pre feasibility report...pfr of swastik laminates page 2 of 17 1. introduction m/s. swastik...

PFR of Swastik Laminates

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PRE FEASIBILITY REPORT

FOR OBTAINING ENVIRONMENTAL CLEARANCE

For the Proposed Resins and

Laminated Sheets Manufacturing Unit of

M/s. Swastik Laminates

Survey No. : 203/15, Behind Shaktiman Rotawetar,

NH road, Bhunava, Taluka: Gondal, District: Rajkot, Gujarat.

Pin code: 360311

Contact No.: 9725119980

Email: [email protected]

Prepared By:

T. R. ASSOCIATES

C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump,

S. G. Highway, Ahmedabad

Contact No.: 98253 71099

Email: [email protected]

April 2017


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1. Introduction

M/s. Swastik Laminates is a partnership firm which manufactures only laminated sheets at

Survey No.: 203/15, B/h. Shaktiman Rotawetar, N.H. Road, Village : Bhunava, Taluka:

Gondal, District : Rajkot - 360311, Gujarat. Now they wants to set up a small scale Resin

Manufacturing plant at the above said location. Project Proponent and their back ground

is given below:

Sr.

No.

Name of the

Partner

Mobile no. Address Education Past experience

1 Pradeep Bhai

Suva

9725119980 C/o. D. K.

Suva, Opp.

Kerala Public

School, Vijli

Road, Upleta,

Rajkot - 360490

M. Pharm

3 years’ experience

in Laminated

Sheets

2 Yogesh Bhai Suva 9904545550 B.E

(Mech)

2 years’ experience

in Laminated

Sheets

2. Brief description of nature of the project:

M/s. Swastik Laminates is proposing to manufacture Melamine Formaldehyde Resin,

Phenol Formaldehyde Resin & Urea Formaldehyde Resin at Survey No.: 203/15, B/h.

Shaktiman Rotawetar, N.H. Road, Village : Bhunava, Taluka: Gondal, District : Rajkot -

360311, Gujarat. Proposed products will be used for captive consumption as well as for

sale purpose.

The exisaitng final product Laminated Sheets does not attract Environmental Clearance

(EC) from Ministry of Environment, Forest & Climate Change (MoEF & CC), New Delhi.

However, the proposed products like Melamine Formaldehyde Resin, Phenol

Formaldehyde Resin and Urea Formaldehyde Resin falls under Category 5(f) as stated in

Environment Impact Assessment Notification Published on 14th September, 2006. Further,

the location of the proposed project is outside the notified industrial estate. Hence, the

project proponent has to obtain the EC from the Ministry of Environment, Forest &

Climate Change, New Delhi. M/s. T. R. Associates has been appointed to carry out

EIA/EMP studies for obtaining Environmental Clearance.

The total land area of company is 9942 m2 out of which 3,220 m2 (32.38 % of total land)

area will be used for greenbelt development. The estimated cost of the proposed project is

1.25 Crores. Total budget allocation towards Environmental Management Facilities will be

approx. Rs. 40 Lakhs. Total 60 persons will be employed including skilled persons,

unskilled persons and office staff.


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Need for the project and its importance to the country and or region:

Resins are used predominantly in the wood based product manufacturing industry as

adhesives. Growth of the resin market is strongly correlated to construction/remodeling

activity (which accounts for over 50% of consumption), and to a lesser degree, to the

automotive industry.

The proposed products like Resins (Melamine Formaldehyde, Urea Formaldehyde and

Phenol Formaldehyde Resins) mainly used to manufacture Laminated Sheets. These

sheets have good market demand to develop the home and office for furniture.

Demand-Supply Gap:

The average production of laminated sheets has crossed approximately 130 million sheets

inclusive of all thicknesses but the gap between installed capacity and demand is growing

bigger. During FY 2011-2012 phases that gap narrowed with sudden demand in lower

thickness segment but later capacities came in place and the laminated sheets market

became a pressure driven market. It is caution for any new comer that if he enters, he

should be prepared for "More investments, more efforts and a long wait for margins".

The burgeoning market demands of urban and semi-urban India are estimated at Rs

5,00,000 Crore. The demand-supply gap has already attracted foreign players to India; and

the e-retailing boom offers immense business opportunities. But a mere 15% of India's

woodworking industry is organized. Its semi-skilled carpenters, self-styled interior

decorators and small-scale local manufacturers will need to be trained and organized to

meet future market demands and exploit business opportunities.

Imports v/s Indigenous production:

Indian market is open and big that is why every kind of import is booming. Indian

plywood and panel trade has become global place as the consumption of different

imported ply panels are on the rise. Unlike before Indians are now welcomed by plywood

manufacturer of China. Earlier India was a self dependent country for commercial or high

quality plywood, but sharp drop in domestic manufacturing output has resulted in

material sourcing from countries like Burma, Malaysia, Indonesia, China, Vietnam etc.

Now Indian plywood market is somehow curtailed or competed by incoming panel

products from China. Be it film face, decorative, laminate or MR plywood everything is

now being imported partially or more and is sold. Indian industrialist must understand

the fact that its no more a regional shift, it is a global shift. Indian technology should be

upgraded and updated at par with international standards.


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The working environment in India has changed tremendously. Earlier the trade fairs were

hardly participated by foreign timber, lumber and plywood manufacturing companies

where as now it is flooded with global suppliers.

Export Possibility:

There is only market of Resins is local market. Resins are intermediate products for

manufacturing of Laminated Sheets. Resins are quite expensive for export. So we have

only local market for sale.

Employment Generation (Direct and Indirect) due to the project:

This project will provide direct employment to 60 persons whereas it will provide

employment to many others indirectly. Plywood and Laminated sheet manufacturing

industries provide employment to large number of people.

3. Project Description

(i) Type of project including interlinked and interdependent projects:

Resins including P.F. resin, M.F. resin & U.F. resin are used in production of

laminated sheets and plywood. So plywood industries, laminated sheets industries

will be interdependent on resin industries.

(ii) Location

Proposed project is to be located at Survey No.: 203/15, B/h. Shaktiman Rotawetar,

N.H. Road, Village: Bhunava, Taluka: Gondal, District: Rajkot - 360311, Gujarat.

Geographic Coordinates

Latitude: 22° 3’ 45.74” N

Longitude: 70° 46’ 28.85” E

Google image showing proposed project site is given below;


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Salient features in the surroundings area of the proposed site within 10 km radius are as

follows:

Sr. No. Important Features Description

1 Location Survey No.: 203/15, B/h. Shaktiman

Rotawetar, N.H. Road, Village : Bhunava,

Taluka: Gondal, District : Rajkot - 360311,

Gujarat.

2 GPS Coordinates Latitude: 22° 3’ 45.74” N

Longitude: 70° 46’ 28.85” E

3 Temperature Range 25 0 C – 40 0 C

4 Mean Sea Level 174 m

5 Annual Rain Fall 600 mm

6 Nearest Railway Station Ribda Railway station (7.46 Km)

7 Nearest city Rajkot (20.18 km)

8 Nearest village Bhunava (0.82 km)

9 National HW NO N. H. No. 27 (0.87) km

10 State HW No S. H. No. 233 (4.84 Km)

11 Seismic Zone Zone-III (Less Active)

12 National Parks / Sanctuary None within 10 km radius.


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(iii) Alternative Sites considered

No other sites were selected.

(iv) Size or magnitude of operation

List of Proposed Products

Sr. No. Product Capacity

1. Melamine Formaldehyde Resin 300 MT/Month

2. Phenol Formaldehyde Resin 300 MT/Month

3. Urea Formaldehyde Resin 400 MT/Month

4. Laminated Sheets** 2,00,000 Sheets/Month

Note: (1) Laminated sheets are the existing product for M/s. Swastik Laminates

(2) Resins will be used for captive consumption as well as sell purpose.

(v) Project description with process details

Details of manufacturing process are given in Annexure- 4 of Form- 1.

(vi) Raw material required along with estimated quantity

Sr. No. Name of the Product Name of the Raw Materials

Quantity

(MT/Month)

1 Phenol Formaldehyde

Resin

Phenol 138.31

2 Formaldehyde 179.05

3 Caustic 1.6

4 Melamine Formaldehyde

Resin

Melamine 120

5 Formaldehyde 180

6 Urea Formaldehyde Resin Urea 158

7 Formaldehyde 238

8 Caustic 2

9 Acetic Acid 2


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(vii) Resource optimization/ recycling and reuse envisaged in the project, if any, should

be briefly outlined.

Latest Process technology will be adopted as available in market with optimum

resources requirement with highest yield and less waste and pollution generation.

Treated industrial effluent will be reused in cooling and other possible activities. In

addition to this, all the feasible cleaner production technologies will be adopted.

(viii) Availability of water its source, Energy/ power requirement and source should be

given.

Energy/power requirement will be 200 kVA which will be procured through Paschim

Gujarat Vij Company Limited.

The total water requirement will be 23 kl/day which will be fulfilled by own

Borewell/Open well.

(ix) Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal

Hazardous Waste Generation and Disposal

Details of hazardous waste generation and its disposal are given in Annexure- 5 of

Form- 1.

Wastewater Generation and Disposal Facility

Details of domestic as well as industrial wastewater generation and its disposal are

given in Annexure- 7 of Form- 1.

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

EIA purpose


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1. Site Analysis

(i) Connectivity

Nearest Railway station Ribda 7.46 Km

Nearest Airport Rajkot 27.33 Km

Nearest State highway NH 27 0.87 Km

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

Proposed project site has already been procured by proponent and it is already working as

M/s. Swastik laminates which is presently manufacturing only laminated sheets.


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(iii) Existing Land Use Pattern


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(iv) Topography Map

Project Site


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(v) Existing Infrastructure

(1) Nearest railway station: Ribda Railway station is 7.46 km from the project site

(2) Nearest Highway: National highway 27 is 0.87 km from the project site.

(3) Nearest Airport: Rajkot is 27.33 km from the project site.

(4) Power: 200 kVA from PGVCL.

(5) Water: Source of the water is Bore well/Open well.

(6) Basic amenities: Post office, Telephone, Bus stop & Road facilities are available

in nearby village Bhunava.

(vi) Soil classification of Rajkot District

Rajkot district is situated in the central part of Saurashtra peninsula. The northern

part of the district bordering the Rann of Kachchh and comprising mainly the Malia

taluka, is monotonous alluvial plain country. Towards south, i.e., in Morbi and

Wankaner talukas, the topography is mainly rugged and undulating because of the

underlying sandstone formations. The topography in these parts in intersected by

ridges form by sandstone and intrusive dykes. Further south, the main underlying

rock type is Deccan Trap basalt giving rise to rugged and rolling topography

intersected by ridges formed by the dykes. Some of these ridges are as high as 300m

AMSL. The most prominent ridge is situated along the northern boundary of the

Bhadar River and runs along the basaltic dyke locally known as Sardhar Dyke.

The elevations range from almost sea level to more than 300 m AMSL. The highest

point is 304 m located near Bhadala in the east-central part of the district. The soils

found in the district are mostly of Inceptisol and Entisol order and of Othids,

Ochrepts, Orthents, Fluvents, Psamments and Aquepts suborder. In the northern

most part of the district comprising Malia taluka, the soils are sandy, loamy sand,

clayey and silty type. They are moderately deep (25 to 75 cm). The colour of the soils

is dark yellowish brown to very dark greyish brown. These soils are mostly saline

with EC more than 4.0 mmhos/cm and cation exchange capacity of 20 to 40 me/10 gm

of soil. In the central part of the district comprising Wankaner, Morvi, Paddhari,

Lodhika, Jasdan, Rajkot, Jam Kandorna and Kotada Sanghani talukas, the soils are of

clayey loam to clay type. They are moderately deep to deep and vary in colour from

very dark brown to very dark greyish brown and reddish brown.

The EC of the soils is generally less than 1.0 mmhos/cm and cation exchange capacity

is between 40 and 60 me/100 gm of soil. The soils in the southern part of the district

comprising Jetpur, Dhoraji, Upleta and Gondal talukas are similar to the soils of the

central part. They are clayey loam to clayey type, very dark grey to dark greyish and


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dark brown in colour and moderately deep (25 to 75 cm). The EC of the soils is

generally less than 1.0 mmhos/cm and cation exchange capacity is between 30 and 35

me/100 gm of soil.

(vii) Climate data from secondary source

Temperature

Period of march to may is one of the continuous rise in temperature. May is the hottest

month while January is the coldest month. Temperature range is 11.1° - 40.3°C.

Humidity

The relative humidity are generally over 81 % in the monsoon. In the rest of the year the

air is comparatively dry, especially in the afternoons. During the period of November to

May the relative humidity varies between 40% and 50%.

Wind

Winds are generally light to moderate in summer and in the south-west monsoon season.

Wind direction is between W & NE in October, January & February; between N & E in

November & December while during summer between SE & NW.

Rainfall

The annual rainfall is received during SW monsoon season from June-September, with

July being the highest rainfall month. Average annual rainfall is 500-1000 mm.


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(viii) Social Infrastructure available.

Rajkot city is near to project site. The social infrastructure of district has good education,

health and other facilities.

(1) Education

There are 1845 primary, 426 secondary and higher secondary schools in the district

along with it there are several Polytechnic Pharmacy Engineering medical colleges.

Saurashtra University is a major university in Rajkot which was established in 1967.

The university is well known for several departments such as journalism, economics,

biosciences, pharmaceutical science, electronics, chemistry, among several others.

There are 5 engineering colleges in the district offering courses in computers,

electronics and communication, instrumentation and control, mechanical, IT, and

electrical engineering.

R.K. College in Rajkot imparts education in major branches such as engineering,

management and pharmacy.

Various Industrial Training Institutes provide training in areas like electronics,

instrument and motor mechanic, wielding, dress making, tailoring and cutting,

painting, stenography, carpentry and Wood working, oil engine and tractor repairing

and others.

(2) Health

Rajkot has 50 primary healthcare centers, 13 community healthcare centers, 3 civil

hospitals and 12 government hospitals.

N M Virani Wockhardt Hospital in Rajkot is the first dedicated super specialty

hospital which offers comprehensive end-to-end care in cardiology, cardiac surgery,

neurology, neurosurgery, orthopedics, joint replacement and minimal access surgery.

It also provides services in other specialties like urology, nephrology, medical and

surgical oncology, endocrinology, gynecology, pediatrics, critical care, emergency care

and preventive healthcare.

Other major hospitals in Rajkot are Civil hospital, G.T. Seth Eye hospital, K.T.

Children Hospital and R.Z. Women Hospital which has radiology department,

physiotherapy department, surgery department and laboratory.


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2. Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town and

Country Planning/Development authority Classification.

Proposed Project site is located near to the National Highway 27 which is well

connected to the Rajkot & Morbi having all the infrastructural and transportation

facilities.

The occupational pattern in Rajkot is primarily based on manufacturing and service

sector. About 42% of workers are engaged in service activities and 34% in

manufacturing activities. Manufacturing activities are concentrated in two main

industrial estates – Aji and Bhaktinagar. In the past, Rajkot concentrated around the

establishment of cloth mills. The current trend of industrial growth is towards the

Engineering and Autoancillary sector. In this sector, diesel engine is the leading

business with around 105 manufacturing units operational in the district. The district

also has various manufacturing units for machine tools, industrial equipments, lathe

machines, metallurgical industries, electronics, engineering and auto ancillary sector.

Small and medium industries are dominated by foundries, engineering & automobile

works, textile related units gold & silver jewellery, handicrafts, spices, medicines, and

wall clocks. Jetpur taluka of the district is famous for dyeing and printing business

and Paddhari taluka for ginning and pressing business in the entire State.

(ii) Population

An official Census 2011 detail of Rajkot, a district of Gujarat has been released by

Directorate of Census Operations in Gujarat. Enumeration of key persons was also

done by census officials in Rajkot District of Gujarat.

In 2011, Rajkot had population of 3,804,558 of which male and female were 1,974,445

and 1,830,113 respectively. In 2001 census, Rajkot had a population of 3,169,881 of

which males were 1,642,018 and remaining 1,527,863 were females. Rajkot District

population constituted 6.29 percent of total Maharashtra population. In 2001 census,

this figure for Rajkot District was at 6.26 percent of Maharashtra population.

There was change of 20.02 percent in the population compared to population as per

2001. In the previous census of India 2001, Rajkot District recorded increase of 26.08

percent to its population compared to 1991.


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(iii) Land use planning (breakup along with green belt etc).

Sr.

No. Particular Area (m2)

1 Built Up Area 4744.00

2 Green belt area 3220.00

3 Open/ Road area 1978.00

Total 9942.00

(iv) Assessment of Infrastructure Demand (Physical & Social).

Surrounded villages in 10 km area from the project site are having all the necessary

physical and social infrastructure facilities due to agricultural activities, animal husbandry

and industrial development within the area as well the nearby Morbi Town and

Wankaner Town & Rajkot City.

(v) Amenities/Facilities.

All the basic amenities/facilities such as power connection & power back-up, drinking

water, internal roads, water & wastewater treatment plant etc. will be provided.

3. Proposed Infrastructure

a. Industrial Area

Industry has provided 4744.00 m2 built up area for industrial process/manufacturing

activity which provides all needed facility including proper ventilation, safe handling

system, etc.

b. Residential Area

Industry will provide labor quarter for their labors and provide all basic facilities to

them.

c. Green Belt.

3,220 m2 area will be proposed for greenbelt development. In addition to this, project

proponent will participate in greenbelt development programs in nearby areas under

their CSR.

d. Social Infrastructure

The proponent will provide social infrastructure facilities within 10 km radius of the

proposed project.


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Education Facilities:-Many Facilities for village schools like game kits, drawing kits,

table-chairs; school construction (classroom/toilet/school boundary), ceiling fans/

coolers or books for school library are proposed.

Health Facilities:-Assistance to existing health facilities in nearest Hospital, for

improvement in health facilities or services.

e. Connectivity (Traffic and Transportation Road / Rail / Metro / Water ways

Proposed project site is located adjacent to National Highway 27 and well connected to

the internal roads and highways. The site is well connected to Morbi Town and

Wankaner Town & Rajkot City.

f. Drinking Water Management

In proposed project, out of 23.0 kl/day water approx. 7.3 kl/day (6.1 KLD fresh water +

1.2 KLD treated sewage) water will be consumed for domestic purpose

g. Sewerage System.

Domestic wastewater 6.7 kl/day will be treated in the sewage treatment plant.

h. Industrial Wastewater Management.

Industrial wastewater will be generated from process, boiler, cooling tower blow-

down, washing & RO-1. Wastewater (washing and process) will be collected collection

cum neutralization tank. Then wastewater will be given Chemical Oxidation treatment.

After completion of chemical treatment, wastewater will be taken to Nutch Filter/Filter

Press for chemical sludge separation. Chemically treated process and washing water

will be mixed with RO-1 rejects, cooling tower blow down, boiler blow down in

holding tank. After that it will be passed through RO-2. Reject of RO-2 will be taken to

an Evaporator followed by condenser. RO - 2 permeate along with condensate from

evaporator will be reused in RO - 1. ETP sludge along with evaporation residue from

evaporator will be will be disposed of at TSDF site. Thus, unit will maintain Zero

Effluent Discharge.

i. Solid/Hazardous Waste Management

ETP waste + evaporation residue, discarded bags/barrels, used oil & edge cutting waste

are the main solid hazardous waste that will be generated from the proposed unit. ETP

sludge will be collected, stored into solid waste storage area and disposed to

authorized TSDF site. Discarded bags and containers will be sold to approve vendor.

Edge cutting waste will be disposed off to common incineration facility. Spent carbon

will be disposed at common Incineration facility or sold to authorized vendor.


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j. Power Requirement & Supply / source

Power requirement for the proposed project will be approx. 200 kVA which will be

obtained from PGVCL.

4. Rehabilitation and Resettlement (R & R) Plan

Not applicable.

5. Project Schedule & Cost Estimates

(i) Likely date of start of construction and likely date of completion

(Time schedule for the project to be given)

Construction work is not yet started. Construction work related to Resin

manufacturing plant will be started only after obtaining EC.

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

project.

Total cost of the Resin plant is approx. 1.25 Crore.

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pre feasibility report...pfr of swastik laminates page 2 of 17 1. introduction m/s. swastik...

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