ACNielsen ORG-MARG
Situation Analysis for SME Sector
Vapi Cluster
Submitted to TERI
By ACNielsen ORG-MARG
SUMMARY OF FINDINGS
• There are nearly 600 units spread across this chemical cluster.
➢ ANNUAL TURNOVER
Annual Turnover (In crores) 50 47 44 43 43 40 40 34 35 33 29 31 31 30 27 27 28 24
20 14 11 9 10 2 3 3
0 2005-06 2006-07 2007-08
Upto 25 Lakh 25 to 50 Lakh 50 to 100 Lakh 100 to 200 Lakh 200 to 500 Lakh 500 to 1000 Lakh Above 1000 Lakh
➢ PRODUCTION
Annual Production (In Tonnes per Annum) 60 55 54
50 45 43 40 39 40 35 34 32 28 26 27 30 26 22 26 20 21 20 11 11 7 10 5 5 2 2 0 2005-06 2006-07 2007-08
Upto 1000 Tonnes 1000 to 2000 Tonnes 2000 to 5000 Tonnes 5000 to 10000 Tonnes
10000 to 20000 Tonnes 20000 to 30000 Tonnes 30000 to 50000 Tonnes Above 50000 Tonnes
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➢ ENERGY REQUIREMENTS
• CUMULATIVE FUEL USAGE
Qty consumer per annum Number of Units using the fuel Electricity 30857544 Units 203 LDO 2207160 Liters 134 Firewood / Husk 4086 Tonnes 47 FO 1108944 Liters 29 HSD 181200 Liters 8
• USAGE OF ELECTRICITY (IN UNITS CONSUMED PER ANNUM)
32% Usage of Electricity (In Units consumed per annum)
Upto 50000 Units 50000 to 100000 Units 100000 to 150000 Units 25% 150000 to 200000 Units 22% 200000 to 500000 Units 500000 to 1000000 Units 2% Above 1000000 Units 2% 8% 9%
• USAGE OF LDO (IN LITERS PER ANNUM)
47% Usage of LDO (In Liters per annum) Upto 2500 Liters 2500 to 5000 Liters
21% 5000 to 10000 Liters 10000 to 20000 Liters 20000 to 50000 Liters 8% 50000 to 100000 Liters 1% 10% 10% 3% Above 100000 Liters
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• USAGE OF FIREWOOD / HUSK(IN TONNES PER ANNUM)
Usage of Firewood / Husk (In Tonnes per annum)
70% Upto 50 Tonnes
50 to 100 Tonnes
17% 100 to 200 Tonnes
2% Above 200 Tonnes 11%
• USAGE OF FO (IN LITERS PER ANNUM)
52% Usage of FO (In Liters per annum)
Upto 3000 Liters
3000 to 6000 Liters 21% 6000 to 15000 Liters
Above 15000 Liters 3% 24% ACNielsen ORG-MARG
➢ RAW MATERIAL REQUIREMENT
• CUMULATIVE RAW MATERIAL USAGE
RAW MATERIAL Quantity Due to the variety of products Major Raw material include Hydrochloric being manufactured, the raw Acid, Lead Oxide, Butyl, Methylene, Caustic materials were different for each Soda, Sulphuric Acid, Soda Ash, Sodium set of units. Thus there were a Sulphate, Lithium Carbonate, Various large number of raw materials Solvents, etc with each having relatively less cumulative usage.
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FIELD OBSERVATIONS
✓ Vapi Industrial Estate, developed by Gujarat Industrial Development Corporation. The Estate, developed in phases (1 to 4). About 70% of the Industries are chemical & Chemical related such as Dyes & Dyes intermediates, Pigments, Pesticides, Fine Chemicals and Pharmaceuticals etc. Total units approx 450 to 475 units are there ✓ Maximum units are functioning SINCE 12 -15 years, since majority of the units are engaged in organic, inorganic, fine chemicals, pigments used by the polymer processing, master batches as well as the pharmaceutical companies, textile chemicals etc. ✓ The process vary for dyes, pigments as well as chemicals in terms of equipments used, the pigments manufacturing units have a capacity of 5 to 6 tpd. ✓ Majority of the units are having an LT connection
Major Raw materials Caustic soda, Soda Ash, Hydroflamic acid, Potasium Sulphate, sulphuric acid, Solvent, Calcium carbonate, carbon black,Nitric acid, sodium hypochlorite, Acetic Acid, Sodium Hexumeta, Phosphate, Magnecium chloride, sodium etc.
Equipments ❖ Vessels (up to 50,000 ltr.) ❖ Dryer (Tray & Rotary) ❖ Steam Boilers (100 C. in kg/hr)/using up to 700 kg. ❖ Blender (Ribbon & Sigma) up to 100 hp & capacity 25,000 ltr. ❖ Ball Mill (up to 100 hp & capacity 10 ton) ❖ Ice Crusher ❖ Dust Collector ( up to 50 hp motor) ❖ Pulverizers ❖ Eccentric Vibrating Screen ❖ Rotary Screen
Fuel/Energy
✓ Supply by State Electricity board. In Vapi total 5 grid (66 kv 3rd phase, 66 kv 4th phase, 66 kv GIDC SS, 66 kv Damanganga, 220 kv Balitha) each grid minimum 10 to 15 feeders & each fedder 11kv. Power available 24 hr. weekly one day power cut. Phase wise staggering is there. (Wednesday, Thursday, Friday & Saturday). Per unit rate @ Rs.5.80
✓ Gas supply by Gujarat State Petroleum Corporation Ltd. (GSPC), per unit rate Rs. 15.50/- basic price & vat 15% extra. They offer service wherein minimum consumption 100 units per month & maximum no limit. At present gas availability problem. Other fuel FO/ LDO/Coal/ Wood getting from local traders. ( Wood cost Rs. 3/- per kg.) Due to cheap cost maximum are using wood.
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Process
Mixing all raw Filter press (up to 8 Dryer (60 to 70oC
materials (Mainly in hr.) Temperature
Pressure Vessel for required)
4/5 hours)
Pulverizers / Ball Finish product mill (Packaging)
Problems
✓ Since last 6/7 months labor cost has increased, raw material have become expensive and order have reduced, volumes have come down.
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Steam boiler
Steam boiler inner part.
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Steam boiler
Blender
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Pulveriser
Ball mill
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Vessels
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Service Providers
Equipment Supplier • Ace Industries, J-718/2, 40 Shed Area, GIDC Estate, Vapi, M-9377001430 - Mr. Jitendra Patel
• Evershine Engineering works Plot no. 136/3, Phase-2, GIDC, Vapi, 9375863322 - Mr. Z. Fernandes
• Fab India (Laximen-fab) 25, Nilsin Plot, Nr. Patel Alloys Steel, Phase-1, GIDC, Vatva, Ahmedabad 079-25890134 • H.P. Engineering Works, 317/3, 40 Shed area, GIDC, Vapi, 9377012212 Mr. Yogesh Panchal
• Mechanical Steel Fabricators Plot no. 613, 100 sheds Area, GIDC, Vapi-396195 M-9824181695 Bhaichand M.Panchal
• Mechwell Industries L-6101/5, Phase-4, GIDC, Vapi-396195, 0260-2453553
• Industrial Fabricators 2321 J type, Phase-3, GIDC, Vapi, 9825125637 - Mr. Yogesh N. Pandya
• Mech Form, Plot no- 5111/2, Phase-4, GIDC, Vapi 9998953769 - Ramesh bhai
• Mech Job Engineering, C1B/22, Nr. Filter Plant, Phase-1, GIDC, Vapi 0260-2425992 (Mr. George Mendonsa)
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• Mega Machinery, Plot No- 4791 Lyka lab road, GIDC, Ankleshwar. 9824101133, ( M.D. Patel)
• Monesh Engineering, 317/2A, GIDC, Vapi, 9825007669, ( Mr. P.S.Patel)
• Padmavati Fabrications, C1/6028, Phase-4, GIDC, Vapi, 9227803237, ( Mr. Shrenik shah)
• Reva Chem Feb Plot no-262, GIDC, Bhadakmora, Vapi, 9820294437, ( Mr. A.V. Panchal)
• Sai Om Industries B1-3, Phase-2, GIDC, Vapi, 9824155234, ( Mr. R.R.Shunda)
• Shreyas Engineering Works 283/2/A, Opp. Grauer & well (I) ltd, GIDC, Vapi, 0260-2420593, (Mr. J.M.Patel)
• Vasu Engineering Works Plot no-747, 40 shed Area, Nr. VIA forge, GIDC, Vapi. 9824152516 (Mr. Pravin Patel)
Raw Material supplier • Hardik Enterprises, A/202, Hitarth Co-Op Society Ltd, GIDC, Vapi, M- 9825872787 ( Mr. Nathu Patel) • Jagruti Enterprises, B-2/104, Mangal Tirth jalaram Soc. Charwada Road, GIDC, Vapi, 0260-2452680 M-9825872787 • Mahalaxmi chemical, Plot no. L-1/6022/2, Nr. Ramji Paper Mill, GIDC, Vapi, M- 9426809387, (Mr. Mahesh Patel) • Pera Chem Industries, C-1/B-82, Plot no-536, 100 Shed Area, GIDC, Vapi, M- 9825007526 (Mr. Kishor Patel) • Pruthvi Enterprises, Plot no-646, 100 shed Silvassa Road, Vapi, M-9824171782 (Mr. Vipul Patel) • Rainbow Chem, Plot no/33, Phase-1, J type area, GIDC, Vapi, M-9825644881 ( Mr. Ashish Nayak) • N.B. Enterprise, Plot no-706/1, Shop no.11, 40 shed area, GIDC, vapi, M- 9821082566 (Mr. Bharat Mehta) • Soham Trading co, Plot no-322/1/A, Shop No-7, 40 shed , GIDC, Vapi, M- 9825371164 (Mr. Yogesh Lal Patel) ACNielsen ORG-MARG
Bankers
➢ Bank of Baroda, Vapi Ind. Estate branch, GIDC, Char Rasta, Vapi, 0260-2422168 ➢ Dena bank, 0260-2420732 ➢ ICICI Bank, Plot No 135, VIA House, GIDC cross Roads, Vapi, Gujarat 396195, 0260-2400800 ➢ Gujarat Industrial Bank, 0260-2465545 ➢ Valsad Dist. Central co-op. Bank ltd, 0260- 2420783 ➢ State bank of India, 0260-2431496 ➢ Bank of India, SSI Plot no CM/16,Vapi-396195 ➢ IDBI Ltd, Advance complex, N.H. No-8, Vapi-396191 ➢ State Bank of Saurashtra, Silvasa Road, Imran nagar, Vapi-396195 ➢ Punjab National Bank, 0260-2424585 ➢ Indian overseas Bank, 0260-2422298 ➢ State bank of Indore, 0260-2432763 ➢ HDFC Bank, 0260-2465038/2464684 ➢ Union Bank of India, 246, Bazar road, Vapi-396191