[COMPANY PROFILE] D.Manoharlal (shellac) pvt. Ltd.

ABOUT THE COMPANYM/S. D.Manoharlal (shellac) pvt. Ltd.

2017

D.MANOHARLAL (SHELLAC) PVT.LTD.

2017

More than half a century back, Established their shellac manufacturing unit in the most prominent belt of lac producing in India i.e. Chhattisgarh & set up his office in one & only trade zone of shellac in India i.e. Calcutta.

Initially the company use to produce seedlac, button lac, heat processed machine made shellac. There after the company started manufacturing dewaxed & decolorized shellac grades. Now the company is manufacturing one of the best grades of dewaxed shellac forcing Indian exporters & foreign consumers to depend on the firm for dewaxed grade.

A fully fledged modern testing laboratory has been set up in the factory for quality control at every stage of manufacture.

One of the director, looking after the technical aspects holds a master degree in science & training certificate from Indian lac research institute.

Shellac BackgroundLac is the name given to the resinous secretion of the tiny lac insect (Laccifer lacca) which is parasitic on certain trees in Asia, particularly India and Thailand. This insect secretion is cultivated and refined because of the commercial value of the finished product

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known as shellac. The term shellac is derived from shell-lac (the word for the refined lac in flake form), but has come to refer to all refined lac whether in dry or suspended in an alcohol-based solvent.

Shellac is primarily used as a wood sealer and finisher today. It has the great advantage of being soluble in ethyl or denatured alcohol, an environmentally-safe solvent. Alcohol solvents also render shellac a quick dry—shellac coatings on wood generally dry in about 45 minutes, as opposed to oil finishes which take many hours to dry. In addition, shellac does not fade in sunlight or oxidize over time. However, shellac has a limited shelf life and may not dry properly if it has exceeded the shelf life recommended by the manufacturer. This shelf life may be as short as six months or as long as three years depending on the manufacturer's additives.

Industrial uses for shellac include floor polishes, inks, grinding wheels, electrical insulations, and leather dressings. This natural, resinous sealer is non-toxic and is Federal Drug Administration (FDA) approved for use to coat candies, pharmaceuticals, fruit, and baby and children's furniture.

Shellac is available at most hardware or paint stores in clear or white shellac or orange shellac, which imparts an orange-red tint to natural wood. Other tints derive their color not from dyes or bleaches, but because of the tree to which the lac bug has attached itself—the sap affects the color of the bug secretions thus altering the color of the refined shellac. Shellac may be applied to wood, over varnish, paint, glass, ceramics, even plastic with remarkable adherence, but it cannot be used under synthetic sealers such as polyurethane.

History of Shellac3 | P a g e

Lac has been cultivated for three centuries. For most of that time, the lac bug secretions were valued for the purple-red dye derived from being soaked in water. This dye was used to color silk, leather and cosmetics and was cultivated primarily for this purpose until the 1870s. Then aniline or chemical dyes began to supplant these and other natural dyes.

As early as the sixteenth century, references were made to the usefulness of the lac bug secretions as a decorative lacquer for furniture and fine musical instruments. Natives of the Far East had laboriously cultivated and processed the shellac by hand, scraping the branches encrusted with the lac bug secretions, forcing the secretions into muslin, and holding long muslin bags of the secretions over the fire to liquefy and purify it. They pulled it by hand into huge sheets and then broke the sheets into flakes for re-moisturizing later.

Hand processes were partially replaced by the mid-nineteenth century. Just as the lacderived dye was about to fade in popularity, industrial plants began processing the lac secretions for use as a wood sealer and finish. In 1849, William Zinsser founded Wm. Zinsser & Company in New York. Zinsser's shellacs were soluble in ethyl alcohol and were the first quick-drying, tough, colorless finishes available in the United States.

Shellac was particularly popular late in the nineteenth century and in the early twentieth century when houses were being quickly built in early subdivisions at break-neck speed—shellac was an ideal wood finisher because it was so fast to dry and several coats could be applied in a single day. A shellac known as buttonlac, a very dark shellac, imparted a very deep walnut color to inexpensive woodwork that people then found very desirable.

Shellac...It is a hard, amorphous resin.

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It has a good resistance against solvents based on hydrocarbons.It is not toxic.It is physiologically harmless.It is thermoplastic.It is approved for various applications in the food industry. It has a low melting point (about 90°C).It is soluble in lower alcohols and various other solvents. It is UV-resistant. It is water soluble in water-alkaline solutions.It has excellent dielectric properties, dielectric strength, a low dielectric constant, good tracking resistance, etc.It has excellent film forming properties.It forms smooth, high gloss films and surfaces.It coatings do not change their electrical properties under UV-radiation.It coatings have excellent adhesion to many substrates.It coatings can be polished.It has a low thermal conductivity and a low coefficient of expansion.

Trade Names: English: Shellac German: Schellack

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French: Gomme Laque Spanish: Goma Laca

CAS NUMBER FOR SHELLAC : 9000-59-3 HS CODE FOR SHELLAC : 130190

Origin:Shellac is mainly produced in India and Thailand. Smaller quantities come from china and Vietnam. The product is manufactured in a process known since the old times as melting filtration. Now a days high-quantity, dewaxed And decolorized shellac is manufactured.

Components:Raw shellac (sticklac) contains 60-80% pure shellac,4-6% shellac wax and impurities such as splinters of wood, dead insects and moisture. Seedlac is washed and purified sticklac and consists, according to its quality, of 85-90% pure shellac,5-8% shellac wax and 2-5% impurities.

Packing: Jute bags of 25 kgs or 50 kgs NETT

Paper bags of 25 kgs NETT

Cotton Bags of 25 & 50 Kgs NETT

Different Uses Of Shellac:Fruit CoatingConfectionery GlazePharmaceutical Applications

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CosmeticsWood PolishShellac WaxAbrasivesBulb Capping CementFood & Food PackagesPrinting InksPyrotechnics

The most fascinating uses of shellac have nothing to do with finishes. Because of its specific characteristics, it has a wide variety of uses, most of which continue to this day. According to the D. MANOHARLAL (SHELLAC) PVT LTD Company, which is the largest manufacturer of shellac in this country, the top four uses for the dry shellac flakes are pharmaceutical, confectionery, hats, and food coatings, in order from highest to lowest. Protective coatings for wood ranks about number eight. 

Pharmaceutical   –

Shellac is used to coat enteric pills so that they do not dissolve in the stomach, but in the lower intestine, which alleviates upset

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stomachs. Its also used as a coating on pills to "time release" medication. 

Confectionery   – Shellac is used to provide protective candy coatings or glazes on candies like Reese's Pieces, because of its unique ability to provide a high gloss in relatively thin coatings (like a French Polish). It was used at one time on M&M's. It is approved by the FDA as a food safe coating when dissolved in pure ethanol (not denatured).

Hats   -

Shellac is used to stiffen felt used to make hats. It allows the makers to shape the felt into brims, bowl shapes, etc. 

Food Coatings   –

Because of its FDA approval, shellac is used to coat apples and other fruits to make them shinier. 

Electrical   – Shellac mixed with marble dust is used by lamp manufacturers to glue the metal base to glass incandescent bulbs. 

Shellac Wax   : As the biggest Dewaxed Industry, we are able to load container

Of Shellac Wax. Shellac Wax can be used in replacement Of Carnuaba Wax & Candelilla Wax. Shellac Wax can be used in consistency agent in Cosmetics, High Gloss Polishes, Lipsticks & for cosmetic industry.

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Other Uses Of Shellac: Other uses for shellac are in the manufacture of grinding wheels

(it allows the abrasive particles to break off at the low heat generated by the grinding process, thus exposing new, fresh abrasive particles), leather finishing and painting (shellac pigmented with white titanium dioxide is widely used by painters as a stain sealer, wallboard primer, and knot and sap sealer on wood).

Other former uses for shellac are electrical insulators, as a glue (it bonds glass and metal surprisingly well), phonograph records (the old 78's were a mixture of shellac, fillers and lampblack), hair spray, no-rub floor polishes, and as a finish for bowling alleys (the weight of the ball dropping on the shellac surface did crack the finish).

The demise of shellac's many uses was brought about by the emergence of more durable synthetic resins such as Bakelite, cellulose nitrate, acrylics and urethanes. However, as mentioned above, it still finds a wide variety of applications in our society. It's interesting to note that many attempts in the early part of this century were made to duplicate the shellac resin. Despite the attempts by scientists to duplicate shellac synthetically, a little Indian bug still makes it best.

Making The Cut: The ratio of dry shellac flakes dissolved in alcohol is known as

the cut. It refers to the amount in pounds of dry shellac flakes dissolved in 1 gallon of alcohol. A 3 lb. cut would be 3 pounds

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of shellac dissolved in 1 gallon of alcohol. A 1 lb. cut would be 1 pound of shellac dissolved in a gallon an so on. Since a gallon is a large amount for most finishing tasks, you can factor down the ration to suit your needs. For example ¼ lb flakes dissolved in 1 pint of alcohol will yield a 2 lb. cut. It’s best to weigh the shellac flakes – small inexpensive food portion scales calibrated in ounces are available at house ware supply stores. 

Implications of Shellac: Wood Treatment (primers, high gloss and mat polishes);

Electrics (insulators); Printing inks, inks and china inks; Cosmetics (binder for mascara, shampoo, film former for hairspray, micro incapsulation of fragrances); Food (fruit coatings, parting and glazing agent for confectionary and chocolates); Pharma (tablet coating); Abrasives (binder for grinding wheels); Dental; Hat manufacturing (for stiffening); Conditioning for wooden floors; Leather finishes; Pyrotechnics; Coating of seeds; Micro incapsulation of dyestuffs.

Specification Of Shellac Grades:

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DM Shellac ( Equivalent To Platina )

LL Shellac ( Equivalent To Super-Blonde)

DN Shellac ( Equivalent To Blonde )

Dewaxed Lemon

Dewaxed Orange

Dewaxed Garnet

Waxy Shellac ( Standard One )

Shellac Wax

Dewaxed Bleached Shellac

Handmade Lemon One Shellac

Machine made TN Shellac

Machine made Lemon One Shellac

Machine made Orange Shellac

SPECIFICATION IN DETAILS

DM Shellac ( Equivalent To Platina )

DEWAXED

Grade: DM Shellac (Physical Data)Color Gardner in 20%

ethanolMax. 8

Acid No. (DAB 9) 65-80Arsenic (DAB 9) Max. ppm 1.5Ash (DAB 9) Max. % 0.2

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Insolubility in hot alcohol

Max. % 0.2

Melting Range (DAB 9) 65-85 CMoisture Max. % 2.0Saponification No. (DAB 9) 190-230Wax (USP XXIII) Max. % 0.2

LL Shellac ( Equivalent To Super-Blonde)

DEWAXED

Grade : LL Shellac (Physical Data)Colour Gardner in 20%

ethanolmax. 11

Acid No. (DAB 9) 65-80Arsenic (DAB 9) max. ppm 1.5Ash (DAB 9) max. % 0.2Insolubility in hot alcohol

  max. % 0.2

Melting Range (DAB 9) 65-85 CMoisture   max. % 2.0Saponification No. (DAB 9) 190-230Wax  (USP XXIII) max. % 0.2

DN Shellac ( Equivalent To Blonde )

DEWAXED

Grade : DN Shellac (Physical Data)Colour Gardner in 20%

ethanolmax. 13

Acid No. (DAB 9) 65-80Arsenic (DAB 9) max. ppm 1.5Ash (DAB 9) max. % 0.2Insolubility in hot alcohol

  max. % 0.2

Melting Range (DAB 9) 65-85 C

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Moisture   max. % 2.0Saponification No. (DAB 9) 190-230Wax  (USP XXIII) max. % 0.2

Dewaxed Lemon

DEWAXED

Grade : Dewaxed Lemon (Physical Data)Colour Gardner in 20%

ethanolmax 15

Acid No. (DAB 9) 65-80Arsenic (DAB 9) max. ppm 1.5Ash (DAB 9) max. % 0.2Insolubility in hot alcohol

  max. % 0.2

Melting Range (DAB 9) 65-85 CMoisture   max. % 2.0Saponification No. (DAB 9) 190-230Wax  (USP XXIII) max. % 0.2

Dewaxed Orange

DEWAXED

Grade : Dewaxed Orange (Physical Data)Colour Gardner in 20%

ethanolmax 16

Acid No. (DAB 9) 65-80Arsenic (DAB 9) max. ppm 1.5Ash (DAB 9) max. % 0.2Insolubility in hot alcohol

  max. % 0.2

Melting Range (DAB 9) 65-85 CMoisture   max. % 2.0Saponification No. (DAB 9) 190-230

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Wax  (USP XXIII) max. % 0.2

Dewaxed Garnet

DEWAXED

Grade : Dewaxed Garnet (Physical Data)Colour   DarkAcid No. (DAB 9) 65-80Arsenic (DAB 9) max.ppm 1.5Ash (DAB 9) max. % 0.2Insolubility in hot alcohol

  max. % 0.2

Melting Range (DAB 9) 65-85 CMoisture   max. % 2.0Saponification No. (DAB 9) 190-230Wax  (USP XXIII) max. % 0.2

Waxy Shellac ( Standard One )

WAXY SHELLACImpurities Insoluble In Hot Alcohol 0.48 %Moisture 0.90 %Polymerization Time 32 Mn.Flow 38 MmHalphen – Hicks Test PositiveIodine Value 15.24Color Dark Yellow

Shellac Wax

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SHELLAC WAXAs Per is 5467 - 1986Melting Point 70 -80 *CColour Light YellowAcid Value 10.00 (MAX)Natural Resin Content 5.00 %(MAX)Volatile Matter 1.00 % (MAX)Ash Content 0.5 % (MAX)Density 0.970 (MAX)

Handmade Lemon One Shellac

HANDMADE LEMON ONE SHELLACAcid Value  65-76 Ester Value 110-175Saponification Value  175-240Wax Content 5.50% max.Moisture 2% max.Insolubility in Hot Alcohol 0.75%-1.00%

Dewaxed Bleached Shellac

DEWAXED BLEACHED SHELLACAcid Value 65-90Ester Value 135-195Saponification Value 200-260Melting Point 75ºC-91ºC CWax Content 0 .20% max.Moisture 6% max.Insolubility in Hot Alcohol 0.10% max.Rosin Content NilAsh Content 0.50% max.Heavy Metals 10 PPMColour Pale Yellow

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Machine made TN Shellac

MACHINE MADE TN SHELLACAcid Value  65-76Ester Value 110-175Saponification Value 175-240Wax Content 5.50% max.Moisture 2% max.Heavy Metals as Pb 10 PPM max.Insolubility in Hot Alcohol 0.75%-1.00%

Machine made Lemon One Shellac

MACHINE MADE LEMON ONE SHELLACAcid Value 65-76Ester Value 110-175Saponification Value 175-240Wax Content 5.50% max.Moisture 2% max.Insolubility in Hot Alcohol 0.75%-1.00%

Machine made Orange Shellac

MACHINE MADE ORANGE SHELLACAcid Value 65-76Ester Value 110-175Saponification Value 175-240

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Wax Content 5.50% max.Moisture 2% max.Heavy Metals as Pb 10 PPM max.Insolubility in Hot Alcohol 1.00%-1.25%

Raw MaterialsShellac is generally made from two ingredients, raw seed lac and ethyl alcohol. In fact, most companies want to purify shellac as completely as possible—impurities from the bug, the cocoon etc. are removed, as are natural waxes. Shellac is generally shipped in dry or flaked form and is re-moisturized with an alcohol solvent, generally denatured alcohol. Some companies add ingredients to lengthen the shelf life of their product but will not reveal these proprietary additives. Shellac that is bleached (or made into clear shellac) are dissolved in sodium carbonate and centrifuge to remove insolubles and then bleached with sodium hypochlorite

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We Manufacture The Following Products:

DM SHELLAC (PLATINA,ASTRA)LL SHELLAC ( SUPER BLONDE,SONNE)SK SHELLAC (BLONDE,LUNAR)DN SHELLAC (152,KOMET)

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DEWAXED ORANGE SHELLACDEWAXED LEMON SHELLACDEWAXED GARNET SHELLACSTANDARD ONE SHELLACSHELLAC WAXTN SHELLAC (MACHINE MADE)LEMON NO.1 SHELLAC (MACHINEMADE)ORANGE SHELLAC (MACHINE MADE )LEMON NO.1 SHELLAC (HANDMADE)DEWAXED BLEACHED SHELLAC

The Manufacturing   Process

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The role of the lac bug

Shellac is produced by a tiny red insect. Swarms of the insects feed on certain trees, primarily in India and Thailand, known informally as lac trees. The lac bugs' life cycle is only six months, in which time they eat, propagate, and secrete the resin they've taken in from the tree to produce shellac.

In certain seasons of the year, these insects swarm in huge numbers on the trees, settle on branches, and project protrusions into the tree to penetrate the bark. They suck up the sap and absorb it until they feed themselves to death

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(called the feast of death amongst the indigenous peoples). At this same time, propagation continues, with each female lac bug laying about 1,000 eggs before dying.

The sap is chemically altered in the lac bug's body and is then exuded onto the tree branch. On contact with the air, the excretion forms a hard shell-like covering over the entire swarm. This covering forms a crust over the twig and insects. As the female lac bug is exuding the ingested sap she is preparing to die and is providing a fluid in which her eggs will mature under protection. The males' role is to fertilize the female, and it is after fertilization that the females' lac output is vastly increased. The adult males and females become inactive, and the young start to break through the crust and swarm out.

Refining the crusty resin

Workers cut millions of encrusted branches, called sticklac, for transportation to refineries of some sort (either hand refined or mechanically refined). Some workers use mallets and break off the crusty coating much as ice is broken from branches in the winter (it is referred to as grainlac).

At refining centers, sticklac is scraped to remove the secretions from the twigs. Sticklac and grainlac is ground with rotating millstones. The resulting ground material is quite impure, containing resin, insect remains, twigs, leaves, etc. The mixture is forced through a screen, removing the largest of the impurities.

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The sifted resin mixture is put into large jars and stomped by a worker to crush granules and force the red dye from the lac seeds and the insect remains will be freed from the resin. Dye water, scum, and other impurities are then washed away in several rinsing. The mixture is spread out on a concrete floor to dry and called seedlac because it resembles seed. Seedlac is the raw material from which both orange shellac and bleached or clear shellac are produced.

Shellac may be made from seedlac by hand or by modern mechanical equipment. Nearly all American-used shellac is refined with the help of machinery, using a heat-or solvent-based process.

Mixing shellac for the consumer

Large shellac manufacturers are shipped the dry shellac flakes. They then remoisturize the flakes by adding denatured ethyl alcohol. Shellac is offered to the consumer in flake form or suspended in denatured alcohol. It is the latter than is most popular with the consumer. Manufacturers of shellac refer to the concentration of shellac flakes to denatured alcohol in terms of pounds of cuts—the number of pounds of shellac flakes dissolved into a single gallon of denatured alcohol. Thus, a one pound cut of shellac contains

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one pound of shellac flakes dissolved in a gallon of alcohol—very dilute shellac. The manufacturers' standard cut offered to the consumer pre-mixed is termed a three pound cut. Some consumers then dilute it further with denatured alcohol if they so desire.

The most popular shade of shellac sold premixed is the orange shellac although clear or white shellac is also offered pre-mixed to the consumer. Manufacturers always stamp the date of mixing of the shellac into the can. Each manufacturer has a recommended shelf life for the product and the consumer should heed that the product is not used after the period suggested by the manufacturer. If used after the time span recommended, the shellac may never dry completely.

For woodworkers who prefer the deep rich colors of garnet shellac or buttonlac, the dried flakes of these shellacs may be purchased from the manufacturer and mixed with denatured alcohol by the consumer.

Quality Control

Chemical analysis does not assist in determining the quality of shellac. More important are empirical tests such as flow and shelf life that most customers have articulated as of great concern. In addition, carefully examining the purity of the shellac by removing as many of the natural impurities found within the sticklac is of utmost importance (insoluble’s are defined by the undissolved matter remaining when the resinous compound is mixed with hot alcohol). All refining processes are monitored for their effectiveness in removing these undesirables.

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...:: HEAD OFFICE ::...Address : D.Manoharlal(Shellac) Pvt. Ltd.

5, Dr. Rajendra Prasad Sarani(Clive Row),1st Floor, Room No.24Kolkata - 700001 (India)

Phone : +91 33 22627165Fax : +91 33 22627166Mobile : +91 9339487674, +91 7828811249

E-mail : sumeet@dmshellac.comnikhil@dmshellac.com

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Website : www.dmshellac.com

...:: FACTORY ::...Address : D.Manoharlal (Shellac) Pvt. Ltd.

Po. Sakti, Distt. Janjgir-Champa, Chhattisgarh - 495689, India

Phone : +91 7757 233249Fax : +91 7757 233149Mobile : +91 9300694469

+91 9300491249+91 9300894111

E-mail : dmshellac@rediffmail.comWebsite : www.dmshellac.com

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