PFR of Swastik Laminates


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: , . 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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PFR of Swastik Laminates

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. Name of the Mobile no. Address Education Past experience No. Partner 1 Pradeep Bhai 9725119980 C/o. D. K. M. Pharm 3 years’ experience Suva Suva, Opp. in Laminated Kerala Public Sheets 2 Yogesh Bhai Suva 9904545550 School, Vijli B.E 2 years’ experience Road, , (Mech) in Laminated Rajkot - 360490 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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PFR of Swastik Laminates

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. Page 3 of 17

PFR of Swastik Laminates

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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PFR of Swastik Laminates

(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. Quantity Name of the Product Name of the Raw Materials (MT/Month) 1 Phenol Formaldehyde Phenol 138.31 Resin 2 Formaldehyde 179.05

3 Caustic 1.6

4 Melamine Formaldehyde Melamine 120 Resin 5 Formaldehyde 180

6 Urea Formaldehyde Resin Urea 158

7 Formaldehyde 238

8 Caustic 2

9 Acetic Acid 2

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PFR of Swastik Laminates

(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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PFR of Swastik Laminates

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 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, , Lodhika, , 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, , 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. Particular Area (m2) No. 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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