls of his house measuring 5000 sq. mtr. in 'Merrie Pink' colour. His budget for the paint is for emulsion paint of about Rs.160 / litre or Rs.10 / sq. mtr. The customer gives his inputs into the human machine interface available in the form of membrane keypad of embedded control system or a computer, and menu driven process starts as shown in flow chart shown in Fig. 4 as detailed below :
Select - Design your own paint (emulsion paint).
Select - Interior room walls.
Enter area to be painted as 5000 sq. mtr.
Select "budget range, enter value as Rs.160 / litre.
Select 'Tinted Paint' - Shade selected 'Merrie Pink'.
Select highest priority property - Washability or Wet scrub.

Step 7: Default options of paint with highest wetscrub resistance possible in given cost
of Rs.160 / litre and with which, Merrie Pink shade can be achieved.
These options are picked up based on inputs given in Step 1 to Step 6.
Step 8: Iterate other properties i.e., opacity, whiteness, wet scrub & gloss on a
slider scale. This iteration automatically revises the option.
Step 9: Select revised option and 'confirm'. If still not satisfied, go back to Step 8
for further iteration of properties.
Step 10: After confirmation, display of selected Paint properties, quantity required,
pack sizes, Cost/litre and total material cost is seen on screen.
Step 11: If satisfied, select - ' Submit'.
Step 12: Ingredients are computed of Base Paint selected from database #1 and
'Colourants type & quantity computed from Database #2 & 3, to get
Merrie Pink shade.
Step 13: Commands are given to the device, which starts the pump to dispense
computed quantity of each ingredient and required colourants to make the
required total quantity of paint in multiples of biggest pack sizes.
Step 14: Filled pack is closed and taken out and kept inside a gyroshaker and mixed
for 3 minutes to give final paint having the customer defined and designed
properties. At the end of the above operation the paint designed by the customer having the desired properties and cost is produced.
• Advantages of the device of the present invention:
1. The device has the options to determine the cost, usage and functional properties i.e. coverage, opacity or hiding, whiteness, wet scrub, colour depth, stain resistance, gloss, etc. of the paint.
2. Infinite number of variations possible for all parameters - present bulk manufacturers have 4-5 grades as economy, premium, deluxe, etc.
3. The device can be used for manufacturing desired quantity, which may be small or large. Presently manufacturing is done in bulk, which is in large quantity.
4. The customer-defined paint can be manufactured using the device at the point of sale.

5. The customer defined paint can be manufactured and tinted to the desired colour using the device at the point of sale. Presently pre-determined Base Paint in a particular type of paint are to be used to get desired colour. By using this device, any Base paint can be converted to desired colour.
6. The customer-defined / designed paint can be manufactured within a few minutes. The coarse & fine feed arrangement is done by pump speed variation thereby cutting off dispensing instantly without residual dripping.
7. As the device is a menu driven control system, the process of manufacturing paint
employing the device is very much reliable.
8. There is no wastage of paint as the customer manufactures the paint as per his actual requirements.
9. The device can be operated by a layman, meaning that no special skill is required.

We claim
1. An improved device for instant manufacture of customized paint which comprises a housing (1) incorporating at least three cans (2) for holding ingredients useful for preparing the desired paint, each can being provided with top openings for the ingredients to be filled and bottom openings for connecting to the individual pumps (3) through the pipes (4) the pumps being provided for pumping the ingredients from the said cans (2) into the paint container (6) through flexible pipe (5), the pumps (3) being provided with individual variable frequency drive (VFD) (7) for varying the flow rate of the said ingredients from the said cans (2) to the container(6), the paint container (6) being removably placed on a weighing platform (8), for weighing the paint formed in the paint container (6), the weight signal from the weighing platform being transmitted to a control system (9), the control system comprising an embedded controller having a LCD (liquid crystal display) (10), the control system also being provided with a central processing unit (11) and an interface ( 18 ) for connecting to a server for facilitating internet connection, the output of weighing platform (8) being connected to the central processing unit (11), one terminal of the central processing unit being connected to the LCD (liquid crystal display) (10), second terminal of the central processing unit ( 11 ) being connected to a smart card reader ( 12 ), the third terminal of the central processing unit interacting with the memory (13 ), the fourth terminal of the central processing unit being connected to the input of the digital input/output device (14) , the fifth terminal of the central processing unit being connected to a tinting unit (17), the output of the digital input /output device ( 14 ) being connected to a relay board (15 ) and the output of the relay board (15) being connected to the variable frequency drive ( 7 ), and a membrane keyboard ( 16 ) is provided for human interface. Colourants being dispensed from the tinting unit (17) to get the desired color.
2. .An improved device as claimed in claim 1 wherein the container ( 1 ) is partly closed, as shown in Fig. 1 of the drawings.
3. An improved device as claimed in claims 1 & 2 wherein the container ( 1 ) is provided with doors at appropriate places.
4. An improved device as claimed in claims 1 to 3 wherein the ingredient raw material are added to the tank under gravity. 5 An improved device as claimed in claims 1 to 4 wherein the device contains four cans (
2 ) for holding the ingredients. 6 An improved device as claimed in claims 1 to 5 wherein each can ( 2 ), contains (i) filler base (ii) Ti02 base (iii) emulsion base (interior) and (iv) emulsion base (exterior) respectively. 7 An improved device as claimed in claim 6 wherein the filler base such as blends of
extenders likejalc, china clay, calcite, etc. is used.
8. An improved device as claimed in claim 6 wherein the TK^base such as rutile titanium dioxide is used.
9. An improved device as claimed in claim 6 wherein the emulsion base, such as high binding acrylic emulsion polymer along with rheological modifiers are used.
10) An improved device as claimed in claims 1 to 9wherein the pipes ( 4 ) and pipes ( 5 ) are made of PVC.
11. An improved device as claimed in claims 1 to 10 wherein the pumps employed are screw pumps.
12. An improved device as claimed in claims 1 to 11 wherein the cans used to hold the ingredients are of suitable size such as 50 litres, 100 litres and the like based on the appropriate use of the device at the point of sale (retailer or stockist or depot).
13. An improved control system ( 9 ) for use in a device as defined in claims 1 to 12
which comprises an embedded controller having a LCD (liquid crystal display) (10 ) provided with a central processing unit (11), and an interface (18 ) for connecting to a server for facilitating internet connection, one terminal of the central processing unit being connected to the LCD (liquid crystal display) ( 10 ), second terminal of the central processing unit( 11 ) being connected to a smart card ( 12 ), the third terminal of the central processing unit interacting with the memory ( 13 ), the fourth terminal of the central processing unit being connected to the input of the digital input/output device ( 14 ), the fifth terminal of the central processing unit is capable of being connected to the tinting unit (17), the output of the digital input /output device ( 14 ) being connected


to a relay board ( 15 ) and the output of the relay board ( 15 ) being connected to the variable frequency drive( 7 ) and membrane keyboard (16 ) for human interface. 14. An improved method for the instant manufacturing of customized paint using a device as defined in claims 1 to 12 substantially as herein described with reference to the Figs. 1 to 4 of the drawing accompanying this specification.
'15} An improved control system for use in a device as claimed in claims 1 to 12 substantially as herein described with reference to the drawing Fig 3 accompanying this specification.
16. An improved device for instant manufacture of customized paint substantially as herein described with reference to Figs. 1 to 5 of the drawing accompanying this specification.
Dated 3oth day of Nov 2004