of the proposed enhancement of...

OF

THE PROPOSED ENHANCEMENT OF MANUFACTURING CAPACITY AND ADDITION OF NEW PRODUCTS OF

“MANMADE FIBER (OTHER THAN RAYON)”

(POLYESTER TEXTURISED & TWISTED YARN, POLYESTER ORIENTED YARN / FULLY DRAWN YARN, BULK CONTINUOUS FILAMENT YARN

AND NYLON FILAMENT YARN)

Activity: 5(d) Category-A (Due to the applicability of General Condition)

OF

Unit Located at: Survey No. 205/1-2 & 207, 204/1-2-3, 205/6 & 206 and

Plot No. 60, 62, 64 & 65 Govt. Ind. Estate, Village: Masat-Samarvarni,

Silvassa-396 230 (Dadra and Nagar Haveli)

Prefeasibility Report-Annexure M/s. Beekaylon Synthetics Pvt. Ltd.

INDEX

1. Executive Summary……………………………………………………………………………………….……………… 04

2. Introduction……………………………………………………………………………………..………….………………. 06 i. Identification of the Project and Proponent. 06 ii. Brief Description of the project 06 iii. Need of the project and its importance to the country and or region 07 iv. Demand –Supply Gap 07 v. Imports vs. Indigenous production 07 vi. Export Possibility / Domestic / export Markets 07 vii. Employment Generation (Direct and Indirect) due to the project. 07

3. Project Description………………………………………………………………………………………………………… 08 i. Type of Project including interlinked and interdependent projects, If any 08 ii. Location (map showing general location, Specific location, and project boundary

& project site layout)with coordinates 08

iii. Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted :

09

iv. Size or magnitude of operation 09 v. Project description with process details (a schematic diagram/ flow chart

showing the project layout components of the project etc. should be given) 09

vi. Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product:

13

vii. Resource optimization/ recycling and reuse envisaged in the project, If any, should briefly outlined

13

viii. Availability of water its source, Energy/power requirement and source should be given

13

ix. Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal

15

x. Schematic representations of the feasibility drawing which give information of EIA purpose

18

4. Site Analysis………………………………………………………………………………………………………………… 19

i. Connectivity 19 ii. Land Form, land Use and Land Ownership 19 iii. Topography (along with map) iv. Existing land use pattern (agriculture, non-agriculture, forest , water bodied (

including area under CRZ), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification should be given

20

v. Existing Infrastructure 20 vi. Soil classification 20 vii. Climate data from secondary sources 20 viii. Social Infrastructure available 20

5. Planning Description……………………………………………………………………………………………………… 21

Expansion Project 2 Manufacturing : Manmade Fiber Industry


i. Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning/Development authority Classification.

21

ii. Population Projection 21 iii. Land use planning (breakup along with green belt etc. 21 iv. Assessment of Infrastructure demand (Physical & Social) 23 v. Amenities/ Facilities 23

6. Proposed Infrastructure ……………………………………………………………………………………………….. 23 i. Industrial Area (Processing Area) 23 ii. Residential Area (Non Processing Area). 23 iii. Green belt 23 iv. Social Infrastructure 23 v. Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc.) 23 vi. Drinking Water management (Source & Supply of water) 23 vii. Sewerage System 23 viii. Industrial Waste Management 24 ix. Solid Waste Management 24 x. Power Requirement & Supply / Source 24

7. Rehabilitation and Resettlement (R&R) Plan…………………………………………………………………. 25

I. Policy to be adopted (Central/ State) in respect of the project affected persons

including home oustees, land oustees and landless laborers (a brief outline to be given):

25

8. Project Schedule & Cost Estimates…………………………………………………………………….............. 25

i. Likely date of start of construction and likely date of completion 25

ii. Estimated project cost along with analysis in terms of economic viability of the project 25

9. Analysis of Proposal (Final Recommendations)…………………………………………………............. 26 i. Financial and social benefits with special emphasis on the befit to the local people

including tribal population, if any, in the area 25



1. EXECUTIVE SUMMARY

Name of the Project: M/s. Beekaylon Synthetics Pvt. Ltd. Location: Survey No. 205/1-2 & 207, 204/1-2-3, 205/6 & 206 and Plot No. 60, 62, 64 & 65, Industrial Zone, Village: Masat-Samarvarni, Silvassa-396 230 (Dadra and Nagar Haveli)

Project • M/s. Beekaylon Synthetics Pvt. Ltd. is an existing company set up industrial unit at Survey No. 205/1-2 &

207, 204/1-2-3, 205/6 & 206 and Plot No. 60, 62, 64 & 65, Industrial Zone, Village: Masat- Samarvarni, Silvassa-396 230 (U.T. of Dadra & Nagar Haveli) since 1975.

• The unit is manufacturing Manmade Fiber other than Rayon (i.e. Polyester Oriented Yarn (POY) / Fully Drawn Yarn (FDY) @ 31500 TPA and Polyester Texturised & Twisted Yarn with dyeing @ 24960 TPA.

• M/s. Beekaylon Synthetics Pvt. Ltd. obtained “Environmental Clearance” from the Ministry of Environment & Forests through vide F. No. J-11011/66/2010- IA II (I) dated 30.12.2010 and Consent under The water Act and the Air Act from Pollution Control Committee DD & DNH.

• Now the company proposes to enhance the production capacity of existing product and addition of new products under the category “Manmade fiber”.

• Total Project Cost (after expansion): Rs. 135.45 Crores (for proposed expansion Rs. 61.45 Crores)

Applicability of EIA notification – 2006 • As per the EIA notification- 2006 as amended: existing products (i.e. Polyester texturised & twisted yarn

and polyester oriented yarn) are covered under the Category-5(d) – “Manmade fiber other than Rayon”. • Manufacturing of “Manmade fiber other than Rayon ” is covered under Category –B, but due to the

applicability of General Conditions this project is categorized as Category-A and applied to MoEF&CC for obtaining Environmental Clearance.

Project Proponent • Indian Private Limited Firm comprising 3 directors • Large Scale Unit LIST OF FINISHED PRODUCTS (Existing, proposed ant total) • Production capacity of Polyester Texturised & Twisted Yarn will be enhanced from 24960.00 TPA to

60000.00 TPA. • Production capacity of Polyester Oriented Yarn (POY) / Fully Drawn Yarn (FDY) will be enhanced from

31500.00 TPA to 100000.00 TPA. • New products as Bulk Continuous Filament Yarn/ Nylon Filament Yarn will be manufactured @ 72000.00

TPA.

Resource Requirement • Raw materials The raw materials required for the manufacturing of Polyester Texturised & Twisted Yarn will be POY

@ 57000.00 MT/annum and Antistatic oil @ 300.00 MT/annum. The raw materials required for the manufacturing of Polyester Oriented Yarn (POY) / Fully Drawn

Yarn (FDY)/ Bulk Continuous Filament (BCF)/ Nylon Filament Yarn (NFY) will be Polyester chips/ Nylon Chips @177160.00MT/annum and Spin finish oil @1376.00MT/annum.



• Utilities Power (Electricity) will be sourced from DNH Power distribution corporation Ltd. The existing

unit is having power supply of 10750 KVA and proposing to obtain additional 12000 KVA for the proposed expansion project.

As a standby power source existing unit is having a D.G. Set of capacity 750 KVA. For proposed expansion, four additional D.G. Sets of capacity of 1000 KVA each are proposed. HSD will be used as fuel to run the D.G. Sets.

Water and Waste Water Management • Total Fresh Water requirement is @ 452.00 KL/day (Existing: 177.00 KL/day & proposed: 275.00KL/day)

and fresh Water will be catered from Daman Ganga Canal Authority. • Industrial waste water generation @ 117.00 KL/day (Existing: 74.00 KL/day & proposed: 43.00KL/day) in

the form of washing, boiler & cooling tower blow down will be treated in the existing full-fledged Effluent Treatment Plant and treated effluent is partially recycled back to process and partially utilized for gardening purpose.

• Domestic waste water generation @24 KL/day (Existing: 14 KL/day & proposed: 10 KL/day) will be disposed off through Septic Tank.

Air Emission and its Control Measures • The existing unit is having two nos. of coal fired Steam Boilers of capacity 2 Tons/ hr each. Bag filter with

adequate chimney height is being provided for the same. • Two nos. of coal fired steam boilers (capacity- 2 Tons/hr. each) and one no. of D.G. Set (capacity- 750

KVA) is installed for the existing manufacturing facilities. The company has provided adequate chimney height to D.G. Sets in order to control utility emissions.

• There will be four additional installation of D.G. Set of 1000 KVA each to be used in case of power failure. Adequate chimney height will be provided for the proposed D.G. Sets also.

Hazardous Wastes and its Management • ETP waste (35.3) will be generated from ETP operation @ 20 MT/annum which will be sent to TSDF site

(GEPIL site, Silvassa) for final disposal. • Used oil (5.1) from plant and machineries generated @4.00 KL/annum will be sold to registered refiners/

sent to TSDF site. • Empty drums (33.1) and Empty bags (33.1) from raw material handling generated @950 Nos./annum

and @88200 Nos./annum respectively will be reused for packing /sold to authorized scrap vendor. • Process Residue (22.2) occasionally generated from process @50.00 MT/annum will be sent to

authorized recycler or for co-incineration. Non-hazardous Solid Wastes and its Management • The non-hazardous Yarn waste and Tex. Yarn waste from process generated @ 1500.00 MT/annum and

@11.53 MT/annum respectively will be will be recycled back /sold to actual users.

Details of Hazardous Chemicals There are no hazardous chemicals used in the existing manufacturing process. Also, there will be no hazardous chemicals involved in the process in the proposed expansion project.



2. INTRODUCTION (i) Identification of Project and proponent.

Name of the project Proponent: M/s. Beekaylon Synthetics Pvt. Ltd. M/s. Beekaylon Synthetics Pvt. Ltd. located at 205/1-2 & 207, 204/1-2-3, 205/6 & 206 and Plot No. 60, 62, 64 & 65, Govt. Industrial Estate, Village-Masat-Samarvarni, Silvassa, D & NH-396 240 (U.T.) is manufacturing “Texturised, Twisted and Dyed Polyester Yarn” which is used in the process of weaving and knitting of fabrics meant for suiting, shirting, dress materials and home furnishings.

The company has a wider customer base and to cater to the increased market demand, the Company proposes expansion by way of increasing the existing production capacity of “Polyester Texturised & Twisted Yarn and Polyester Oriented Yarn (POY)/Fully Drawn Yarn (FDY)” and addition of new product.

The company is already manufacturing Polyester Texturised & Twisteded Yarn at 24960 MT/Annum and Polyester Orient Yarn (POY)/ Fully Drawn Yarn (FDY) at 31500 MT/Annum.

The company has been promoted by, well experienced Khemani family, having sound financial strength and demonstrated track record in the Textiles business. The senior members of the family have been active in textile industry for more than Three decades. Khemani family is well known amongst the textile industrialist for their commitments towards quality and customer relationship. The family is also known for philanthropic works in society.

Details related to them are given below:

Sr. No. Name of Directors Residential Address

1. Mr. Nand K. Khemani 32, Elcid, 13, Ridge Road, Malabar Hill, Mumbai – 400 006.

2. Mr. Ashok K. Khemani 32, Elcid, 13, Ridge Road, Malabar Hill, Mumbai – 400 006.

3. Mr. Mahesh Lakhwani Beekaylon Bungalow, Kalvani Road, Silvassa, D & NH.

(ii) Brief description of nature of the Project M/s. Beekaylon Synthetics Pvt. Ltd. proposes the expansion of their existing unit by increasing the production capacity of existing product and addition of new products at 205/1-2 & 207, 204/1-2-3, 205/6 & 206 and Plot No. 60, 62, 64 & 65, Govt. Industrial Estate, Village-Masat-Samarvarni, Silvassa, D & NH-396 240 (U.T. of Dadra and Nagar Haveli).

The proposed expansion project involves the increase in the production of “Polyester Texturised & Twisteded Yarn and Polyester Orient Yarn (POY)/ Fully Drawn Yarn (FDY)” and addition of new products “ Bulk Continuous Filament Yarn and Nylon Filament Yarn” which are manmade fibers, used for the process of weaving and knitting of fabrics meant for suiting, shirting, dress materials and home furnishings.

As per the EIA notification- 2006 as amended proposed products are covered under Activity 5(d) Category-B and hence required Prior Environmental Clearance.

For the proposed project, the company intends to procure the best available technology for manufacturing the products as listed.



(iii) Need for the project and its importance to the country and or region The industrial sector in the past few years has seen a drastic boom and also the keeping in mind the globalization trend, we have identified the demand for the proposed products and with continuous R&D found that it can be developed in-house and produce commercially for domestic market as well as an eye more on export markets.

The proposed project provides a potential growth opportunity for the already running business of the company. The company is already engaged in the business of manufacturing of “Polyester Texturised & Twisteded Yarn and Polyester Orient Yarn (POY)/Fully Drawn Yarn (FDY)” and the proposed expansion project would increase the overall export and also increase the foreign revenue. Products are now well established and acceptable in the international markets.

(iv) Demand –Supply Gap The products have very high demand for the process of weaving and knitting of fabrics meant for suiting, shirting, dress materials and home furnishings.

(v) Imports vs. Indigenous production Existing products manufacturing in the country will be very much economical compare to Imports of the same and also the export of the same will earn extra revenue generation for our county.

(vi) Export Possibility / Domestic / export Markets There is a huge demand of synthetic filament yarn in the export market. Our products are widely used and are in demand in the domestic Textile industry

(vii) Employment Generation (Direct and Indirect) due to the project There will be very good opportunity of employment generation directly and indirectly due to proposed expansion. We anticipate employing of up to 200 workmen and 25 office staff directly in the proposed expansion project.



3. PROJECT DISCRIPTION

(i) Type of Project including interlinked and interdependent projects, If any : The proposed project is interdependent project of the company.

(ii) Location (map showing general location, Specific location, and project boundary & project site layout) with coordinates: The map showing general location, specific location and project boundary and project site layout of M/s.Beekaylon Synthetics Pvt. Ltd. Located at 205/1-2 & 207, 204/1-2-3, 205/6 & 206 and Plot No. 60, 62, 64 & 65, Govt. Ind. Estate, Village: Masat-Samarvarni, Silvassa-396 230 (Dadra And Nagar Haveli).

Fig. 3.1: Location map showing the Project site and inter-state boundary with 10 kms radius



(iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted : Since proposed project is an expansion project by capacity enhancement of existing products and addition of new products within the existing developed site and adjoining plots, hence alternate site consideration is not envisaged.

Profile of Project Site:

Sr. No. Nearest Infrastructure Feature Distance from Project Site (Aerial Distance)

1 Geographical Position Lat.: 20°15'30.05"N, Long.: 73° 0'50.28"E

2 Elevation above Sea Level 44 Meters (Approx.)

3 Nearest Village Samarvani 0.3 km SW (Approx.) Masat, 1.70 Km W (Approx.)

4 Nearest Town Silvassa– 2 Km N (Approx.)

5 Nearest National Highway NH 8: 13.44 km W (Approx. Route Distance)

6 Nearest State Highway SH:0.70 km W (Approx. Route Distance)

8 Nearer RW Station Bhilad-13.29 km W (Approx. Route Distance)

9 Nearest Airport Daman, 26 Km NW (Approx.)

10 Nearest Surface water Resource/Reservoir

Damanganga River 2.50 km W Madhuban Dam 8.56 km SE

11 Forest Land Reserve Forest 2.69 km W Protected Forest 8.69 km S

12 Location of Archaeologically /Historically important places

Silvassa 2.00 Km N (Approx.) Bindrabin 12.5 Km SE (Approx.)

13 National Park/Sanctuary or Ecologically sensitive Area

D & NH Wild Life Sanctuary 8.69km S (approx.) Vasona , Lion safari 7.37 km SE & Dapada, Satmaliya Deer Park 8.69 km S

14 National or State Boundary Interstate – Gujarat 3.66 km NW Maharastra 5.79 Km SW (Approx.)

15 Tourist Places

Silvassa- 2 Km N (Approx.) Madhuban Dam- 8.56 km SE (Approx.) Dudhani-17.56 KM SE (Approx.) Khanvel- 14 KM SE (Approx.) Tighra-7.8 KM NW (Approx.)

(iv) Size or magnitude of operation :

As per the proposed project cost the project is covered under Large Scale category of manufacturing industries.

(v) Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given):

Detailed project description with process details –



• LIST OF FINISHED PRODUCTS

Sr. No.

Products Name Production Capacity (TPA)

Existing Additional Total

1. Polyester Texturised & Twisted Yarn 24960.00 35040.00 60000.00

2. Polyester Oriented Yarn (POY) / Fully Drawn Yarn (FDY) 31500.00 68500.00 100000.00

3. Bulk Continuous Filament Yarn/ Nylon Filament Yarn 0.00 72000.00 72000.00

Total Manmade fiber 56460.00 175540.00 232000.00

• INFRASTRUCTURE, MACHINERIES, EQUIPMENT & TECHNOLOGIES Within the existing premises with required minor civil work for manufacturing of additional capacity of

products. Within the existing premises and infrastructure the installation of some additional plant and machineries

will be required.

• MANUFACTURING PROCESS The company is using the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance for the product. Product: Synthetics filaments yarn (i.e., Polyester Texturised & Twisted Yarn, Polyester Oriented Yarn (POY) / Fully Drawn Yarn (FDY), Bulk Continuous Filament Yarn/ Nylon Filament Yarn)

a. Manufacturing Process: Manufacturing process for all the products are similar, only their physical properties vary as per requirement of the finished product. Partially oriented yarn (POY), Fully Drawn Yarn (FDY) and Bulk Continuous Filament (BCF) will be made from Polyester chips (granule).

Polyester/Nylon chips & granules is procured from the open market. Spin finish oil is used during the spinning stage to avoid the adhesion of yarns and antistatic coning oil is used during texturization stage for better quality of products. Step wise process is as follows: Unloading and storage of polyester/Nylon chips & Granules and Conveying pneumatically by dense phase conveying system. In Fluidized bed crystallizer cum dryer Moisture level of chips is brought to 0.003%. Dried chips are fed into extruder for melting, compression and mixing (homogenization by a moving spiral barrier type screw. Screw barrel is treated in five different constant temperature zones. Melt is filtered up to 20 micron through C.P.F (Continuous Polymer Filter) and fed to various pumps.

METERING: Positive displacement pump of different capacity speed controlled by inverter, decides. Melt comes to pack contains various filters and spinneret which decides number of filament in yarn.

QUENCHING: Melt in yarn shape is quenched in cold air (23oC) in quench chamber were air is equally distributed by honey combs. Spin finish oil is applied to the yarn for better binding & reduction& static charge generation by positive displacement pump. Speed controlled by inverter. Yarn is given “S” wrap by two Godet rollers for controlling tension. Driven by inverter. Additional three HOT godet are used for FDY in same process.



WINDING: Yarn is wrapped on paper tube by high speed spindle driven auto turret winder 2800-3400 meter / min for FDY4500 to 5200M/Min. Inspection & Testing and Grading (POY/FDY/NFY/PPFY) can be sale directly or further. Bobbins are sent for further processing i. e. Texturising to get texturized yarn Texturized Yarn is sent to Twisting to get twisted Yarn.

Packing and dispatch for further processing to make fabrics.

• Process Flow Diagram:

Inspection & Testing and Grading (POY/FDY/NFY/BCFY) Can Be Sale Directly Or Further processing

Texturising of Yran to get texturized yarn/monofilament yarn/ twisted yarn/ Splitting Yarn/ Intermingled Yarn

Required operation to get required properties of yarn and application of antistatic conning oil

Packing and dispatch for further processing to make fabrics

Spinning of Yarn as per required denier and QUENCHING

Spin finish oil application to Yarn

Physical Property control by tension and temperature

Winding of Yarn by high speed spindle driven auto turret winder

Filtration through C.P.F and METERING

Dried chips melting, compression and mixing in extruder

Drying in Fluidized bed crystallizer cum dryer

Polyester/Nylon chips / colour master batches conveying pneumatically



The generated waste water will be treated in adequate effluent treatment plant (ETP). The detail of the same is as given below:



(vi) Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product : Detailed raw material requirement along with estimated quantity, likely source, marketing are of final products mode of transport of raw material and finish product

• Raw material requirements:

Product-wise list of Raw-materials

Sr. No.

Name of the product Raw Materials RM Consumption (MT/Annum)

Existing Additional Total after expansion

01. Polyester Texturised & Twisted Yarn

Polyester Oriented Yarn 23712.00 33288.00 57000.00 Antistatic oil 124.80 175.20 300.00

02. Polyester Oriented Yarn (POY) / Fully Drawn Yarn (FDY)/Bulk Continuous Filament (BCF)/ Nylon Filament Yarn (NFY)

Polyester chips/ Nylon Chips

32445.00 144715.00 177160.00

Spin finish oil 252.00 1124.00 1376.00

• Marketing area of final products: Company is manufacturing “Polyester Texturised & Twisted Yarn and Polyester Oriented Yarn (POY) / Fully Drawn Yarn (FDY)” which is used in the process of weaving and knitting of fabrics meant for suiting, shirting, dress materials and home furnishings. The company has a wider customer base and to cater to the increased market demand, the company proposes expansion by way of increasing the existing production capacity.

• Transport of Raw material and Finish products: Sr. No.

Name Storage Capacity

Means of Storage

Mode Of transport

Source

1. Partially Oriented Yarn (POY) for PFY

1000 MT Ware house

-- Captive

2. Chips for POY / FDY/ BCF 5000 MT Ware

By road in truck Manufacturer

3. Spin finish oil 30 MT Storage

By road in tanker Manufacturer

4. Antistatic oil 10 MT Storage

By road in tanker Manufacturer

(vii) Resource optimization/ recycling and reuse envisaged in the project , if any , should briefly outlined : By adoption continuous improvement in technology and process the reduction in process waste

generation will be achieved.

Efficient handling of raw materials the wastages of raw materials will be reduced.

(viii) Availability of water its source, Energy/power requirement and source should be given: Availability of water its source, Energy/power required and its source will be as given below.



• Water Requirement Sr. No.

Particulars Quantity (KL/Day)

Fresh Existing Additional Total after expansion 1. Domestic 32.00 17.00 15.00 32.00

2. Gardening 0.00 20.00 (+ Recycled water

0.00 20.00

3. Industrial

Process 0.00 0.00 0.00 0.00

Boiler 20.00 20.00 0.00 20.00

Cooling 242.00 55.00 250.00 305.00

Washing 0.00 65.00 10.00 75.00

Sub Total

327.00 140.00 260.00 400.00

Total 359.00 177.00 275.00 452.00

Note: Fresh water requirement will be catered from Damanganga Irrigation Canal.

• Energy Requirements and its source:

Sr. No.

Particulars Existing Additional Total after expansion

Source

1 Steam requirement 4 Tons/ Hr. Nil 4 Tons/ Hr. 2 Boiler having steam generation capacity of 2 tons/Hr each.

As there is no increase in dyed yarn production capacity, hence no requirement to increase the steam generation in propose capacity enhancement.

• Power Requirements and its source: Sr. No.

Particulars Existing Additional Total after expansion

Source

1. Power –Electricity requirement

10750 KVA 12000 KVA 22750 KVA DNH Power distribution

corporation Ltd.

2.

Power- from D.G. Sets (as standby source for maintaining the melt during power failure)

750 KVA (Qty.- 1 No.)

1000 KVA (Qty.- 4 Nos.)

750 KVA (Qty.- 1 No.),

1000 KVA (Qty.- 4 Nos.)

From Authorized Manufacturer

• Water requirement letter:

Copy of Agreement of permission to cater water through canal for Proposed Enhancement project is enclosed as Annexure- I

• Utility Emission & Control Measures (Existing & Proposed): Sr. No.

Particulars Fuel / Power & it’s

Qty. Probable

Pollutants & Limits Control Measures

1. Stem Boiler – 2 Nos. (Existing) Capacity- 2 tons/Hr each

Coal Fired: 0.05MT/Hr

PM <150 mg/Nm3

SO2 < 100 ppm Bag filter Chimney ht: 30 m



Nox< 50 ppm Diameter: 500 mm

2. D.G. Set – 1 No. (Existing) Capacity: 750 KVA with Acoustic enclosure

HSD: 120 Lts/Hr. PM <150 mg/Nm3

SO2 < 100 ppm Nox< 50 ppm

Chimney ht: 11 m Diameter: 200 mm

3. D.G. Set – 4 Nos (Proposed) Capacity: 1000 KVA each with Acoustic enclosure

HSD : 160 lit/Hr. Each

PM <150 mg/Nm3

SO2 < 100 ppm Nox< 50 ppm

Chimney ht: 11 m Diameter: 200 mm

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal: Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal.

• Quantity of Solid Waste generation and its management :

Types of Waste & Category

Source of Generation

Quantity per Annum

Method of Disposal

ETP waste (35.3)

From ETP 20.00 MT

Will be sent to GEPIL site, Silvassa for final disposal.

Used oil (5.1)

From plant and machineries

4.00 KL Will be sold to registered refiners/ sent to TSDF site

Empty drums (33.1)

Raw material cons. 950 Nos.

Will be reused for packing /sold to authorized scrap vendor

Empty bags (33.1)

Raw material cons. 88200 Nos

Will be reused for packing /sold to authorized scrap vendor

Process Residue (22.2 )

From process 50.00 MT

Will be sent to authorized recycler or for co-incineration.

Yarn waste From process 1500.00 MT Will be recycled back /sold to actual users. Tex. Yarn waste From process 11.53 MT Will be recycled back /sold to actual users.

Details of Hazardous Chemicals There are no hazardous chemicals used in the existing manufacturing process. Also, there will be no hazardous chemicals involved in the process in the proposed expansion project. • Quantity of Waste Water (liquid waste) generation and its management :

Sr. No.

Particulars Quantity (KL/Day)

Recycle/reuse Existing Additional Total after expansion 1. Domestic 0.00 14.00 10.00 24.00

2. Gardening 30.00 0.00 0.00 0.00

3. Industrial

Process 0.00 0.00 0.00 0.00

Boiler 0.00 5.00 0.00 5.00

Cooling 63.00 10.00 25.00 35.00

Washing 0.00 45.00 8.00 53.00

Sub Total

63.00 60.00 33.00 93.00

Total 93.00 74.00 43.00 117.00

• The waste water generated from domestic is disposed-off through adequate soak pit and septic tank.



• Industrial waste water in the form of washing & cooling tower blow down (during manufacturing POY/FDY) is treated in the existing fully fledged Effluent Treatment Plant with Primary, Secondary & Tertiary units and treated effluent is partially recycled back to process and partially utilized for gardening purpose.

• Industrial waste water in the form of washing & boiler blow down (Texturize yarn and dyeing) is treated in the existing fully fledged Effluent Treatment Plant with Primary, Secondary & Tertiary units and treated effluent is partially recycled back to process and partially utilized for gardening purpose.

• Hence, there is no discharge of treated effluent. There will be no generation of waste water from process due to proposed expansion activities.

• Water Balance Diagram: Water balance diagram considering existing and proposed expansion is as under.



Water Balance Diagram



(x) Schematic representations of the feasibility drawing which give information of EIA purpose:

A schematic representation of the feasibility drawing

Type of Industry Existing unit mfg. of “Polyester Texturised & Twisted Yarn and

Polyester Oriented Yarn (POY)/Fully Drawn Yarn (FDY)”

The company located at Survey No. 205/1-2 & 207 and Plot No. 60, 62, 64 &

65, Govt. Ind. Estate, Village: Masat-Samarvarni, Silvassa-396

Resource requirements • Raw Material: Sourced from Manufacturer / Traders of the

same. • Land: Expansion in Existing premises, At Masat-Samarvani. • Water: will be sourced through Damanganga Canal. • Power: power will be sourced through DNH Electricity

Department • Fuel : Local delear

Env. Mgt. Plan (EMP) • Air Pollution Control Measures: Air Pollution control system will

be provided due to process emissions • Water Pollution : ETP • Greenbelt Area: About 23% of the Total Area will be developed. • Health & Safety measures will be followed properly

• Soak pit/ Septic Tank • Industrial waste water in the form of washing, boiler &

cooling tower blow down will be treated in the existing ETP and treated effluent is recycled back to process/ gardening

• Flue Gas emissions: Adequate chimney height will be provided.

Public consultation: Not required as the project is located in

notified Industrial Zone

Type of cataegory as per EIA notification- Manmade fiber other than Rayon

(Catagery -5(d)-A due to GC applicability

Presentation before the EAC for TOR

Type of Industry Existing unit mfg. of “Polyester Texturised &

Twisted Yarn and Polyester Oriented Yarn (POY)/Fully Drawn Yarn (FDY), BCF and NFY”

The unit is located at Survey no.205/1-2 & 207, 204/1-2-3,

205/6 & 206 and Plot No. 60, 62, 64 & 65 Govt. Ind. Estate, Village: Masat-

Samarvarni, Silvassa-396

Public consultation: Not required as the project is

located in notified Industrial Zone

Submission of Form-1 and Pre-Feasibility Report &

Draft TOR

Proposed Activity: The proposed expansion project

involves the production of "Manmade Fiber - other than rayon"

Type of Activity as per EIA notification- Manmade fiber other than Rayon

(Activity -5(d)-“A” due to GC applicability

Presentation Before the EAC for TOR



4. SITE ANALYSIS 4.0 Site Analysis (i) Connectivity:

The project is located in notified Industrial zone of Silvassa which is very well connected to National Highway no.8, Western Railways. And the nearest airport (Mumbai) and port are 150 KM away from the project site by road.

(ii) Land Form, Land use and Land ownership:

• The land is owned by M/s. Beekaylon Synthetics Pvt. Ltd. • The existing developed land is within the notified industrial zone of U.T. D&NH.

(iii) Topography (along with map) : Topography map showing the elevation of the study area below.



(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including area under CRZ)), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification should be given:

The land of the project site is located within the notified industrial zone of U.T. D&NH. Copy of notification and letter from Planning and Development Authority are enclosed as Annexure- II.

(v) Existing Infrastructure: Govt. Industrial Estate of Silvassa has the entire available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system.

(vi) Soil classification: General soil classification of the area is as under:

• Soil Characteristics & Land use classification: Most of the area cultivated, some area non cultivated under sallow and past forest.

• Surface color: Reddish brown to dark brown, in hilly area very dark, grayish to dark brown and dark Yellowish brown

• Depth of the soil: 0 to 25 cm (shallow to mod deep) in hilly forest 45 to 150 cms. (Deep to very deep) in predominant slope & flood plain alluvial area.

• Predominant Texture: Heavy Texture, predominantly clay. (vii) Climate data from secondary sources:

Rainfall Data:

The northern part has comparatively poor rainfall. Rainfall data was taken fromworldclim.org indicates that the long term mean spanning the period 1965 -2020 is medium to high226 to 259 cm rainfall for the Dadra & Nagar Haveli (DNH Spinners)region as compared to 197 to 242 cm rainfall for the central Gujarat. The isohyetal map for that period shows a high variation in rainfall from the Gujarat, Rajasthan towards the north and south part.

Rainfall data is important in the planning strategy for industry development. The Rainfall map for Dadra &Nagar Haveli shows that Precipitation recorded over a long-term period (1 year) attains a yearly mean maximum of 287 cm for the year 2010.

(viii) Social Infrastructure available: Silvassa infrastructure owes itself largely to the initiatives of Administration, in building the Industrial infrastructure and in attracting young entrepreneurs from Dadra & Nagar Haveli (U.T) Equally, the growth of the social infrastructure – Residential facility, Drinking water, Health-care Facilities , Education Facilities , Socio-Cultural Facilities , Other Public-Semi-Public Facilities ,Police, Fire &Emergency Services ,Communication (Postal Facility) , Recreational Facilities & Open Spaces, Distributive Services, Miscellaneous Facilities, Banking facility Garden etc. - There are good residential and commercial areas Daman and Silvassa (the capital of Dadra and Nagar Haveli) attract both Indian and international tourists. The nearest Railway station is Vapi on Western Railway. All major Mail/Express trains are available at Vapi. The UT of Dadra & Nagar Haveli is almost touching Mumbai - Baroda - Delhi National Highway No. 8 (Western Express Highway). Silvassa is about 14 Kms from Bhilad& 18 Kms from Vapi. Mumbai 180 Kms, Surat 140 Kms, Nasik 140 Kms and Daman 30 Kms.



5. Planning Description 5.0 Brief Planning Description (i) Planning Concept (Type of industries, facilities, transportation etc) Town and Country Planning

/Development authority Classification: There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in

manufacture of variety of products, for example pharmaceuticals, dyes and chemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals and others in the Govt. Industrial Estate of Silvassa.

(ii) Population Projection: This region is Located on the western side of the foothills of Western Ghats encompassing an area of

491 square km, this region is the land of colorful tribal’s. With almost 500 kilometer square of area available for only around 3 lacs of population, it’s part of union territory of Dadra and Nagar Haveli. It has the 2nd least population density among the 7 centrally governed regions. Population of this region is growing at an alarming rate of over 50%, which is the highest population growth rate in all of India. More importantly, it surpasses India's average growth rate almost by 40%.

(iii) Land use planning (breakup along with green belt etc): Area Statement of Plot area:

Sr. No. Title of Land use Area (in m2)

Existing Additional Total 1. Total Plot Area 32300.00 4800.00 37100.00

2. Total Construction Area 13640.20 3944.21 17584.41

3. Total Green belt Area 8500.00 0.00 8500.00

4. Open Plot Area 10159.80 855.79 11015.59



Site Layout Plan (Only layout Plan)



(iv) Assessment of Infrastructure demand (Physical & Social) : There is no need for any additional infrastructure demand in terms of physical or social needs. (v) Amenities/ Facilities:

The industrial zone has the entire available infrastructure like water, electricity, roads, transportation, availability of raw material and drainage system.

6. Infrastructure Details 6.0 Proposed Infrastructure: (i) Industrial Area (Processing Area).

The proposed product capacity enhancement will be implemented in the existing developed unit with the required minor civil construction and installation of required plant and machineries. Basic infrastructure is already developed.

(ii) Residential Area (Non Processing Area): No residential area is involved in the proposed expansion project. (iii) Green Belt: Green belt area will be provided and maintain at the tune of about 23% of the total land area. (iv) Social Infrastructure:

Facilities like road and communication are good. One can be sure of the uninterrupted power supply and adequate water. The places of tourist interests are very well and conveniently connected to Silvassa. There are plenty of hotels, holiday resorts and Government accommodations to choose from. Banks, ATM's and medical facilities are also adequate. Amenities: Education- 215 schools including middle, secondary and higher secondary schools, 15 social welfare hostels, 10 libraries, 1 ITI and 1 college. Medical and Health- There is a Civil Hospital at Silvassa, 1 Community Health Centre, 3 dispensaries, 1 mobile health dispensary and 36 sub centers. Power and water- All the villages are electrified and drinking water facilities are extended to all villages. Rail and Road- The nearest railway station is Vapi (26 km) and Bhilad (20 km) on the western railway, Mumbai-Ahmadabad route. See train table pg 56. From Vapi road transport is easily available. Auto rickshaw Rs. 80-100. From Mumbai-Ahmadabad four lanes NH 8, the town of Silvassa about 180 km is approachable from a turnoff at Talasari, Bhilad or Vapi. From Mumbai it is about 3 hours drive while Surat (120 km) is almost 2 hours drive away. By Air Mumbai is the nearest Airport, well connected to Silvassa by road. As Local Transport Unmetered autorichshaws are the common mode of local transport. Share auto rickshaws are available.

(v) Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc) : The project site is very well connected by road through National Highway No. 8, western railways.

(vi) Drinking Water management (Source & Supply of water): Water requirement will be fulfilled through Canal Water.

(vii) Sewerage System: There will be no discharge of industrial effluent (Zero Discharge). The treated effluent will be utilized for gardening purpose.

Domestic waste water will be disposed off through soak pit system. Expansion Project 23 Manufacturing : Manmade Fiber Industry


(viii) Industrial Waste Management: Due to proposed expansion project, the effluent from cooling and Plant/Equipment washing will be generated and treated in the well-designed Effluent Treatment Plant. The treated effluent will be recycled back as cooling tower make-up.

(ix) Solid Waste Management: Hazardous Solid waste generated will be managed as per it’s disposal rule and the non-hazardous solid waste will be recycled back /sold to actual users.

(x) Power Requirement & Supply / Source:

Power requirement for proposed project will be taken from DNH Power distribution corporation Ltd.



7. Rehabilitation and Resettlement (R&R) Plan (i) Policy to be adopted (Central/ State) in respect of the project affected persons including home

oustees, land oustees and landless laborers (a brief outline to be given): There will be no rehabilitation and resettlement undertaken as labours and workers from local & nearby areas for the proposed construction activity which will be minor as the proposed expansion activity is to be undertaken at the existing site.

8. Project Schedule & Cost Estimates (i) Likely date of start of construction and likely date of completion (Time schedule for the project to be

given) : The proposed project for product capacity enhancement will be implemented within the existing developed site obtained required permission for existing manufacturing activities. After obtaining Environmental clearance and Consent to Establish from PCC, the company shall implement the proposed project.

(ii) Estimated project cost along with analysis in terms of economic viability of the project:

Plant & Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the major heads considered in the Capital Cost Projection for the proposed expansion project. Environment Protection has also been considered in planning the Cost Projection, which will include Green belt development, safety systems, etc.

Capital Cost Projection Sr. No.

Purpose Existing

(Rs. In cores) Proposed

(Rs. In cores) After Expansion

(Rs. In cores) 1. Land 2.70 3.96 6.66 2. Building and Civil Works 9.93 11.00 20.93 3. Plant & Machinery and other fittings 61.15 46.26 107.41

4. Environmental protection measures 0 .22 0.23 0.45

TOTAL : 74.00 61.45 135.45

The existing and proposed investment will be made by company only.

The company will provide budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budgetary planning.

Recurring Cost per annum

Sr. No. Component Proposed

(Rs. in Lacs/annum) 1. Environment & Safety Management System 80.00 2. Greenbelt Maintenance 20.00 3. Solid waste Disposal 10.00 4. Enterprise Social Contribution for @ 5 % for 10 years 50.00

Total 160.00



9. Analysis of Proposal (Final Recommendations) (i) Financial and social benefits with special emphasis on the befit to the local people including tribal

population, if any, in the area: Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare.

• Local people will get direct financial benefit by way of employment. • Local people will get some contracts of supply and services to get indirect income. • Company will contribute in improving education and health facilities in nearby area.


of the proposed enhancement of...

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