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18 line items in process order, each with its tag, specification, quantity, power and an indicative unit price.
Drum racking for 120 × 200 L · sump bunds ≥ 110 % · Ex lighting
Holds resins, solvents, driers and pigments on bunded, earthed racks in a fire-rated store.
20,000 L · double-wall steel · flame arrester · level gauge
Stores white spirit in bulk so solvent is bought by tanker instead of by the drum.
1½" double diaphragm · Ex II 2G · conductive hoses · flow meter
Moves solvent and resin from tank and drums to the dispersers with no electric motor in the zone.
22 kW Ex d motor · VFD · 300 mm Cowles blade · hydraulic lift · closed lid
Wets and disperses pigments and extenders into resin under a closed, nitrogen-blanketed lid.
1,000 L · SS304 · castors · earthing lug · bottom valve
Move each batch between the disperser, bead mill and let-down tanks without re-pumping.
10 Nm³/h · 98 % N₂ · 500 L receiver · O₂ analyser
Blankets disperser and let-down vessels with nitrogen to keep oxygen below the ignition limit.
12 monitored clamps · interlocked to pumps · earth pits < 10 Ω
Proves every drum, tub and tin is earthed before solvent can flow, preventing static sparks.
60 L chamber · 1.0–1.2 mm zirconia beads · 300–600 L/h · packaged chiller
Grinds the mill base to a Hegman 7 fineness for high-gloss enamels.
2,500 L · SS304 · Ex d agitator · load cells · N₂ inlet
Completes each batch with resin, solvent, driers and anti-skinning agent under slow stirring.
16-canister dispenser · 0.077 ml resolution · d/8° spectro · colour software
Doses colourants and measures each batch against the master standard for repeatable colour.
Ford cup & KU viscometer · 60° glossmeter · Hegman gauge · closed-cup flash tester
Tests viscosity, gloss, grind, drying time, density and flash point before release.
SS housing · 50 µm bag + 25 µm cartridge · ΔP gauge · earthed
Removes bead fragments, skins and grit so the paint flows clean into the tins.
Pneumatic · Ex weigh-fill 0.5–20 L · anti-drip nozzle · ±1 % · 400 tins/h
Fills tins and pails by weight with pneumatic valves so no spark source sits at the nozzle.
Pneumatic lid press · semi-auto wrap labeller · inkjet coder
Seals lids, applies GHS hazard labels and prints the batch code and expiry on every pack.
125 L batch · thermal-oil heated · Ex e · water-cooled condenser · ≈ 85 % yield
Distils dirty wash solvent back to clean solvent for the next wash-out.
ATEX fans · 12,000 m³/h · capture hoods at lids & fillers · roof stack
Pulls solvent vapour away from openings so the air stays well below the lower explosive limit.
AFFF-free foam proportioner · deluge heads · 50 m³ fire tank · gas detectors
Floods the stores and process hall with foam and alarms when solvent vapour is detected.
3 m³/min at 7 bar · refrigerated dryer · 1,000 L receiver
Supplies air for diaphragm pumps, pneumatic fillers, lid press and the nitrogen generator.
Indicative ex-works prices (US$, 2026) for budgeting a sample project, not quotations. Photos are illustrative of each machine class.
12 unit operations in order, with the equipment that performs each and its control point.
| Step | Operation | Equipment | Control point |
|---|---|---|---|
| 01 | Receive & store raw materialsResins, solvents, pigments, extenders and driers are checked in and stored on bunded, earthed racks. | RS-101 Flammables Store Racking & Spill BundsST-102 Bulk Solvent Tank (White Spirit) |
COA check · drums earthed · bund ≥ 110 % of largest drum |
| 02 | Solvent & resin transferAir-operated diaphragm pumps meter solvent and resin to the dispersers through conductive hoses. | PU-103 ATEX Air-Operated Solvent PumpsEB-204 Static Earthing & Bonding SystemAC-604 Screw Air Compressor & Dryer |
Bonding interlock proven · ≤ 1 m/s until inlet submerged |
| 03 | Pre-mix & high-speed dispersionPigments and extenders are wetted into resin and solvent under a closed, nitrogen-blanketed lid.Wash solvent → still | HSD-201 Explosion-Proof High-Speed DisperserDT-202 Mobile Dispersion TubsNG-203 PSA Nitrogen Generator |
O₂ < 8 % under N₂ · tip speed 18–25 m/s |
| 04 | Bead-mill grindingGloss mill base is recirculated through the bead mill until it reaches the target fineness. | BM-301 Horizontal Bead Mill (ATEX) |
Hegman ≥ 7 (gloss) · outlet ≤ 45 °C |
| 05 | Let-down with resin & driersThe mill base is completed with resin, solvent, lead-free driers and anti-skinning agent. | LD-302 Let-Down Tank with Ex Stirrer |
Weights to batch card · viscosity adjusted |
| 06 | Tinting & colour matchingColourants are dosed and stirred in until the batch matches the master colour standard. | TM-401 Tinting Dispenser & Spectrophotometer |
ΔE ≤ 1.0 vs master standard |
| 07 | QC testing & batch approvalEach batch is tested for viscosity, gloss, grind, drying time, density and flash point.Off-spec → re-work | QC-402 Paint QC Laboratory |
KU · gloss · Hegman · dry time · density · flash point |
| 08 | FilteringApproved paint is pumped through bag and cartridge filters to remove grit and skins. | FL-501 Bag & Cartridge Filter Units |
50 µm bag / 25 µm cartridge · ΔP logged |
| 09 | Filling tins & pailsEarthed tins and pails are weigh-filled under local extraction hoods. | FM-502 Ex-Proof Semi-Auto Tin FillerVX-602 Vapour Extraction & LEV System |
Fill weight ± 1 % · tin earthed before valve opens |
| 10 | Lid pressing, labelling & codingLids are pressed on, GHS hazard labels applied and every pack batch-coded. | LP-503 Lid Press, Labeller & Batch Coder |
Lid seal · GHS pictograms · batch code legible |
| 11 | Flammables store & dispatchCartons are stored FIFO in the foam-protected finished-goods store and shipped as Class 3 goods. | FS-603 Foam Fire Suppression System |
FIFO · UN 1263 marking · dangerous-goods delivery note |
| 12 | Solvent recovery (distillation)Dirty wash solvent is distilled back to clean solvent for the next equipment wash-out.Residue → licensed waste | SR-601 Solvent Recovery Still |
Pot ≤ 75 % full · condenser flow proven · yield logged |
6 zones arranged for one-way material flow, with every item of equipment placed by tag.
Ex motors, air-driven pumps, nitrogen blanketing and interlocked earthing in every solvent zone.
Hegman 7 grind gives the deep, even gloss that premium enamels are judged on.
A spectrophotometer and dispenser hold every colour within ΔE 1.0 of its master.
The still returns about 85 % of wash solvent, cutting solvent purchases and hazardous waste.
Gas detection and a foam deluge system cover both flammables stores and the process hall.
Lead-free driers and pigments (≤ 90 ppm lead) and a certificate of analysis for every batch.
The core routines operators follow, from start-up to batch release.
7 sections: open any one to read it, or download the whole document.
Rangi Bora Coatings Ltd is a solvent-borne paint plant in Ruiru, Kiambu County, making alkyd gloss enamels, solvent acrylic road-marking, floor and roof paints, red oxide and zinc phosphate primers, wood varnish and thinners. The plant runs a single shift on an ATEX-rated line of two high-speed dispersers, a horizontal bead mill, stirred let-down tanks and explosion-proof fillers, packing 5,500 litres a day into 0.5 L, 1 L and 4 L tins and 20 L pails. It sells through hardware distributors in Nairobi and central Kenya, direct to contractors, and on county and road-agency marking tenders.
| Metric | Value |
|---|---|
| Production Capacity | 5,500 L/day · ≈ 121,000 L/month (single shift) |
| Product Lines | 5 (gloss enamels, road/floor/roof paints, primers, varnish, thinners) |
| Annual Revenue (Year 1) | KES 333,000,000 (~$2.56M) at 45% utilisation |
| Initial Investment | KES 52,000,000 (~$400,000) + KES 25M working-capital facility |
| Average Ex-Works Price | KES 509/L against a full cost of KES 431/L |
| Break-even | ≈ 1,470 L/day (27% of capacity) · operating break-even Month 4 |
| Payback Period | ≈ Month 17 (pre-tax) |
| Employees | 40 |
| Product | Binder / Solvent | Packs | Share of Volume | Ex-Works Price (KES/L) |
|---|---|---|---|---|
| Alkyd gloss enamel (white) | Long-oil soya alkyd / white spirit | 0.5 L, 1 L, 4 L | 18% | 660 |
| Alkyd gloss enamel (colours) | Long-oil soya alkyd / white spirit | 0.5 L, 1 L, 4 L | 27% | 590 |
| Road-marking, floor & roof paint | Thermoplastic acrylic / xylene | 4 L, 20 L | 20% | 480 |
| Red oxide & zinc phosphate primers | Medium-oil alkyd / white spirit | 1 L, 4 L, 20 L | 15% | 380 |
| Wood varnish (clear & tinted) | Urethane-modified alkyd / white spirit | 0.5 L, 1 L, 4 L | 8% | 600 |
| Thinners & cleaning solvent | White spirit, xylene blends | 1 L, 4 L, 20 L | 12% | 250 |
| Ingredient | % w/w | Quantity | Cost/kg (KES) | Total (KES) |
|---|---|---|---|---|
| Long-oil alkyd resin (70% solids in white spirit) | 52.0% | 624 kg | 330 | 205,920 |
| Titanium dioxide, rutile | 22.0% | 264 kg | 480 | 126,720 |
| Micronised calcium carbonate | 5.0% | 60 kg | 25 | 1,500 |
| White spirit | 18.0% | 216 kg | 170 | 36,720 |
| Lead-free driers (cobalt/zirconium/calcium) | 1.5% | 18 kg | 900 | 16,200 |
| Anti-skinning agent (MEKO) | 0.3% | 3.6 kg | 700 | 2,520 |
| Dispersant, anti-settling & flow additives | 1.2% | 14.4 kg | 1,200 | 17,280 |
| Total per 1,000 L | 100% | 1,200 kg | 406,860 | |
| Raw-material cost per litre | ≈ 407 |
Coloured gloss enamels replace most of the titanium dioxide with lower-loading organic and iron-oxide pigments, bringing raw-material cost down to about KES 355/L. Primers use red iron oxide or zinc phosphate with more extender in a medium-oil alkyd, at about KES 230/L.
Road-marking, floor and roof paints are built on a thermoplastic acrylic resin dissolved in xylene with chlorinated-paraffin plasticiser. They dry by solvent evaporation, not oxidation, so they need no driers and reach no-pick-up in under 15 minutes on the road. Road-marking whites use rutile TiO₂ and calcite; yellows use lead-free organic pigments (lead chromate is not used). Glass beads are supplied separately for drop-on retro-reflectivity. Because xylene has a lower flash point than white spirit, these batches are made and filled only with the nitrogen blanket and extraction running.
| Stage | Process | Purpose | Equipment |
|---|---|---|---|
| 1 | Receiving & Storage | Check COAs, store on bunded, earthed racks | Flammables store, 20,000 L solvent tank |
| 2 | Solvent Transfer | Meter solvent and resin with no spark source | 3 ATEX diaphragm pumps, interlocked earthing |
| 3 | Pre-mix & Dispersion | Wet pigments into resin under nitrogen | 2 × 22 kW Ex dispersers, 1,000 L tubs, PSA nitrogen |
| 4 | Bead Milling | Grind gloss mill base to Hegman 7 | 60 L horizontal bead mill with packaged chiller |
| 5 | Let-down | Add remaining resin, solvent, driers, anti-skin | 2 × 2,500 L stirred tanks on load cells |
| 6 | Tinting & Colour Matching | Match to master standard | Colourant dispenser, spectrophotometer |
| 7 | QC Testing | Approve batch against specification | Viscometers, glossmeter, Hegman gauge, flash tester |
| 8 | Filtering | Remove grit, skins and bead fragments | 50 µm bag + 25 µm cartridge filters |
| 9 | Filling | Weigh-fill tins and pails | 2 pneumatic Ex semi-auto fillers under LEV hoods |
| 10 | Lid Pressing, Labelling & Coding | Seal, apply GHS labels, batch code | Lid press, wrap labeller, inkjet coder |
| 11 | Storage & Dispatch | FIFO storage and Class 3 shipment | Foam-protected finished-goods store |
| Licence / Obligation | Authority / Law | Timeline | Cost (KES) |
|---|---|---|---|
| KEBS Standardization Mark per product (KS paint, primer, varnish and road-marking standards) | KEBS | 2–3 months | 0.2% of ex-factory sales (minimum fee applies) |
| Lead in paint ≤ 90 ppm (total lead, all products) | KEBS paint standards | Before first sale | ~15,000 per product test |
| EIA Licence (project report) | NEMA, EMCA 1999 | 2–3 months | 0.1% of project cost + ~250,000 expert fees |
| Air emission (VOC) licence | NEMA, Air Quality Regulations 2014 | 1–2 months | ~50,000/year |
| Hazardous waste handling (still residue, rags) | NEMA, Waste Management Regulations 2006 | Ongoing | ~35,000/t collected |
| Workplace registration, flammables storage & fire audit | DOSHS, OSHA 2007 & Fire Risk Reduction Rules 2007 | 1 month, then annual | ~80,000/year |
| GHS hazard labels & safety data sheets | OSHA 2007, Hazardous Substances Rules 2007 | Before first sale | Design cost only |
| Fire safety certificate | Kiambu County Fire Department | 2 weeks, then annual | ~25,000/year |
| Single Business Permit | Kiambu County | 2 weeks | ~60,000/year |
| Parameter | Method | Alkyd Gloss Enamel | Road-Marking Paint | Primer | Frequency |
|---|---|---|---|---|---|
| Viscosity | Stormer KU (ASTM D562), Ford cup No. 4 | 90–100 KU | 80–95 KU | 75–90 KU | Every batch |
| Fineness of grind | Hegman gauge (ISO 1524) | ≥ 7 Hegman | ≥ 3 Hegman | ≥ 5 Hegman | Every batch |
| Specular gloss 60° | Glossmeter (ISO 2813) | ≥ 85 GU | Matt | Matt | Every batch |
| Drying time (touch / hard) | ASTM D1640 | ≤ 4 h / ≤ 16 h | No-pick-up ≤ 15 min | ≤ 2 h / ≤ 8 h | Every batch |
| Density | Pyknometer (ISO 2811) | 1.15–1.25 kg/L | 1.45–1.60 kg/L | 1.35–1.50 kg/L | Every batch |
| Flash point (closed cup) | ISO 3679 | ≥ 38 °C | ≥ 23 °C | ≥ 38 °C | Every batch |
| Colour | Spectrophotometer ΔE | ≤ 1.0 | ≤ 1.5 | ≤ 1.5 | Every batch |
| Total lead | External accredited lab | ≤ 90 ppm | ≤ 90 ppm | ≤ 90 ppm | Quarterly per product |
Labelling: Every pack carries GHS flammable-liquid pictograms and hazard statements (Category 3 for white-spirit products, Category 2 or 3 for xylene products), UN 1263 shipping marks on outer cartons, the batch code, date of manufacture and a 24-month shelf life.
| Item | Cost (KES) | ~US$ |
|---|---|---|
| Dispersers, tubs, bead mill (with chiller), let-down tanks & tinting | 13,000,000 | 100,000 |
| Filters, Ex fillers, lid press, labeller & coder | 3,900,000 | 30,000 |
| QC laboratory | 1,500,000 | 11,500 |
| Flammables store racking, bulk solvent tank & ATEX pumps | 3,520,000 | 27,100 |
| Safety & environment (N₂, earthing, still, extraction, foam system) | 9,300,000 | 71,500 |
| Screw air compressor & dryer | 1,240,000 | 9,500 |
| Freight, clearance & installation | 4,560,000 | 35,100 |
| Civil works (fire-rated store, bunded floors, interceptor) | 6,200,000 | 47,700 |
| Ex-rated electrical installation & 200 kVA supply | 3,400,000 | 26,200 |
| Electric pallet trucks & delivery truck | 2,300,000 | 17,700 |
| Licences, EIA, KEBS certification & commissioning | 1,280,000 | 9,800 |
| Opening stock & start-up costs | 1,800,000 | 13,800 |
| Total | 52,000,000 | ~400,000 |
Raw materials and distributor credit are funded by a separate KES 25M revolving working-capital facility secured on stock and receivables.
| Product | Raw Materials | Packaging | Conversion | Selling & Distribution | Full Cost | Ex-Works Price | Margin |
|---|---|---|---|---|---|---|---|
| White alkyd gloss (4 L) | 407 | 32 | 43 | 40 | 522 | 660 | 21% |
| Coloured alkyd gloss (4 L) | 355 | 32 | 43 | 40 | 470 | 590 | 20% |
| Road-marking paint (20 L) | 320 | 18 | 43 | 40 | 421 | 480 | 12% |
| Red oxide primer (4 L / 20 L) | 230 | 26 | 43 | 40 | 339 | 380 | 11% |
| Wood varnish (1 L) | 380 | 45 | 43 | 40 | 508 | 600 | 15% |
| Thinners (mixed packs) | 165 | 35 | 15 | 25 | 240 | 250 | 4% |
| Plant average | 318 | 30 | 43 | 40 | 431 | 509 | 15% |
| Item | Monthly (KES) |
|---|---|
| Raw materials (KES 318/L) | 38,478,000 |
| Tins, pails, labels & cartons (KES 30/L) | 3,630,000 |
| Electricity (~20,000 kWh) | 500,000 |
| Distribution & dangerous-goods transport | 1,800,000 |
| Sales, distributor rebates & tinting-point support | 3,000,000 |
| Staff salaries (40 employees) | 2,150,000 |
| Rent & rates | 450,000 |
| Maintenance, beads & filter elements | 300,000 |
| Hazardous-waste disposal, licences & fire insurance | 500,000 |
| Admin & office | 400,000 |
| Total Monthly OPEX | 51,208,000 (~$394,000) |
At full capacity monthly revenue is about KES 61.6M (~$474,000), leaving roughly KES 10.4M EBITDA. Fixed costs are KES 3.8M/month against a contribution of about KES 117/L, so break-even is about 32,400 L/month (≈ 1,470 L/day, 27% of capacity).
| Year | Utilisation | Volume (L) | Revenue (KES) | EBITDA (KES) | EBITDA Margin |
|---|---|---|---|---|---|
| Year 1 | 45% | 653,400 | 333,000,000 (~$2.56M) | 31,000,000 | 9% |
| Year 2 | 65% | 943,800 | 480,500,000 (~$3.70M) | 62,700,000 | 13% |
| Year 3 | 80% | 1,161,600 | 591,400,000 (~$4.55M) | 85,900,000 | 15% |
Payback: cumulative EBITDA covers the KES 52M investment around Month 17 (pre-tax, before working-capital interest).
Kenya's paint and coatings market is estimated at KES 30–35 billion a year, growing 6–8% with housing, roads and commercial construction. Solvent-borne products still hold roughly a third of the value: alkyd gloss is the default finish for doors, windows, grilles and metalwork, and road agencies and county governments buy solvent acrylic road-marking paint every year. Mid-tier brands are squeezed between premium multinationals and unbranded products that often fail on lead, gloss and drying time, leaving room for a certified, lead-free, mid-priced range.
| Tier | Definition | Value (KES) |
|---|---|---|
| TAM | East African solvent-borne decorative, road-marking and protective coatings | 25 billion |
| SAM | Nairobi, central Kenya and Rift Valley distributors, contractors and road tenders | 9 billion |
| SOM (Year 3) | Rangi Bora share at ~6.5% of SAM (≈ 1.16 million L/year) | 591 million |
| Segment | Products | Channel | Share of Revenue |
|---|---|---|---|
| Hardware stores & paint centres | Gloss enamels, primers, varnish, thinners | Distributors, 45-day credit, in-store tinting | 50% |
| Building & fit-out contractors | Gloss, primers, floor paint in 20 L | Direct sales, project pricing | 20% |
| Road agencies, counties & line contractors | Road-marking paint, thinners | Tenders and sub-contracts | 18% |
| Metal fabricators & furniture makers | Primers, gloss, varnish | Direct and trade counter | 8% |
| Institutions & estates | Roof and floor paints, gloss | Maintenance contracts | 4% |
| Player | Positioning | Weakness |
|---|---|---|
| Crown Paints, Basco, Kansai Plascon (Sadolin) | Premium brands, national tinting networks | High shelf prices, little flexibility on contractor terms |
| Mid-size local makers | Price-led gloss and primer ranges | Inconsistent gloss and colour, patchy KEBS certification |
| Unbranded and informal paint | Lowest price in hardware stores | Lead-containing driers and pigments, poor coverage, no SDS |
| Imported road-marking paint | Specified on large highway contracts | Long lead times, currency exposure |
Rangi Bora differentiation: bead-milled, lead-free gloss with a certificate of analysis for every batch, spectrophotometer colour matching within ΔE 1.0, locally made road-marking paint delivered in days, and 20 L contractor packs priced 15–20% below premium brands.
| Month | Milestone | Owner | Dependency |
|---|---|---|---|
| M1 | Lease industrial site, submit EIA project report, fire engineer's layout | MD | Site with separation distance for the flammables store |
| M2 | Equipment order (30% deposit), 200 kVA power application | MD | Financing closed |
| M2–M4 | Civil works: fire-rated stores, bunded floors, interceptor, tank plinth | Plant Manager | EIA licence issued |
| M3–M4 | Formulation trials with resin suppliers, colour card and master standards | Technical Manager | Lab equipment on site |
| M5 | Equipment arrives; Ex electrical installation and earthing tests | Plant Manager | Power supply energised |
| M6 | Commissioning, fire system acceptance, DOSHS and county fire inspections | Plant Manager | Foam system tested |
| M6–M7 | KEBS product testing and S-Mark, lead test certificates | QA Lead | Trial batches approved |
| M7 | Commercial launch through 30 distributors at 35% utilisation | Sales Lead | KEBS marks issued |
| M12 | Single shift at 55–60% utilisation, first road-marking tender | MD | Tender pre-qualification |
| Risk | Impact | Mitigation |
|---|---|---|
| Fire or vapour explosion | High | ATEX zoning, nitrogen blanketing, interlocked earthing, gas detection, foam system, hot-work permits |
| TiO₂, resin and solvent price swings | High | Quarterly supplier contracts, 45 days of stock, price reviews with distributors every quarter |
| Currency depreciation on imported pigments | Medium | Local resin sourcing, USD-linked price clauses on large contracts |
| Distributor credit and bad debt | Medium | Credit limits, 45-day terms, credit insurance on large accounts |
| Price competition from premium and informal brands | Medium | Certified lead-free quality, contractor packs, tinting points in partner stores |
| Delayed tender payments from road agencies | Medium | Cap tender work at 20% of revenue, invoice discounting |
| Hazardous-waste or VOC non-compliance | Medium | Solvent recovery, licensed waste handler, extraction monitoring, NEMA returns |
Equipment specifications, process flow diagrams, recipes and the business plan, bundled as one download.
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