PRE FEASIBILITY REPORT - Welcome to...

PFR of M/s. Welmica Laminates

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PRE FEASIBILITY REPORT

FOR OBTAINING ENVIRONMENTAL CLEARANCE

For the Proposed project of Resins and

Laminated Sheets Manufacturing Unit of

M/s. Welmica Laminates

Survey No. 98, Opp 66 KV Substation, Before Millennium tiles,

Old Rafaleshwar road, At Village: Bhadiyad,

Taluka & District: Morbi 363642, Gujarat.

Contact No.: 7802987670

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]

JUNE 2017


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1. Introduction

M/s. Welmica Laminates Pvt. Ltd. is a partnership firm proposing to set up a medium

scale Resin and Laminated Sheet Manufacturing unit at Survey No.: 98, Opp 66 KV

Substation, Before Millenium tiles, Old Rafaleshwar road, At Village: Bhadiyad, Taluka &

District : Morbi 363642, Gujarat. Project Proponent and their back ground

Company is promoted by its partner. Detail of partners is as given below.

Sr.

No. Name of the Partner Background

1. Mr. Ravi Dayalal Adroja

Chartered finance analyst, M.Sc. in

Finance, M.Com, Director of Calypso

Ceramics Pvt. Ltd.

2. Mr. Nilesh Dayalal Adroja

M.E (Civil) & Government Contractor in

AA class category. Director of Calypso

Ceramics Pvt. Ltd.

2. Brief description of nature of the project:

M/s. Welmica laminates Pvt. Ltd. is proposing to manufacture Laminated sheet, Phenol

formaldehyde resin and melamine formaldehyde resin at Survey No.: 98, Opp 66 KV

Substation, Before Millenium tiles, Old Rafaleshwar road, At Village: Bhadiyad, Taluka &

District: Morbi 363642, Gujarat. Now they want to propose this production capacity due to

higher market demand. This is kind information to you that resin will be used for

manufacturing of laminate sheets as well as sale purpose.

M/s. Welmica Laminates Pvt. Ltd is willing to manufacture Melamine Formaldehyde

Resin, Phenol Formaldehyde Resin & Urea Formaldehyde Resin as well as Laminated

Sheets. The products will be used for captive consumption as well as for sale purpose.

Manufacturing of Laminated sheets does not require environmental Clearance from the

ministry of Environment Forest and Climate change, New Delhi. But phenol

formaldehyde resin, melamine formaldehyde resin and urea formaldehyde resin

manufacturing process falls into 5(f) category (Synthetic organic chemicals) of the EIA

notification 2006 and their amendments required to obtain Environmental clearance from

the MOEF&CC. In order to obtain EC for manufacturing of laminated sheets, Phenol

formaldehyde resin, Melamine formaldehyde resin & Urea formaldehyde resin, M/s. T. R.

Associates has been appointed to carry out EIA/EMP studies for obtaining Environmental

Clearance.

As per amendment in EIA notification dated on 15/01/17, industry have water

consumption 33.7 KLD, formaldehyde (37%) storage capacity is greater than 5 Kl, and fuel


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consumption proposed is 4.7 MT/day. Due to above said condition; company will have to

obtain EC for Proposed capacity from the MoEFCC, New Delhi.

The total land area of company is 13,456 m2 out of which 4470 m2 (33 % of total land) area

will be used for greenbelt development. The total cost of the project proposed is 1.3

Crores. Total budget allocation towards Environmental Management Facilities will be

approx. Rs. 30 Lacs. Total 100 persons will be employed including skilled persons,

unskilled persons and office staff.

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:

Laminated sheets are becoming very popular particularly plastics, paper & wooden.

Wooden laminates are highly popular.

Laminations are used for industrial purposes as well as decorative purposes. Industrial

lamination is used mainly for packaging materials. To looking its uses we can say that

there is a good scope for any new entrants.

Indian market for laminates is mainly driven by increasing demand from housing market.

The demand has increased due to growing significance of new construction industry.

Laminates have become an indispensable part of big and evolving markets. The increased

demand in these markets triggers the demand in the laminates market. Apart from this,

increasing urban population, rising per capita income and a gradual shift towards non-

food industry are other key factors driving the growth of laminates industry in India. The

combined worth of the plywood and laminates industry is believed to be to the tune of

Rs.21,000 crore per year, with laminates accounting for a share of approximately Rs.3300

crore, and the industry is expected to keep on growing further in the years to come.

Global demand for decorative laminates is expected to rise 5.6 per cent per year to 10.7

billion square meters in 2018, valued at $40.8 billion. Demand will benefit from expected

increases in the manufacture of products such as cabinets, ready-to-assemble (RTA)


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furniture, and flooring, which are often made from laminated engineered wood. Gains

will also be driven by increased market penetration at the expense of other surfacing

materials (wood veneer and paint) due to cost and performance benefits. Laminates will

benefit from the continued improvement in textures and in printing techniques that create

advanced graphics rivalling the aesthetics of alternative materials.

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 it’s no more a regional shift, it is a global shift. Indian technology should be

upgraded and updated as per the international standards.

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 market of Resins as well apart from laminated sheets. Resins are intermediate

products for manufacturing of Laminated Sheets. Resins are quite expensive for export, as

compared to the export of laminated sheets. So we have only local market for sale for

resins.

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

This project has already provided direct employment to 100 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.


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(ii) Location

Proposed project is to be located at Survey No.: 98, Opp 66 KV Substation, Before

Millennium tiles, Old Rafaleshwar road, At Village: Bhadiyad, Taluka & District: Morbi

363642, Gujarat.

Geographic Coordinates - Latitude: 22°47'42.45"N and Longitude: 70°52'17.96"E

Google image showing proposed project site is given below;

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.: 98, Opp 66 KV Substation, Before

Millennium tiles, Old Rafaleshwar road, At Village:

Bhadiyad, Taluka & District : Morbi 363642, Gujarat

2 GPS Coordinates Latitude: 22°47'42.45"N & Longitude: 70°52'17.96"E

3 Temperature Range 15˚C to 43˚C

4 Mean Sea Level 57 m

5 Annual Rain Fall 500 - 600 mm

6 Nearest Railway

Station

Nazarbaug Railway Station – 2.70 km in NW

direction

7 Nearest Airport Rajkot Airport – 53.6 km in South direction

8 Nearest Town Lakhdirpur– 3 km in NNE direction

9 Nearest Village Bhadiyad – 1.1 km in NW direction

10 Nearest National

Highway

NH 8A – 1.3 km in NE direction

11 Nearest River/Water

body

Macchu River – 1.8 km in West direction

12 National

Parks/Sanctuary

Paneli Reserved Forest – 4 km East. Open Jungle – 5

km – SSE direction. Wild Ass Sanctuary (Ghudkhar

Abhyaran) is approx. 52.85 km away in NE direction

from project site.


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Google Image of Proposed Location:

Sr. No. Latitude Longitude

Project Site 22°47'42.45"N 70°52'17.96"E

(iii) Alternative Sites considered

No other sites were selected.

(iv) Size or magnitude of operation

List of Products

Sr. No.

Name of Product Proposed Quantity

(MT/Month)

1 Phenol Formaldehyde Resin 700

2 Melamine Formaldehyde Resin 400

3 Urea Formaldehyde Resin 400

4 Laminated Sheets 2,50,000 Sheets/Month Note: 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.


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(vi) Raw material required along with estimated quantity.

RAW MATERIAL CALCULATIONS

Sr. No.

Name of the product Name of the raw

material

Proposed Quantity

(MT/Month)

1 Phenol

Formaldehyde resin

Phenol 323

Formaldehyde (37%) 418

Caustic 3.7

2 Melamine

Formaldehyde resin

Melamine 160


Caustic 2

3 Urea Formaldehyde

resin

Urea 160


Caustic 2

Acetic Acid 2

4 Laminated Sheets (Sheets/Month)

Kraft paper 360

Design Paper 56.3

Resin 675

Methanol 33.8

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

be briefly outlined.

Latest Process technologies are 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 33.7 kl/day which will be fulfilled by own borewell.

(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.


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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

1. Site Analysis

(i) Connectivity

Nearest railway station Nazarbaug 2.70 km in NW

Nearest national highway NH 8A 1.3 km in NE

Nearest airport Rajkot 53.6 km in South

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

Proposed project site has already been procured by proponent to obtain the

Environmental Clearance certificate.

(iii) Existing Land Use Pattern


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(iv) Topography Map

The link to the topographical map is here.


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(v) Existing Infrastructure

(1) Nearest railway station: Nazarbaug railway station is 2.7 km away from the

project site in the NW direction.

(2) Nearest highway: National Highway 8A is 1.3 km away from the project site in

NE direction.

(3) Nearest airport: Rajkot Airport is 53.6 km from the project site in the South

direction.

(4) Power: Total 200 kVA will be procured from Paschim Gujarat Vij Company

Limited.

(5) Water: Source of the water will be Borewell.

(6) Basic amenities: Good road connectivity with state and national highway.

(vi) Soil classification of Morbi District

The soils of Morbi district 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.

(vii) Climate data from secondary source

General climate of the district is sub-tropical and is characterized by three well-defined

seasons, i.e. summer - from April to June, monsoon - from July to September, and winter -

from October to March.

Temperature

Highest temperature is 43 to 46 degree centigrade in summer and lowest temperature

comes down to 7 to 15 degree in winter season.

Humidity

The relative humidity is generally over 75 % in the south west 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

In the south west monsoon season, the wind direction is towards west and south west. In

the post monsoon/cold season, wind blow from the north-north east direction. In summer

seasons the direction of the wind is mainly between north west and south west. The wind


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speed gradually increases from February and reaches the peak in July when the south

west monsoon is most active. It again decreases from August and becomes low.

Rainfall

More than 90% of the rainfall occurs during the monsoon. Rainfall during the winter and

summer months is negligible. The average annual rainfall of the district is 489 mm and in

the year 2016 it is 366 mm only which is around 75 % of the average annual rainfall.

(viii) Social Infrastructure available.

Industrialisation/Entrepreneurship:

On account of availability in huge quantity and suitable climatic condition in the

district has induced the growth of Ceramic industries hugely in Morbi taluka. At

present more than 700 enterprises in around Morbi are Manufacturing Ceramic

Tiles, Floor Tiles, Luster Wall Tiles, Glazed Wall Tiles, Vitrified Tiles, Laminated

sheets, Porcelain Tiles, 2D, 4 D Tiles, Spartek, Roofing and Mosaic Tiles. More than

100 enterprises are manufacturing specialized Vitrified Tiles which has great

demand in the region as well as all over the country. It is also hub of digital and

other types of watch and clocks manufacturing enterprises such as Ajanta, Samay,

Sonera and Sonam which are World leaders in this sector. After 2002, Paper

industries have grown rapidly as ancillary sector due to need of high quality craft

grade papers very suitable for packing of goods. There are number of export-

import houses working in the district. Besides, many enterprises deals in consumer

durables and engineering goods. Tourism also fetches significant income to the

economy of the district as many visitors visit the district having historic values.

Though the concept of avoiding risk factor for the Governmental regulations and

process causes adverse effect and resulted in weakened industrial growth.

Industrial Training Institutes, Productivity Development Centres, Small Scale

Enterprises Development Institute- Ahmedabad, District Industries Centre- Morbi

and other Non-Governmental organizations must come forward to promote more

and more training programmes to increase and motivate the productivity of the

labour force available in the district.

Marketing Potential:

There are well developed Market Yards in Morbi, Wankaner and Halvad taluka of

Morbi district for the distribution of the agricultural produces. Farmers can accrue

more competitive prices for their produce in these market yards by selling their

produces. There is good infrastructure in the district for the sale of industrial goods

and services manufactured and produced.


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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 National Highway 8A and well connected to

the internal roads and highways. The site is well connected to Wankaner, Morbi as

well as Rajkot region, where all the infrastructural and transportation facilities are

available.

At present more than 700 enterprises in around Morbi are manufacturing various

types of Tiles. More than 100 enterprises are manufacturing specialized Vitrified Tiles

which has great demand in the region as well as all over the country. It is also hub of

digital and other types of watch and clocks manufacturing enterprises such as Ajanta,

Samay, Sonera and Sonam which are World leaders in this sector. After 2002, Paper

industries have grown rapidly as ancillary sector due to need of high quality craft

grade papers very suitable for packing of goods.

(ii) Population (Source : MSME, Morbi (2016-17))

Description No.

Population Total : 9,60,329 Person

Male : 4,94,726 Person

Female: : 4,65,603 Person

Population density 481 persons per sq. km.

Village Population Total: 6,01,909 Person

Urbanised Population Total: 3,58,420 Person

Population increase rate N.A

Male- Female ratio 1000 : 961

Scheduled Caste population 49,902persons

Scheduled Tribe population 4,036 persons


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

Sr. No. Particular Area (m2) % of Total Land

1 Built-up area 5343 39.7

2 Greenbelt area 4470 33.2

3 Open area 3643 27

Total 13,456 100

(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 5343 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.

4470 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.

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.


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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 8A 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 33.7 kl/day water approx. 11.3 kl/day water will be

consumed for domestic purpose

g. Sewerage System.

Domestic wastewater 10.3 kl/day will be treated in the STP.

h. Industrial Wastewater Management.

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

down, washing. 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, cooling tower blow down, boiler blow down in holding tank. 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 the common incineration facility.

j. Power Requirement & Supply / source

Power requirement for the proposed project is 200 kVA which will be obtained from

PGVCL.

4. Rehabilitation and Resettlement (R & R) Plan

Not applicable.


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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 will be started after June 2018. Construction work related to proposed

project of Resin manufacturing plant will be only started after obtaining EC.

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

project.

Total cost of the entire project is approx. 1.3 Crore.

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