Leather Solid Wastes

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Welcome & Greetings

ECOMARK

Indian Institute of Science Banglore 28 March 2006

2006

Leather & Leather Products

1975

Leather & Leather Products business

Established In 1975 Largest Tannery In India Among The Top three Goat tanneries in the World Leader in leather exports from India since 1982

Genesis

Pioneers in leather industry in India and in the region i i i i i i i Exploring new markets New Product development Profile Setting quality standards Value proposition for sustainable customer relationship Recognized for R&D capabilities Responsible corporate citizen

Export PerformanceOverall Exports Export PerformanceFinished Leather Export PerformanceFootwear Components Export PerformanceLeather Garments ISO 14001 Certificate for Environment Management System

Number one Position in India. Number one Position in India. Number one Position in India. Number two Position in India. First in India.

Leather Global Business of TATA Group One of the few global businesses of the group with 85% of turnover from international markets Global Markets Exporting products to over 35 countries across the globe Global Sourcing RM from Middle East, Far East, g , , Bangladesh, Africa, CIS etc. Global Supply Chain India (Dewas, Chennai, Kolkata, pp y ( , , , Kanpur), China, Bangladesh, Italy. World-class Technology Chemicals / Waste recycling / Advanced Machines. Global Alliances Graziella & Missardi of Italy; Lloyd / Ara of Germany; Getever & Lianyon of China.

Leather GBUs Partners with Global BrandsFinished Leather Peter Kaiser Aerosole A Ara Naturalizer Gabor Leather G L th Garments t Mango Zara Pierre Cardin Escada Betty Barclay Footwear F t Gabor Marks & Spencer Fl Florsheim h i Ara / Lloyd Ambiorix Grenson Hush Puppies

How Environment friendly is our leather ?R&D capabilities

Environmental CareLiquid Waste Management ETP to meet all the norms through physiochemical and microbiological treatment

Environment Excellence Awards

Reverse Osmosis to optimize the recycling of liquid waste Solid Waste Management The worlds first plant to use bio methanation technology for solid waste treatment based on in-house patented technolog in house UNDP/TIL/MNES sponsored project Developed process for specialty leathers like Zero Chrome (Minerals free)

ISO 14000 Certification from RWTUV,Germany

Most Environmental Friendly way of disposal/recycling of Waste

Ecolabelling First Leather company in India recommended for Eco Labelling

TOWARDS SUSTAINABLE LEATHER INDUSTRY

Two Lacs Trees Planted all Around the Complex

Energy Saving e gy Sav g- Large Solar array (~700 nos.) for heating Boiler feed water. - Capacit 50M3 per day to 80oC Capacity da C. - Specific Power consumption reduction in leather processing - Biogas from leather waste.

Ground and Roof Water Harvesting

Pollutants Generated:

SOLID WASTE : LIQUID WASTE :

SHAVING DUST FROM WET BLUE AND TRIMMINGS EXHAUST LIQUORS FROM DRUMS OF DYE HOUSE

AIR POLLUTION : VAPOURS FROM SPRAY BOOTHS

How Environment friendly is our leather ?Environment Care

Pole View of Effluent Treatment Plant

POLLUTION TREATMENT MEASURES TAKEN:

Water Recycling- Reverse Osmosis Plant on Treated Effluent Recycling. - RO plant capacity ~ 200 M3 per day. - Ground and Roof water harvesting.

LEATHER SOLID WASTE CONTAINING CHROMIUM

Hazardous Waste Recycling :

- Recycling Capacity of 700 tons per annum of Chromium i C i f 00 fC i containing leather waste. - Bio gas from Chromium containing leather waste project Bio-gas Chromi m aste 50% sponsored by MNES/UNDP - Methane gas production 250M3 per day - Chromium Recovery and recycling, 12 tons per annum as Chromium Sulphate. - Two Patents on Hazardous Waste Recycling

Industry Leadership & Accolades2005 2005 2005 2004 2003 2002 2000 1998 1995Winner of the CLEs Best Exporter Award In Leather from 1984 to 2004 ECOMARK

ECO MARK for FINISHED LEATHER TERI Corporate Environment Award Across Industries MP State Award for Best practices in Environment protection ISO 9001 Certification for Chennai Supply Chain operations Rajiv Gandhi Award for Environment Protection Best f All, l l th B t of All only leather company in India i I di ISO 14001 certification 1st in India Rajiv G Gandhi National Quality Award Q Best of All, only leather company in India ISO 9000 certification for Leather Garments and Footwear - 1st in India ISO 9000 certification - 1st tannery in India

How Environment friendly is our leather ? Eco friendly leather :In house eco friendly leather manufacturing process has been developed which is chrome free.

Bio-Methanation plant :Implemented in house developed patented technology for gainful utilization of solid waste. At present the gas generation is around ili i f lid A h i i d 250 m3/day.

Eco labeling of finished leather:Eco labeling of our finished leather has been Awarded by Bureau of Indian Standards (BIS). Implemented to make our leather free from banned items like PCP, formaldehyde, Azo dyes to meet the eco criteria.

How Environment friendly is our leather ?ETP Treatment by new process:A new process has been developed at pilot level for reducing chemical , manpower & energy cost as well as sludge reduction.

Substitution by cheaper chemicals:Expensive & hazardous chemicals have been replaced with cheaper & environment friendly chemicals. Chemicals from Waste Recycling Up gradation of technology: Adopted Reverse Osmosis technology for further improving the effluent treated water. Daily 200 M3 water as good as drinking water is supplied to boiler house. house

MANUFACTURING PROCESS:WET BLUE (WB) SKINS SHAVING OF WET BLUE

SOLID WASTE

DYE HOUSE

LIQUID WASTE

MECHANICAL OPERATIONS

FINISHING SPRAY BOOTH W/H DESPATCH

AIR POLLUTION

ENVIRONMENT FRIENDLY TOTAL SOLUTION FOR LEATHER SOLID WASTE CONTAINING CHROMIUM SO S CO GC O U

MODE:

GAINFUL UTILIZATION THROUGH BIOTECHNOLOGY/BIOMETHANATION

ENVIRONMENT FRIENDLY TOTAL SOLUTION FOR LEATHER SOLID WASTE CONTAINING CHROMIUML E A T H E R B U S IN E S S P e rfu m e W A S T E G E N E R A T IO N S O L ID W A S T E B o a rd Sheet F ib e r T r im m in g s Used P ro d u c t

L I Q U ID W A S T E E f f lu e n t S h a v in g Dust B u f f in g Dust

D ru m S lu d g e

ETP

L a n d F illR e v e rs e O s m o s is B io M e t h a n t io n P la n t P ig m e n t C h r o m iu m R e c o v e ry B io lo g ic a l P ig m e n t A m in o A c id s F e r t i l iz e r S a la b le E l c t r o p la t in g le l i B io G a s L e a th e r C h e m ic a ls

O n Land

H o rm o n e

E n zym es Power G e n e r a t io n

Non-Environment Friendly

Innovative Route

Recycle

Present

LEATHER SOLID WASTE BIOMETHANATION BULK IMPLEMENTATION.DEMONSTRATION PLANT FOR LEATHER SOLID WASTE BIOMETHANATION

AT TATA INTERNATIONAL LTD DEWAS BASED ON IN-HOUSE R&D PATENTED TECHNOLOGY

WITH SUPPORT FROM UNDP / MNES (G.O.I.) & MONITORED BY CLRI.

CONCEPT:

A novel innovative scheme for utilizing these wastes in-house as an economically self sustaining environmental care project project.

The concept was to treat the solid wastes to separate the chrome and the organics. The organics would go for Biomethanation and chrome would be recycled for leather making.

Patents/Publication by TIL, R&D: TIL

Two Patents granted by Govt. of India in August 2003 1. Indian patent no. 188788 (612/BOM/98) Dated 22nd September S t b 98 A process for the production of methane containing fuel gas and nitrogenous fertilizer by Biomethanation of pelt/chromed leather solid wastes. 2. 2 Indian patent no. 188789 (613/BOM/98) Dated 22nd no September 98 A process for the recovery of Basic Chromium p y Sulphate (BCS) from chromed leather solid wastes.

High Rate Biomethanation Plant Based on Solid Waste From Leather Industry Place of Installation : Date of Commissioning : Status of Functioning : Implementing Agency : Technology : Technology Institution for Monitoring : Dewas, Madhya Pradesh September, 2002 Continuously Running Tata International Limited UNDP & MNES (Govt of India) Tata International Limited Central Leather Research Institute, Chennai

Plant Installation Agency : Mailhem Engineers Pvt. Ltd

Progress Report On Biomethanation Plant

Chronology of events for Bulk implementation: 1994-96: Bench scale data established. Late 96: Ministry of Non Conventional Energy Sources (MNES) (Govt. of India) Brainstorming session on leather industry Solid waste treatment process. 97: 98: 99-00 MOU signed by TATA, Central Leather Research Institute (CLRI), Chennai/MNES/UNDP. ( ), Patent application. DPR preparation Tender document preparation by CLRI, All India tender invitation, screening & awarding of t d f tender.

Chronology of events for Bulk implementation: gy p

March 01:

Final agreement signing between TIL, MNES & Mailhem for implementation of the UNDP sponsored project. project Plant installed.

Aug. 02 Mar 03 Apr 03 Mar 06

Commissioning. O&M Completed. Run by TIL

PROCESS FLOW DIAGRAM: The process flow for Hazardous solid waste treatment from leather is as given below

W e t b lu e s h a v i n g d u s t, tr i m m i n g s S p l i t w a s te s

C h e m ic a l tr e a tm e n t

F i l tr a ti o n

S o lid re sid u e

C o n v e r te d to B C S

F o r C h ro m e ta n n i n g

B i o -g a s to B o i l e r t F i l tr a te fe d to B i o m e th a n a ti o n p la

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