The study is aimed at developing an optimal approach for synthesis of flame-retardant coatings by using a comparative study of various techniques based on the tuning parameters involved, for applications involving the safeguarding of materials such as wood and polymer, when exposed to fire. The focus is on the development of intumescent coatings, with uniform char thickness, using different materials, formulations, and synthesis techniques, and developing an understanding of key process parameters. The formulation is based on Ammonium polyphosphate (APP) and other flame-retardant additives & fillers in which epoxy resin is used as a binder. Influence of the flame retardant additives and fillers is characterized using thermo gravimetric analysis (TGA), oxygen index test, smoke density test, and flammability test. TGA showed that addition of graphite as a filler increased the maximum degradation temperature. The combination of graphite, flame retardant additives and fillers was found to give the best fire retardant performance with good adhesion properties, without dripping, along with good expansion of char layer and good thermal stability. (C) 2018 Elsevier Ltd. All rights reserved.