{
  "formula_id": "AE-EXT-10Y-001",
  "product": {
    "product_code": "WB-AE-EXT-10Y-001",
    "product_name": "Exterior Acrylic Emulsion Paint (10-Year Grade) — White Base (Example)",
    "category": "Architectural Coatings",
    "process_stage": "Paint Manufacture",
    "system_type": "Waterborne Acrylic Emulsion",
    "form": "Liquid paint",
    "version": "1.0",
    "date": "2026-01-05",
    "notes": [
      "JSON-first model for SaitechLabs/SaitechAI. Validate by lab trials before scale-up and site claims.",
      "Maintain good dispersion and pH control to avoid viscosity drift and poor scrub/opacity.",
      "Use biocide and film preservative per local regulations and supplier guidance."
    ]
  },
  "batch_basis_kg": 100.0,
  "targets": {
    "paint_pH_25C": {
      "min": 8.5,
      "max": 9.5
    },
    "application": {
      "recommended_dft_microns": [
        35,
        50
      ],
      "recommended_wft_microns": [
        90,
        130
      ],
      "coverage_m2_per_L_per_coat": [
        10,
        14
      ]
    },
    "notes": [
      "Final targets depend on pigment grade, extender PSD, thickener package, and emulsion MFFT.",
      "Exterior durability depends on binder quality, PVC, additives, and film thickness."
    ]
  },
  "composition_wt_percent": [
    {
      "rm_code": "RM-WATER",
      "wt_percent": 20.0,
      "role": "carrier",
      "notes": "Deionized water"
    },
    {
      "rm_code": "RM-NIS-001",
      "wt_percent": 0.3,
      "role": "surfactant",
      "notes": "Non-ionic surfactant"
    },
    {
      "rm_code": "RM-ADS-001",
      "wt_percent": 0.4,
      "role": "dispersant",
      "notes": "Anionic dispersant (assumed ~40% active as given)"
    },
    {
      "rm_code": "RM-DEF-SIL",
      "wt_percent": 0.2,
      "role": "defoamer",
      "notes": "Silicone-based defoamer"
    },
    {
      "rm_code": "RM-PRES-IC",
      "wt_percent": 0.2,
      "role": "in_can_preservative",
      "notes": "In-can preservative"
    },
    {
      "rm_code": "RM-AMP95",
      "wt_percent": 0.1,
      "role": "pH_adjuster",
      "notes": "Ammonia/AMP-95"
    },
    {
      "rm_code": "RM-TIO2-RUT",
      "wt_percent": 12.0,
      "role": "pigment",
      "notes": "Rutile TiO2 (exterior grade)"
    },
    {
      "rm_code": "RM-CALC-FG",
      "wt_percent": 18.0,
      "role": "extender",
      "notes": "Calcite (fine ground)"
    },
    {
      "rm_code": "RM-TALC-HY",
      "wt_percent": 10.0,
      "role": "extender",
      "notes": "Hydrophobic talc"
    },
    {
      "rm_code": "RM-MICA-CRS",
      "wt_percent": 4.0,
      "role": "extender",
      "notes": "Coarse lamellar mica"
    },
    {
      "rm_code": "RM-KAOL-W",
      "wt_percent": 4.0,
      "role": "extender",
      "notes": "Washed kaolin"
    },
    {
      "rm_code": "RM-SIL-REP",
      "wt_percent": 0.5,
      "role": "water_repellent",
      "notes": "Silane/siloxane water repellent (assumed ~40% active as given)"
    },
    {
      "rm_code": "RM-UV-ABS",
      "wt_percent": 0.2,
      "role": "uv_absorber",
      "notes": "UV absorber"
    },
    {
      "rm_code": "RM-HALS",
      "wt_percent": 0.2,
      "role": "light_stabilizer",
      "notes": "HALS"
    },
    {
      "rm_code": "RM-COAL-TEX",
      "wt_percent": 1.0,
      "role": "coalescent",
      "notes": "Texanol/DPnB"
    },
    {
      "rm_code": "RM-ACR-52",
      "wt_percent": 26.0,
      "role": "binder",
      "notes": "Silicon modified pure acrylic emulsion (52% solids as given)"
    },
    {
      "rm_code": "RM-HEUR",
      "wt_percent": 0.3,
      "role": "rheology_modifier",
      "notes": "HEUR thickener (18% active as given)"
    },
    {
      "rm_code": "RM-HEC",
      "wt_percent": 0.2,
      "role": "rheology_modifier",
      "notes": "Cellulosic thickener (HEC)"
    },
    {
      "rm_code": "RM-PRES-FILM",
      "wt_percent": 0.2,
      "role": "film_preservative",
      "notes": "OIT + IPBC + DCOIT"
    },
    {
      "rm_code": "RM-WATER-FIN",
      "wt_percent": 2.2,
      "role": "makeup_water",
      "notes": "Final viscosity adjustment water"
    }
  ],
  "process": {
    "parts_from_csv": [
      {
        "part": "A",
        "phase": "premix",
        "items": [
          {
            "line_no": 1,
            "rm_code": "RM-WATER",
            "qty_kg": 20.0,
            "notes": "Deionized water"
          },
          {
            "line_no": 2,
            "rm_code": "RM-NIS-001",
            "qty_kg": 0.3,
            "notes": "Non-ionic surfactant"
          },
          {
            "line_no": 3,
            "rm_code": "RM-ADS-001",
            "qty_kg": 0.4,
            "notes": "Anionic dispersant (assumed ~40% active as given)"
          },
          {
            "line_no": 4,
            "rm_code": "RM-DEF-SIL",
            "qty_kg": 0.2,
            "notes": "Silicone-based defoamer"
          },
          {
            "line_no": 5,
            "rm_code": "RM-PRES-IC",
            "qty_kg": 0.2,
            "notes": "In-can preservative"
          },
          {
            "line_no": 6,
            "rm_code": "RM-AMP95",
            "qty_kg": 0.1,
            "notes": "pH adjuster"
          }
        ]
      },
      {
        "part": "B",
        "phase": "grind",
        "items": [
          {
            "line_no": 7,
            "rm_code": "RM-TIO2-RUT",
            "qty_kg": 12.0,
            "notes": "Rutile TiO2 exterior grade"
          },
          {
            "line_no": 8,
            "rm_code": "RM-CALC-FG",
            "qty_kg": 18.0,
            "notes": "Calcite fine ground"
          },
          {
            "line_no": 9,
            "rm_code": "RM-TALC-HY",
            "qty_kg": 10.0,
            "notes": "Hydrophobic talc"
          },
          {
            "line_no": 10,
            "rm_code": "RM-MICA-CRS",
            "qty_kg": 4.0,
            "notes": "Coarse lamellar mica"
          },
          {
            "line_no": 11,
            "rm_code": "RM-KAOL-W",
            "qty_kg": 4.0,
            "notes": "Washed kaolin"
          }
        ]
      },
      {
        "part": "C",
        "phase": "letdown",
        "items": [
          {
            "line_no": 12,
            "rm_code": "RM-SIL-REP",
            "qty_kg": 0.5,
            "notes": "Silane/siloxane water repellent (assumed ~40% active as given)"
          },
          {
            "line_no": 13,
            "rm_code": "RM-UV-ABS",
            "qty_kg": 0.2,
            "notes": "UV absorber"
          },
          {
            "line_no": 14,
            "rm_code": "RM-HALS",
            "qty_kg": 0.2,
            "notes": "HALS stabilizer"
          },
          {
            "line_no": 15,
            "rm_code": "RM-COAL-TEX",
            "qty_kg": 1.0,
            "notes": "Coalescent Texanol/DPnB"
          },
          {
            "line_no": 16,
            "rm_code": "RM-ACR-52",
            "qty_kg": 26.0,
            "notes": "Silicon modified pure acrylic emulsion (52% solids)"
          },
          {
            "line_no": 17,
            "rm_code": "RM-HEUR",
            "qty_kg": 0.3,
            "notes": "HEUR thickener (18% active as given)"
          },
          {
            "line_no": 18,
            "rm_code": "RM-HEC",
            "qty_kg": 0.2,
            "notes": "Cellulosic thickener HEC"
          },
          {
            "line_no": 19,
            "rm_code": "RM-PRES-FILM",
            "qty_kg": 0.2,
            "notes": "Film preservative OIT+IPBC+DCOIT"
          },
          {
            "line_no": 20,
            "rm_code": "RM-WATER-FIN",
            "qty_kg": 2.2,
            "notes": "Final viscosity adjustment water"
          }
        ]
      }
    ],
    "mixing_order": [
      "Part A (Premix): Charge water, start agitation; add surfactant and dispersant; add defoamer and in-can preservative; adjust pH with AMP-95/ammonia.",
      "Part B (Grind): Add TiO2 and extenders slowly under high shear; disperse to required fineness (e.g., Hegman); control foam and temperature.",
      "Part C (Letdown): Under low–medium shear add water repellent, UV absorber, HALS, coalescent; add acrylic emulsion slowly; add thickeners (pre-diluted/activated as per supplier); add film preservative; top-up water to final viscosity; mix until uniform."
    ],
    "qc_checks": [
      "Fineness of grind (Hegman): record",
      "pH (25°C): within target",
      "Viscosity (KU/Brookfield): set as per application",
      "Density (kg/L): record for batch fingerprint",
      "Appearance: uniform, no seeds/lumps"
    ]
  },
  "safety": {
    "ppe": [
      "Safety goggles",
      "Gloves",
      "Mask/respirator for powder handling",
      "Ventilation"
    ],
    "warnings": [
      "Avoid inhalation of TiO2/extender dust; use dust control.",
      "Preservatives/biocides can be sensitizers; follow SDS.",
      "Add powders slowly to avoid lumping and dusting."
    ]
  }
}