Manufacturing Process

Manufacturing Process Of Shellac In Industries 

The separation process is only applicable to get the raw material. The seedlac is further processed to get the high-quality shellac. Several machines are used to get the finished product. The two-primary process to manufacture shellac is heat process and solvent process. But there are many other processes which are taken into consideration. Here is the manufacturing process of Shellac in India:

• Heat Process

First, the seedlac is melted on a large scale. The method of heating used is indirect. The liquid obtained after heating is forced through a clean cloth. This process is used to get the filtered product, which gets collected in a large steam heat boiler. A large roller is used after filtration. The liquid is passes through the roller to create many thin sheets of shellac. Therefore, this sheet is further crushed to get the shellac flakes India, which are mixed with alcohol to get the consumer ready product.

• Solvent Process

The solvent process is a very common method of shellac wax extraction which is practiced by every manufacturing industry. The seedlac is mixed with ethyl alcohol before filtration process. The filtered seedlac is further sent to the evaporators for the removal of alcohol. Then it comes in a viscous state. The viscous liquid is run through the rollers to form thin sheets. These sheets are dried to make it harder and then broken down into shellac flakes for export.

• Bleached Shellac

The first step to manufacture bleached shellac is to dissolve the seedlac in an alkali soluble or sodium carbonate. The impurities are removed with the help of a filtration process and bleached with a solution called sodium hypochlorite to get the perfect colour. The bleached shellac India is further precipitated with the dilute sulphuric acid. Then it is washed with clear water and dried in vacuum driers and ground to fine flakes to get the finished product.

• Quality Control

Every process is performed very carefully, and the quality of the work is maintained efficiently. The customers are satisfied with the product as the shelf life and quality of the finished product is too good. The manufacturing industries ensure the quality of the product. The quality of work makes the natural resin for casting India. Removal of wax and impurities are done subsequently, which results in dewaxed bleached lac India. 

Why Shellac is known as the only Thermo-setting resin?

Shellac is a natural resin which is extracted from lac insects. These insects sit in certain trees such as Leguminosae and Moraceae. The colour of lac insect is Laccifer laca Kerr. The sticks get lumps and a resinous pigment forms around the twigs which is known as sticklac. Shellac is also known as the natural polyester, whose raw material is seedlac. Here are some reasons why it is known as thermo-setting resin:

• Shellac is highly soluble in solutions in normal temperature.
• It is a strong oil resistance substance.
• It is a strong insulator.
• Abrasion residence in nature.
• Increase durability on its application on any materials.
• It is only soluble in alcohol and insoluble in water.

Solvent Process

Another common process to manufacture shellac wax India is via the solvent process. In this process, the seedlac is mixed with industry grade solvents, usually ethyl alcohol, before it is refluxed and filtered. The filtered shellac is then sent through evaporators to remove the alcohol, which gives it the characteristics viscous form.

Manufactures and shellac exporters in India then runs the viscous liquid through rollers, giving it thin sheet-like shape, which is then dried and broken for export.

In recent years, the demand for a clear shellac has increased significantly. Manufactures produce bleached shellac India to remove the red dye from shellac seeds during the refining process.

Bleached Process

Manufacturing bleached shellac begins with dissolving seedlac in an alkali-soluble, water- based solution of sodium carbonate. This mixture is then filtered to remove any impurities, and bleached with sodium hypochlorite solution to give it the desired colour.

The bleached shellac India is then precipitated with using diluted sulfuric acid and washed with water. This finished component is dried in vacuum driers and ground to a fine powder for final export.

Quality Control

Every step of manufacturing handmade and machine made shellac in India is proceeded with strict quality control. The shelf life and flow of the finished product is of great concern to both us and our customers. We carefully remove impurities from the seedlac before processing it, ensuring only the highest quality of finished product. Moreover, every step of the mixing, processing, and refining process is monitored for efficient and quality manufacturing.