M/s CELLO INDUSTRIESenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/...INSULATION UNIT IN THE EXISTING COMPLEX BY M/S CELLO INDUSTRIES.-21 M/s CELLO INDUSTRIES PLOT NO. –

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ENVIRONMENTAL CLEARANCE FOR PROPOSED INSTALLATION OF POLYURETHANE (PU)

INSULATION UNIT IN THE EXISTING COMPLEX BY M/S CELLO INDUSTRIES.

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M/s CELLO INDUSTRIES

PLOT NO. – 1, SECTOR NO. – 2, IIE, SIDCUL,

RANIPUR, HARIDWAR, UTTARAKHAND

PRE-FEASIBILITY REPORT & EMP

FOR

PROPOSED INSTALLATION

OF

POLYURETHANE (PU) INSULATION MANUFACTURING

UNIT

TO PRODUCE

PLASTIC HOUSE HOLD GOODS

PREPARED BY:

ENVIRONMENT MANAGEMENT DIVISION

M/s INDIA GLYCOLS LTD.

A – 1, INDUSTRIAL AREA, KASHIPUR, UTTARAKHAND

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1.0 EXECUTIVE SUMMARY:

CELLO as a brand made its inception through its founder Shri Ghisulal Rathod in 1974.

Cello started its journey making Thermoware for Indian kitchens from a small factory at

Mumbai, in 1986. Today under the able stewardship of Shri G. D. Rathod, along with his

sons, Shri Pradeep Rathod and Shri Pankaj Rathod have successfully taken the group into

its next generation further with his grandson, Shri Gaurav Rathod. They have led the

diversification of the group into new products and markets, resulting in Cello becoming the

largest manufacturer of branded commodities in India and worldwide, with a wide range of

plastic molded products.

Cello ventured into manufacturing of elegant, versatile and durable Plastic Molded

Furniture bringing convenience and style to consumers at surprisingly economical prices,

made from special grade plastic and state of the art moulds from Italy. Cello Pens was

created in 1995 which exploded on the scene with cello clear pens with Swiss Tips and

German Ink. The revolutionary new smear free smooth flowing pen not just took the

market by storm but marked a new era in writing instruments. Further to this a new feather

in the cap was the inception of Cello Oral Hygiene Products in the year 1997. Cello

marched towards Exports in the year 1990 which won the titles of „The Largest Exporter of

Insulated Thermoware and Writing Instruments from India‟ and Winner of the Prestigious

Plex Council Award as „Highest Exporter‟. Turning to innovation in the field of Extrusion

Technology cello set up processing of Bubble Guard Sheets in 2003-04 with a range of

products for interior, advertising, packaging and construction application.

The flying saucer of cello not only stopped with the above but entered into Construction

activities which includes commercial, residential and malls in the year 2005 being successful

into multiple projects on Pan India basis. And now launched its new product „cello Air

Coolers‟ in 2015.

CELLO has spearheaded the modernization of Indian plastic industry with many

technology advancements. The world acknowledges its outstanding quality, which always

seeks perfection. Million families in India and millions around the world have put their trust

in cello. To delight and deliver beyond expectation through ingenious strategy implied

entrepreneurship impaired technology, innovative products, insightful marketing and

inspired thinking about the future. To establish the company as „India‟s Best Company‟

being the Marketing Objective cello brand is a top rung group with a vision of

Uncompromising Quality and Total Consumer Satisfaction.

M/s Cello Industries SIDCUL, Ranipur, Haridwar is a leading organization in

manufacturing House hold goods. These products of Cello Industries are having a wide

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range of Kitchen wares. Presently the company is producing Plastic house hold goods

2244.00 MTPA, Plastic Moulded Parts (PMP) 480.00 MTPA and Pet Preforms & Bottles

48.00 MTPA. Proposed Project is for Installation of Polyurethane (PU) insulation Unit

(450.00 MTPA) to produce Plastic House Hold Goods & DG Set (350.0 KVA) by M/s

Cello Industries at Plot No. – 1, Sector No. – 2, IIE, SIDCUL, Ranipur, Haridwar,

Uttarakhand. The proposed project is falling in activity 5(f), category “B” of the schedule.

Since proposed small Unit shall be installed in the existing complex of Notified industrial

estate, having water consumption <25 KL/Day & not covered in the category of MAH

Units as per the Management, Storage & Import of Hazardous Chemical Rules, 1989.

(MoEF & CC Notification - Annexure – IX).

1.1 Employment Status:

Sl. No. Category No. of Employees (Proposed)

01. Plant Head --

02. Production Manager 02

03. Supervisors 07

04. Semiskilled Workers 140

05. Unskilled Workers 06

Total 155

1.2 Water Balance (Proposed): Total water requirement: 9.0 KLD

Requirement Input Losses Recycled Output

Manufacturing Process: Cooling Tower

(make-up water) (KLD)

1.5 1.45 0.00 *0.05

Domestic (KLD) 7.00 1.40 0.00 5.60

Miscellaneous i.e. Equipment/Floor

Washings etc.

0.5 0.00 0.00 0.50

Total output to CETP 6.10

Note:

Zero discharge shall be achieved.

Bleed water from Cooling Tower shall be reused in the existing green belt.

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After proposed installation of production facilities, waste water generated (6.10 KLD) from

Domestic Purpose will be treated in the CETP, already installed in the SIDCUL. Company

has already made a contract between SK UEM Water Projects Pvt. Ltd.

1.3 Salient Features of the Project:

S. No. Parameters Description

(1) Plant Capacity (Proposed) Manufacturing of 450.0 MTPA Polyurethane (PU)

Insulation

(2) Total area of the Plant 20265.00 Sq. m

(3) Area required for PU Unit 150.00 Sq. m

(4) Capital Cost Approx. 100.00 Lacs

(5) Location Plot No. – 1, Sector No. – 2, IIE, SIDCUL,

Ranipur, Haridwar, Uttarakhand.

(6) Coordinates Latitude: 290 57‟ 02.20” N

Longitude: 780 03‟58.52” E

(7) Water Requirement/Source About 9.0 KLD

a) Total water Requirement 9.0 KLD

b) Source of water Existing Bore well

(8) Water Break-up Process (Cooling) : 1.50 KLD

Domestic : 7.00 KLD

Miscellaneous : 0.50 KLD

Total : 9.00 KLD

(9) Waste Water Management Approx. 6.10 KLD of waste water from Domestic

purpose shall be generated, which shall be

subjected to the CETP installed at SIDCUL.

(10) Employment Generation 155 Person

(11) Power supply 100.0 KVA (Sourced from UPCL)

(12) Alternate Power Green Insulated D.G. Set 350.0 KVA for Alternate

Power is Proposed.

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2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION:

Polyurethane foam is widely used in many applications, such as the automotive, comfort as

in mattresses and cushions, appliances as in refrigerators, shoe soles, construction, house

hold goods & among others. Flexible, integral and rigid foams are essentially part of our

daily lives.

Polyurethane Foam is produced by mixing two liquid components; polyol and isocyanate,

which then through a chemical reaction produce the desired foam type. In this process, a

third component is added, the so called blowing agent, which due to the expansion in the

chemical process, supports the formation of a cell structure (similar to a honeycomb) and to

some extent remains trapped in the rigid cell structure. The insulation foam which is

normally rigid is characterized not only by thermal insulation, but also by good mechanical

properties.

There are other foams, the most common being polystyrene based such as expanded

polystyrene (EPS) and extruded polystyrene (XPS), which are based on the same principle

of a cell structure containing air and blowing agent, whereby polyurethane foam is one of

the most efficient insulators available today.

2.1 Identification of the Project:

M/s Cello Industries is a team of young professionals, whose collective motto is to

contribute in development of house hold goods sector through sharing existing

knowledge/technology/services with those in need of it. The objective to bring the best of

technologies and services available globally to India and extend the cost competitive house

hold products.

The difference lies in the endeavor of the group to explore the opportunities available or

work on it to render it suitable for everyone. The group also aspires to contribute actively in

customer education, distant learning program for experts and create awareness among

masses. Though the dream is life-size and the course is easier said than done the group

believes that in whatever minuscule size it achieves, it can present the approach to further

work on.

M/s Cello Industries SIDCUL, Ranipur, Haridwar is a leading organization in

manufacturing House hold goods. These products of Cello Industries are having a wide

range of Kitchen wares.

Presently the company is producing Plastic house hold goods 2244.00 MTPA, Plastic

Moulded Parts (PMP) 480.00 MTPA and Pet Preforms & Bottles 48.00 MTPA.

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Proposed Project is for Installation of Polyurethane (PU) insulation Unit (450.00 MTPA) to

produce Plastic House Hold Goods & DG Set (350.0 KVA) by M/s Cello Industries at Plot

No. – 1, Sector No. – 2, IIE, SIDCUL, Ranipur, Haridwar, Uttarakhand.

The proposed project is falling in activity 5(f), category “B” of the schedule. Since proposed

small Unit shall be installed in the existing complex of Notified industrial estate, having

water consumption <25 KL/Day & not covered in the category of MAH Units as per the

Management, Storage & Import of Hazardous Chemical Rules, 1989.

2.1.1 Company Background:

M/s Cello Industries SIDCUL, Ranipur, Haridwar is a partnership company & it has

obtained DIC registration from Directorate of Industries, Uttarakhand on 28 Feb, 2014 at

the existing location. M/s Cello Industries manufactures Plastic House Hold Goods, Plastic

Moulded Parts and Plastic Pet Preforms & Bottles and manufacturing facilities are based in

Haridwar on 20265.00 Sq. m land at Plot No. – 1, Sector No. – 2, IIE, SIDCUL, Ranipur,

Haridwar, Uttarakhand.

The Company is a regular tax payer for Income Tax and Service Tax and has never

defaulted.

2.1.2 The Promoters:

The partnership will enable the promoters of M/s Cello Industries to charter an independent

growth path for the Company which envisages its entry into Plastic House Hold Goods,

Plastic Moulded Parts and Plastic Pet Preforms & Bottles manufacturing business and

expansion in other high potential product lines.

Sr. No. Name Designation

1. Shri Ghisulal D. Rathod Partner

2. Shri Pradeep G. Rathod Partner

3. Shri Pankaj G. Rathod Partner

4. Smt. Pampuben G. Rathod Partner

5. Smt. Sangeeta P. Rathod Partner

6. Smt Babita P. Rathod Partner

7. Master Gaurav P. Rathod Partner

2.2 Nature of Project:

M/s Cello Industries is a leading organization in exports, imports, dealers, manufacturing &

Trading of Plastic house hold & industrial items, Plastic Thermoware, Vaccumwares

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articles, Plastic Moulded Parts, Pens, Ball pens etc. M/s Cello Industries based on Haridwar

is involved in the manufacturing of Plastic House Hold Goods, Plastic Moulded Parts and

Plastic Pet Preforms & Bottles. The Proposed Project is for Installation of Polyurethane

(PU) insulation Unit (450.00 MTPA) to produce Plastic House Hold Goods & DG Set

(350.0 KVA) in the existing complex at Plot No. – 1, Sector No. – 2, IIE, SIDCUL,

Ranipur, Haridwar, Uttarakhand. The proposed project is falling in activity 5(f), category

“B” of the schedule. Proposed small Unit shall be installed in the existing complex of

Notified industrial estate, having water consumption <25 KL/Day & not covered in the

category of MAH Units as per the Management, Storage & Import of Hazardous Chemical

Rules, 1989.

2.3 Need for the Project and its Importance to the Country or Region:

Polyurethanes are one of the most versatile plastic materials. The nature of the chemistry

allows polyurethanes to be adapted to solve challenging problems, to be molded into

unusual shapes and to enhance industrial and consumer products by adding comfort,

warmth and convenience to our lives.

Rigid polyurethane foam is the most commonly used material to insulate household

appliances due to its excellent thermal insulation behavior and process-ability allowing an

easy filling of plastic house hold insulating cavity of any geometry.

Energy efficiency improvement is an important driving force of the global household

appliance industry. In recent years, there has been an increasing need to improve energy

efficiency of hot & cold appliances (refrigerators and freezers) in order to meet

environmental regulations which are becoming more and more stringent around the world.

Indian PU insulation industry is a major contributor to the country‟s economy. M/s Cello

Industries is proposing to install Polyurethane (PU) Insulation Unit for producing house

hold goods in the existing complex at Plot No. – 1, Sector No. – 2, IIE, SIDCUL, Ranipur,

Haridwar, Uttarakhand.

2.4 Demand – Supply Gap:

From the traditional to the modern society, across the globe, plastic house hold goods have

always existed as a major product category in the marketplace. Due to high degree of

urbanization, proliferation of nuclear families and technological advancement, there have

been far-reaching changes in the nature of plastic house hold products. In India,

globalization has also brought about significant changes in cooking, serving and dining

habits. India is also witness to a major shift in buyer or consumer base for house hold

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products. Branded products are increasingly finding favour with Indian consumers in all

segments of the market. Overall demand is growing between 20-30% depending on the sub-

category.

This market is driven by the high growth in the plastic house hold goods sector, strong

performance advantage offered by such products and increasing performance standards in

the industrial sectors. M/s Cello industries are the manufacturer of plastic house hold

goods, PMP & Pet preforms/bottles etc.

2.5 Imports VS. Indigenous Production:

Over the last few years, organized retail or large scale retail has been witnessing tremendous

impetus in India. The growth story is expected to continue in the future. Till about 5 years

back, kitchenware retail hardly received a standalone mention as a major retail category but

now things are different. More than just satisfying the functional needs of the Indian

consumer, modern retail in this sector is emerging to cater to the diverse needs of the

customer – be it on consideration of convenience, fashion or price.

Till the early eighties, kitchenware in the average Indian home would constitute primarily

copper, aluminium and stainless steel utensils; cutleries in the form of tea-cups, saucers and

spoons; cookware of aluminium; plastic bottles to store spices, sugar, salt and edible oil. The

only sophisticated gadgetry was perhaps the pressure-cooker. Gradual changes were seen

with stainless steel utensils replacing copper and aluminium. The microwave made a grand

entry in a number of kitchens in mid-90s, and then newer utensils and storage vessels started

forming a vital part of the Indian kitchen.

Indian kitchens and kitchenware are now evolving from being purely functional to

convenient and fashion-driven. It is the gradual shift in lifestyle that is bringing about

changes in the cooking and eating habits of the Indian consumer. Convenience is emerging

as an important factor for selecting kitchenware and now there is more emphasis on

aesthetics, novelty and style. There were also certain manufacturer-driven factors that drove

this growth, led by brands like Cello Products.

Imports are not expected to impose a significant threat to domestic players in future.

2.6 Export Possibility:

First priority to meet domestic demand, should also take into account the large export

possibilities.

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2.7 Domestic/ Export Market:

Products i.e. plastic house hold articles, plastic moulded parts (PMP), pet preforms & bottles

manufactured by M/s Cello industries has good domestic and export markets.

2.8 Employment Generation - Direct and Indirect:

Total Manpower engaged during operation of the PU Insulation Unit is 155. Apart

from this, 775 – 800 persons are indirectly benefited by this project during the

operation phase for logistic.

Table – 01: Employment Status

Sl. No. Category No. of Employees

(Proposed)

01. Plant Head --


03. Supervisors 07



Total 155

3.0 PROJECT DESCRIPTION:

3.1 Type of Project:

The Proposed Project Proposed Project is for Installation of Polyurethane (PU) insulation

Unit (450.00 MTPA) to produce Plastic House Hold Goods & DG Set (350.0 KVA) by M/s

Cello Industries at Plot No. – 1, Sector No. – 2, IIE, SIDCUL, Ranipur, Haridwar,

Uttarakhand.

The proposed project is falling in activity 5(f), category “B” of the schedule. Since proposed

small Unit shall be installed in the existing complex of Notified industrial estate, having

water consumption <25 KL/Day & not covered in the category of MAH Units as per the

Management, Storage & Import of Hazardous Chemical Rules, 1989.

3.2 Location of the Project:

The plant is located about 9.50 Km from Haridwar City, just outside Municipal limits, in an

Integrated Industrial Estate, “SIDCUL”. Existing land area is 20265.00 Sq. m with plenty of

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green land. However just 150.00 Sq.m area is required for installation of proposed PU

Insulation Unit. No alternate site was considered –

The basis of selection of this site is that the State of Uttarakhand is providing suitable

Industrial environment with proper infrastructure support.

The availability of Raw Material, Power and other infrastructure.

Name of the Company M/s Cello Industries

Administration Office Cello House, Corporate Avenue „B‟ Wing, Sonawala Road, Goregaon (E)

Mumbai – 400 063

Fax – 022 – 2685 3333

Registered Office Plot No. – 1, Sector No. – 2, IIE, SIDCUL, Ranipur,

Haridwar, Uttarakhand – 249 403

Email – [email protected]

Phone – 8171332666

Fax – 01334-230363

The key map of M/s Cello Industries is shown in the Fig. – 01. The latitudes and

longitudes of four corners of the project site are as follows:

Direction Latitude Longitude

N 29° 57'02.39"N 78°03'56.88"E

E 29° 57'01.07"N 78°03'58.22"E

S 29° 56'58.26"N 78°02'55.54"E

W 29° 56'59.80"N 78°03'53.81"E

3.3 Site Description:

The Existing Plant is located at Plot No. – 1, Sector No. – 2, IIE, SIDCUL, Ranipur,

Haridwar, Uttarakhand. The area is situated in the survey of India Topo Sheet No. 53 K

and Coordinates 29° 56'58.26"N 78°02'55.54"E to 29° 57'02.39"N 78°03'56.88"E. The

nearest National Highway NH-58 is 3.45 km S away from the site. The nearest Railway

station Haridwar is about 9.50 km N away from the site.

3.3.1 Site Selection:

As already stated, Proponent has acquired Land about 20265.00 Sq. m at Plot No. – 1,

Sector No. – 2, IIE, SIDCUL, Ranipur, Haridwar, Uttarakhand for proposed Installation of

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Polyurethane (PU) Insulation Unit in the existing complex & DG Set (350.0 KVA) to

Produce plastic house hold goods.

The main features of the site including environmental considerations that make it suitable

for Polyurethane (PU) Insulation Unit are given below:

Availability of sufficient stretch of land with flat terrain

Existing establishment in IIE, “SIDCUL”

No habitation in the plant site, hence no direct R&R issues

Sparsely populated surroundings

Suitable topography and geography for construction of facilities

Suitable seismic zone

The plant site is not falling within the vicinity of any monument or in an

archeologically sensitive area.

No declared biodiversity parks/sanctuaries are there in the surroundings of the site.

Nearness to source of main raw materials

Location of consumer center

Convenient Rail & Road links.

Perennial & adequate sources of water supply

Availability & closeness to source of adequate power supply

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Fig – 01: Key map of M/s Cello Industries

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Fig – 02: Satellite Image of the Project Site

3.4 SIZE OR MAGNITUDE OF OPERATION:

The proposed plant will be designed for 450.00 MTPA PU Insulation production &

installation of DG Set (350.0 KVA). The plant operations are confined to the existing plant

boundary.

3.4.1 Technical Know-How:

The Company will appoint the Technical Staff; those are qualified as per the provision of

the Rules, separately for manufacturing and quality assessment. The Technical Staff will be

assisted by the Supporting Staff.

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3.5 MANUFACTURING PROCESS DESCRIPTION AND TECHNOLOGY:

3.5.1 Existing Manufacturing Process:

The existing manufacturing process is being carried on with the help of plastic injection

Moulding Machines, which is follows as under:

a) The components which make the Houseware Article and Flask are manufactured by

process of Injection Moulding Machines. The components used are outer body,

bottom, inner plate top lid, and Steel Containers & Vacuum Glass Refills.

b) The injection moulding process is one in which the plastic material is fed into the

hopper of the machine. It is then forced into the hoted barrel, in which the material

melts and this melted material is injected to the corresponding moulds and the

material preform is produced. When the body is produced the bottom is fitted to it.

c) The required part inner and outer body will be pouring with proposed PU insulation

materials to make insulated ware and fitted with other parts thereof.

d) The outer parts are sent for screen printing & required design is printed. In case of

Flask plain body is sent for screen printing.

e) Various parts are then assembled and steel containers & vacuum glass refill is placed

in the body & final finishing is done.

f) The product is checked, inspected and only after approval from Quality Control, it is

sent for packing.

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PROCESS FLOW CHART

Procurement of Raw

Materials

Feeding of Plastic

Granules

In Injection Moulding

Machine Formation of Pre

Forms/Plastic Moulded

Parts

Pouring of PU insulation

in different PMP

Assembling of Plastic

Moulded Parts

Fitting of Steel / Glass

Refills

Screen Printing

Finishing of Items

Quality Control Check

Packing into the

Boxes/Cartoon & Dispatch

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3.5.2 Proposed Manufacturing Process:

These products of Cello Industries are having a wide range of Kitchen wares. Presently the

company is producing Plastic house hold goods 2244.00 MTPA, Plastic Moulded Parts

(PMP) 480.00 MTPA and Pet Preforms & Bottles 48.00 MTPA. Proposed Project is for

Installation of Polyurethane (PU) insulation Unit (450.00 MTPA) to produce Plastic House

Hold Goods & DG Set (350.0 KVA) by M/s Cello Industries at Plot No. – 1, Sector No. –

2, IIE, SIDCUL, Ranipur, Haridwar, Uttarakhand.

3.5.3 PU Insulation:

Product Description:

Based on the Plant and Machinery (Low Pressure PU Foaming Machine LP-30 PLC)

proposed to be installed by the Unit, 1.25 MT/Day of PU Insulation would be produced for

manufacturing of house hold goods.

Sr.

No. Product Quantity (MT/Annum)

1. PU Insulation 450.00

Polyurethane

Introduction

Ever since their discovery by Otto Bayer and co-workers in 1937, polyurethanes have

developed as a unique class of materials and have found use in a wide variety of

applications. The name polyurethane was derived from ethyl carbamate, also known as

urethane. Besides incorporating the urethane linkage, these materials also sometimes

contain several other types of linkages such as amide, urea, ether, and ester. The urethane

linkage is formed by the reaction of an isocyanate group of one reactant with the alcohol

group of another component. By controlling variables such as the functionality, chemical

composition, and the molecular weight of the different reactants, a wide class of materials

with significantly varying properties can be obtained. This flexibility has led polyurethanes

to find use as synthetic polymers in foams, elastomers, coatings, sealants, and adhesive

based products. Some of the applications of polyurethanes lie in the automotive, furniture,

construction, thermal insulation, and footwear industries.

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In polyurethane synthesis, tuning the ratio and composition of the isocyanate and alcohol

components results in a segmented block copolymer consisting of alternating hard and soft

blocks. The reaction of an isocyanate group with a chain extender and subsequent phase

separation of the hard segments formed from this reaction, results in the formation of hard

blocks; which are referred to as „hard‟, since they are below their softening temperature at

ambient conditions. These hard blocks are covalently bound through urethane linkages to

„soft‟ polyether or polyester segments which are above their softening temperature, Tg, at

ambient conditions. The phase separation generally leads to good elastomeric properties

wherein the hard blocks serve as filler particles and also act as physical cross-linking points.

One of the major sectors of the polyurethane industry are flexible foams, which are

manufactured by the controlled expansion of a gas during the polymerization process.

Flexible polyurethane foams are designed to be open-celled, i.e., at the completion of foam

expansion, the cells open and form a structure composed of interconnected polymer struts,

which allow the free movement of a gas within the foam cells. The properties of flexible

polyurethane foams depend on both, the elastomeric character of the polymer comprising

the foams, as well as the geometry of the cells. Over the years, polyurethane foams have

intrigued a broad spectrum of scientists who have tried to provide better solutions to the

consumer by investigating the chemistry, physics, engineering, and economic aspects of

these materials. Flexible polyurethane foams are used in applications such as seating,

cushioning, carpet underlayment, fabric backing, insulation, and packaging.

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Figure 03: Applications for Flexible Polyurethane Foams

A polyurethane (IUPAC abbreviation PUR, but commonly abbreviated PU) is any polymer

consisting of a chain of organic units joined by urethane (carbamate) links. Polyurethane

polymers are formed through step-growth polymerization by reacting a monomer

containing at least two isocyanate functional groups with another monomer containing at

least two hydroxyl (alcohol) groups in the presence of a catalyst.

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Fig.04: Example of synthesis of Polyurethane

(Urethane groups -NH-(C=O)-O- linking the units of the product.)

Polyurethanes, also known as polycarbamates, belong to a larger class of compounds called

polymers. Polymers are macromolecules made up of smaller, repeating units known as

monomers. Generally, they consist of a primary long-chain backbone molecule with

attached side groups. Polyurethanes are characterized by carbamate groups (-NHCO2) in

their molecular backbone.

Chemistry

Polyurethanes are in the class of compounds called reaction polymers, which include

epoxies, unsaturated polyesters, and phenolics. A urethane linkage is produced by reacting

an isocyanate group, -N=C=O with a hydroxyl (alcohol) group, -OH. Polyurethanes are

produced by the polyaddition reaction of a polyisocyanate with a polyalcohol (polyol) in the

presence of a catalyst and other additives. In this case, a polyisocyanate is a molecule with

two or more isocyanate functional groups, R-(N=C=O)n ≥ 2 and a polyol is a molecule with

two or more hydroxyl functional groups, R'-(OH)n ≥ 2. The reaction product is a polymer

containing the urethane linkage, -RNHCOOR'-. Isocyanates will react with any molecule

that contains an active hydrogen. Importantly, isocyanates react with water to form a urea

linkage and carbon dioxide gas; they also react with polyetheramines to form polyureas.

Commercially, polyurethanes are produced by reacting a liquid isocyanate with a liquid

blend of polyols, catalyst, and other additives. These two components are referred to as a

polyurethane system, or simply a system. The isocyanate is commonly referred to in North

America as the 'A-side' or just the 'iso'. The blend of polyols and other additives is

commonly referred to as the 'B-side' or as the 'poly'. This mixture might also be called a

'resin' or 'resin blend'. In Europe the meanings for 'A-side' and 'B-side' are reversed. Resin

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blend additives may include chain extenders, cross linkers, surfactants, flame retardants,

blowing agents, pigments, and fillers.

Fig.05: Generalized Polyurethane Reaction

3.5.4 Basic Principles in the Formation of Polymeric Foams

In general, most of the polymeric foams are formed by a process involving nucleation and

growth of gas bubbles in a polymer matrix, except in the syntactic foam where micro−beads

of encapsulated gas are compounded into a polymer system or latex. According to the

nucleation mechanism, the fundamental principle for the formation of polymeric foam

involves three different important stages such as, bubble formation, bubble growth and

bubble stability. The foam is expanded by increasing the bubble size before stabilizing the

system. As the bubbles grow, the foam structure changes through number of stages. These

are the following characteristics observed during the formation of foam.

Initially, small dispersed spherical bubbles are produced in a liquid polymer matrix,

with a small reduction in density. The further growth of cells leads to lower foam

density, which involves distortion of cells to form polyhedral structures, sometimes

idealized as pentagonal dodecahedrons.

Effects of viscosity and surface tension subsequently cause materials to flow towards

the uniform cell formation.

Extensive rupture before the foam is stabilized may lead to foam collapse. Cooling of

closed cell foam before stabilization may lead to shrinkage, because of the reduced

pressure in cells.

3.5.5 Application of Polymeric Foams

Applications of polymeric foams depend on the nature of polymer and their types. For

example, the main applications of flexible foams are for cushioning, packaging, automotive

safety, footwear, etc. The rigid foams are used for insulation in building, transportation,

appliance (refrigerator and freezers), buoyancy and in−fill and packaging.

3.6 MANUFACTURING PROCESS

The Reacting Materials (a Typical Ratio of Polyol to Isocyanate is 1:1.2) are passed through

a Heat Exchanger as they are pumped into pipes.

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The Heat Exchanger adjusts the temperature to the reactive level. Inside the pipes, the

Polymerization reaction occurs.

For the production of Rigid Polyurethane Foam Insulation, a roll of baking paper is spooled

at the start of the processing line.

As the Polymer is dispensed, it is mixed with carbon dioxide which causes it to expand.

The PU insulation is poured into a series of sections that control the width and height of the

insulation.

Excess Foam Insulation is cut automatically to the desired filling. PU insulated Plastic

Moulded Parts then conveyed to the final processing steps.

3.6.1 PROCESS FLOW DIAGRAM OF PU FOAMING PROCESS

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3.7 Detail of Proposed Plant Machinery:

Table – 02: Proposed Plant Machinery

Sr.

No. Equipment Description Capacity QTY

1. Low Pressure PU Foaming Machine

Each Unit Consists:

Arm flexes Foam Insulated M.S. Day Tank

SS Water Tank

ISO/POLY High Precision Volumetric Gear

Pumps

LP – 30 Mixing Head

Heat Exchanger on Supply Line

PLC with color animated touch screen

Supply & return Hose Assembly

Transfer Pumps

30 KG / Minute

each

100 L

20 L

-

-

-

-

-

-

10 Nos.

02 Nos.

01 No.

02 Nos.

02 Nos.

2. Chiller - 01 No.

3. Feed Tanks 01 - 02 KL / SS 02 Nos.

4. Electrical Fitting & Cables - -

3.7.1 PROPOSED UTILITY INSTALLATION:

DG SET:

Presenting, an exclusive variety of high grade Diesel Engine Generating Set that is highly

reliable in nature. Fabricated from quality components, these sets are known for their longer

functional life. Robust in design, these sets have combustion engines that comply with the

latest Central Pollution Control Board emission norms. Owing to their sophisticated

designs, these sets are widely used in small and big industries, commercial buildings, IT

parks, hospitals, hotels and cold storages.

A diesel generator is the combination of a diesel engine with an electric generator (often an

alternator) to generate electrical energy. This is a specific case of engine-generator.

Diesel generating sets are used in places without connection to the power grid, as

emergency power-supply if the grid fails, as well as for more complex applications such as

peak-lopping, grid support and export to the power grid. Sizing of diesel generators is

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critical to avoid low-load or a shortage of power and is complicated by modern electronics,

specifically non-linear loads.

Diesel engine is the prime mover, which drives an alternator to produce electrical energy. In

the diesel engine, air is drawn into the cylinder and is compressed to a high ratio (14:1 to

25:1). During this compression, the air is heated to a temperature of 700–900°C. A metered

quantity of diesel fuel is then injected into the cylinder, which ignites spontaneously because

of the high temperature. Hence, the diesel engine is also known as compression ignition (CI)

engine. DG set can be classified according to cycle type as: two stroke and four stroke.

However, the bulk of IC engines use the four stroke cycle.

Acoustic Enclosure:

The silent series is a Super Silent DG set with a sound proof acoustic enclosure. It offers a

cost effective and perfect solution to the problem of noise pollution. The advanced acoustic

engineering employed in attenuating noise also saves on the expenses for building up a

separate room for the DG set.

DG Set as a System:

Successful operation of a diesel generating set depends on the well-matched performance of

the components, namely:

a) The diesel engine and its accessories.

b) The AC Generator.

c) The control systems and switchgear.

d) The foundation and power house civil works.

e) The connected load with its own components like heating, motor drives, lighting etc.

Process Flow Diagram of DG Set System:

Fig – 06: DG SET SYSTEM

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Energy Saving Measures for DG Sets:

Ensure steady load conditions on the DG set, and provide cold, dust free air at intake

(use of air washers for large sets, in case of dry, hot weather, can be considered).

Improve air filtration.

Ensure fuel oil storage, handling and preparation as per manufacturers'

guidelines/oil company data.

Consider fuel oil additives in case they benefit fuel oil properties for DG set usage.

Calibrate fuel injection pumps frequently.

Ensure compliance with maintenance checklist.

Ensure steady load conditions, avoiding fluctuations, imbalance in phases, harmonic

loads.

In case of a base load operation, consider waste heat recovery system adoption for

steam generation or refrigeration chiller unit incorporation. Even the Jacket Cooling

Water is amenable for heat recovery, vapour absorption system adoption.

In terms of fuel cost economy, consider partial use of biomass gas for generation.

Ensure tar removal from the gas for improving availability of the engine in the long

run.

Consider parallel operation among the DG sets for improved loading and fuel

economy.

Carryout regular field trials to monitor DG set performance, and maintenance

planning as per requirements.

3.8 RAW MATERIALS, QUALITY AND SOURCES:

Following raw materials will be required for the manufacturing of plastic house hold

goods by proposed PU Foaming Machine.

Table – 03: ANNUAL RAW MATERIAL REQUIREMENT

Sl. No. Raw Material Quantity Source

1. Iso Cynate 250.0 MTPA Local Vendors

2. Polyol 200.0 MTPA Local Vendors

3. Cyclopentane 42.0 MTPA Local Vendors

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MAJOR RAW MATERIALS:

Isocyanates

The first essential component of a polyurethane polymer is the isocyanate. Molecules that

contain two isocyanate groups are called diisocyanates. These molecules are also referred to

as monomers or monomer units, since they themselves are used to produce polymeric

isocyanates that contain three or more isocyanate functional groups. Isocyanates can be

classed as aromatic, such as diphenylmethane diisocyanate (MDI) or toluene diisocyanate

(TDI); or aliphatic, such as hexamethylene diisocyanate (HDI) or isophorone diisocyanate

(IPDI). An example of a polymeric isocyanate is polymeric diphenylmethane diisocyanate,

which is a blend of molecules with two-, three-, and four- or more isocyanate groups, with

an average functionality of 2.7. Isocyanates can be further modified by partially reacting

them with a polyol to form a prepolymer. A quasi-prepolymer is formed when the

stoichiometric ratio of isocyanate to hydroxyl groups is greater than 2:1. A true prepolymer

is formed when the stoichiometric ratio is equal to 2:1. Important characteristics of

isocyanates are their molecular backbone, % NCO content, functionality, and viscosity.

Fig.07: Diphenylmethane Di-isocyanate

Only the 4,4'-MDI monomer is sold commercially as a single isomer. It is provided either as

a frozen solid or flake, or in molten form, and is used to manufacture high performance

prepolymers.

Polyols

The second essential component of a polyurethane polymer compounds is the polyols that

contain multiple alcohol groups (OH), called polyols. Materials often used for this purpose

are polyether polyols, which are polymers formed from cyclic ethers. They are typically

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produced through an alkylene oxide polymerization process. They are high molecular

weight polymers that have a wide range of viscosity. Various polyether polyols that are used

include polyethylene glycol, polypropylene glycol, and polytetramethylene glycol. These

materials are generally utilized when the desired polyurethane is going to be used to make

flexible foams or thermoset elastomers.

Polyester polyols may also be used as a reacting species in the production of polyurethanes.

They can be obtained as a byproduct of terephthalic acid production. They are typically

based on saturated aromatic carboxylic acids and diols. Branched polyester polyols are used

for polyurethane foams and coatings. Polyester polyols were the most used reacting species

for the production of polyurethanes. However, polyether polyols became significantly less

expense and have supplanted polyester polyols.

Fig. 08: Polyols

Blowing Agent

One of the most desirable attributes of polyurethanes is their ability to be turned into foam.

Blowing agents such as water, and certain hydrocarbons such as Cyclopentane, can be

incorporated into the poly side or added as an auxiliary stream. Water or Cyclopentane

reacts with the isocyanate to create carbon dioxide gas, which fills and expands cells created

during the mixing process.

Fig. 09: Carbon Dioxide Gas Formed by Reacting Water and Isocyanate

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3.8.1 Mode of Transport of Raw Material:

It has been assumed that major raw materials like Polyol, Isocynate & Cyclopentane are

brought to the plant from outside sources by rail/road and road facility is being availed to

supply the final products.

3.9 RESOURCE OPTIMIZATION:

No waste water is generated from the process. The plant is designed in zero discharge

concept. The manufacturing Process doesn‟t generate any effluent. Bleed water from CT

will be reused into green belt. Waste water generated (6.10 KLD) from Domestic Purpose &

Miscellaneous i.e. Equipment/floor washings etc. will be treated in the CETP. Company


3.10 UTILITIES & AUXILIARY SERVICES:

3.10.1 Water:

Proposed Production Process will require just 1.5 KLD make-up water for Cooling purpose by inbuilt Heat Exchanger of Low Pressure PU Foaming Machine.

Water is required for drinking, sanitation and Washing of Floor purposes. The daily

requirements of water are estimated at 9.0 KLD. The water will be source from existing

bore well.

Table – 04: Total Plant Raw Water Requirement

Sr. No. Particulars Total water requirement (KLD)

1. Process (Cooling Purpose) 1.5

2. Domestic Purpose 7.0

3. Miscellaneous i.e. Equipment/floor

washings etc.

0.50

Total 9.0

WATER BALANCE: Total water requirement – 9.00 KLD

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Table – 05: Water Balance

Requirement Input Losses Recycled Output

Manufacturing Process: Cooling Tower

(make-up water) (KLD)

1.5 1.45 0.00 *0.05

Domestic (KLD) 7.00 1.40 0.00 5.60

Miscellaneous i.e. Equipment/floor

washings etc.

0.5 0.00 0.00 0.50

Total output to CETP 6.10

Note:

Zero discharge shall be achieved. Bleed water from Cooling Tower shall be reused in the existing green belt.

After proposed installation of production facilities, waste water generated (6.10 KLD) from

Domestic Purpose will be treated in the CETP, already installed in the SIDCUL. Company


3.10.2 Fuel:

The Plant requires around 70 Lit/day of HSD for operation of proposed DG set, which

will be sourced from local vendors.

3.10.3 Energy Requirement:

Uttarakhand Power Corporation Limited (UPCL), Dehradun District is major source to

electricity (20 KVA).

DG Set (350.0 KVA) is proposed for alternate source of power for essential services.

4.0 ENVIRONMENT MANAGEMENT:

The Cello Plant is designed with Zero Discharge concept. No waste water generation is

envisaged from the proposed PU Foaming Process. Bleed water from CT will be reused

into green belt. Waste water generated (6.10 KLD) from Domestic & miscellaneous

Purpose i.e. floor/equipment washings will be treated in the CETP.

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Little quantity of solid waste (Approx. 10.0 Kg/day) will be generated during material

sampling, dispensing, handling, production, processing and packing & eventually reuse

into process.

Approx. 5.0 kg / day solid waste will be generated from the proposed production process

such as cutting waste of Puff shall be sold to authorized recyclers for safe disposal.

Approx. 30.0 Kg/day solid waste will be generated as scrap of Empty sacs, Boxes, Plastic

Utensils, and Cans, which will be sold to the respective Dealers.

5.0 SITE ANALYSIS:

5.1 Connectivity:

The plant is located about 9.5 Kms from Haridwar City, just outside Municipal limits, in a

Integrated Industrial Estate of SIDCUL. The existing land area is 20265.00 Sq. M with

plenty of green land. However land area required for installation of proposed Polyurethane

(PU) insulation Unit– 150.00 Sq. m in the vacant space of existing complex. The nearest

National Highway NH-58 is 3.45 km away from the site. The nearest Railway station

Haridwar is about 8.59 km away from the site.

5.2 Land Use:

Proponent has acquired Land about 20265.00 Sq. m at Plot No. – 1, Sector No. – 2, IIE,

SIDCUL, Ranipur, Haridwar, Uttarakhand. Proposed Polyurethane (PU) insulation Unit

will be installed in the part vacant land i.e. 150.0 Sqm of the existing plot.

The land break-up details are shown in Table – 06

Table – 06: Land break-up details

S. No. Construction Area (Sq m.)

1. Total Ground cover area for Plant & Facilities 8752.22

2. Greenbelt 6688.00

3. Open Area 2289.78

4. Parking area 2185.00

5. Loading /unloading area 350.00

Total Land 20265.00

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5.3 Topography:


Haridwar, Uttarakhand – 249 403. The area is situated in the survey of India Topo Sheet

No. 53 K and Coordinates Latitude: 290 57‟ 02.20” N, Longitude: 780 03‟58.52” E. The

nearest National Highway NH-58 is 3.45 km away from the site. The nearest Railway

station Haridwar is about 8.59 km away from the site.

The main features of the site including environmental considerations that make it suitable

for PU Insulation plant are given below:

Availability of sufficient stretch of land with flat terrain

No habitation in the plant site, hence no direct R&R issues

Sparsely populated surroundings

Suitable topography and geography for construction of facilities

Suitable seismic zone

The plant site is not falling within the vicinity of any monument or in an

archeologically sensitive area.

Nearness to source of main raw materials

Location of consumer center

Convenient Rail & Road links.

Adequate sources of water supply

Availability & closeness to source of adequate power supply

The site lies in seismic zone IV as per Seismic zonation & intensity Map of India and has

the lowest seismic potential.

There is no Capable Fault within the study area. The seismic zone map of Uttarakhand is

shown in the Fig. – 10.

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Fig – 10: Seismicity Map of Uttarakhand State

5.4 EXISTING LAND USE PATTERN:

Proponent has acquired Land about 20265.00 Sq. m at Plot No. – 1, Sector No. – 2, IIE,

SIDCUL, Ranipur, Haridwar, Uttarakhand. The products of Cello Industries are having a

wide range of Kitchen wares. Presently the company is producing Plastic house hold goods

2244.00 MTPA, Plastic Moulded Parts (PMP) 480.00 MTPA and Pet Preforms & Bottles

48.00 MTPA.

Proposed Polyurethane (PU) insulation Unit will be installed in the part vacant land i.e.

150.0 Sqm of the existing plot.

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5.5 EXISTING INFRASTRUCTURES:

The proposed PU insulation installation is in existing complex so infrastructure such as

storage facility, Drinking water facility, First-aid facility, Toilet facility is already

available. Internal roads are developed inside the plant premises once all the statutory

clearances are obtained.

Land:

Proponent has already acquired Land about 20265.00 Sq. m, whose building is converted

through modifications to suit to various Products at Plot No. – 1, Sector No. – 2, IIE,

SIDCUL, Ranipur, Haridwar, Uttarakhand.

Power:

The total connected load for smooth operation of the Unit is being sourced from UPCL

(1400 KVA). However just 20 KVA power will be required for the proposed unit.

The Company proposes for installation of Green Insulated DG Set for Alternate Power of

arrangement (350.0 KVA) for continuous supply of power in the manufacturing of

existing/proposed Products during Failure / Shutdown of power at any point of time will

adversely affect the production and quality of Finished Product.

Water:

Total water requirement for PU insulation Unit shall be 9.0 KLD, which shall be sourced

from existing bore wells. Necessary provision for storage of water and water supply has been

made in project cost.

Storage:

Company has already developed storage facility for raw material & finished goods by

providing adequate safety measures.

Transportation:

Promoters have adequate resources for transportation of Raw Material and Finished Goods.

Connectivity:

The Project site is well connected with road as well as Rail route.

All the other infrastructural facilities are expected to be adequately available to the Unit.

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5.6 SOIL CLASSIFICATION:

The topography is undulating in the northern part and more or less plain towards south.

The altitude ranges from 869 to 232 m. In the vicinity of Siwalik Hills, the gradient is steep.

Geomorphologically Hardwar district can be divided into four geomorphic units. These are

flood plain, lower piedmont plain, upper piedmont plain and structural hills.

The flood plain area is relatively flat, low lying and adjacent to Solani River. It comprises

unconsolidated, coarse to fine sand with silt and clay. The area is repeatedly inundated

during the floods. The lower piedmont plain is flat to undulating with gradient towards

southwest having micro relief. The sediments vary from fine clastic to coarse clastic

manifesting in variable runoff and infiltration.

The upper piedmont zone is narrow, southerly sloping upland adjoining the Siwalik Hills in

varying lateral and areal extent formed at the foot hills by the coalescence of several alluvial

fans comprising unsorted coarse clastic sediments (boulders, pebbles, gravels sand and clay).

It has high gradient (about 10 m/km) in the northern part to about 0.4 m/km in the

southern part close to Tarai. In this zone, most of the ephemeral rivers draining the area

disappear. There is high moisture content in upper piedmont zone which support dense

forest and lies to the south of Bhabar zone.

Structural hills show high relief and deep incised drainage with steep and sharp hill slopes

and well defined crest line (northern boundary of the block). This unit shows rugged

topography and homogenous lithology. The vegetation is dense indicating the presence of

loose alluvial material.

Soils play an important role in ground water recharge and the agriculture production of the

area. The land of Bhagwanpur block is highly fertile. The northern part, paleochannels and

active floodplain of rivers have soils of sandy loam, where as remaining part of the block is

covered by silty loam soils. Important soils are Ultisols, which are the brown hill soil,

occurring all through the northern part of the block. These are the soils with a horizon of

clay accumulation and low base supply. Entisols are the soils (also called the Bhabar soil)

occurring all along the foothills of Siwaliks and extends up to Tarai. These soils are without

pedogenic horizons. Though these soils consist of boulders, pebbles, sand, silt and clay, they

are highly fertile. Mollisols, also called the Terai soil, occur in the southern part of the block.

They consist mainly of fine-grained sand, silt and clay. These are the soils with a nearly

black, organic-rich surface horizon and high base supply. These three types of soils are

mineral soils with organic matter less than 25%. These are the most fertile soils of the block.

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5.7 CLIMATIC DATA:

District Hardwar experiences moderate subtropical to humid climate with three distinct

seasons viz. summer followed by rainy and winter seasons. Temperature begins to rise from

March (29.10 C) and reaches to its maximum in May (39.20 C), with the commencement of

monsoon season by mid-June, the temperature begins to fall. During the winter season in

the month of November to February the temperature ranges between 10.50 C and 6.10 C.

The relative humidity is highest in monsoon season (85% in the morning and 79% in the

evening). The lowest humidity is observed during the month of April and May i.e. 24% (in

evening) and 40% in May (in morning).

The mean monthly wind speed is highest in the summer season when it goes up to 7.4 and

7.2 km/hour in the month of May and June and the minimum wind speed is observed

during winter when it is 2.6 km/hour in the month of October. The potential

evapotranspiration is maximum in the month of May 198.9 mm and minimum 38.5 mm in

the month of December.

The average normal annual rainfall in Hardwar district is 1174.3 mm, out of which 84% is

received during monsoon season and only 16% occurs during non-monsoon period. The

district receives heaviest rainfall in northern part. The rainfall gradually decreases towards

south.

5.8 SOCIAL INFRASTRUCTURE:

The Project site comes under the Integrated Industrial Estate, “SIDCUL” Haridwar

District. Project area has education, drinking water facilities, transport facilities, School etc.

6.0 PLANNING BRIEF:

6.1 Planning Concept (Type of Industries, Facilities and Transportation etc.) Town

and Country Planning/ Development Authority Classification:


Haridwar, Uttarakhand. The area is situated in the survey of India Topo Sheet No. 53 K

and Coordinates Latitude: 290 57‟ 02.20” N, Longitude: 780 03‟58.52” E. The nearest

National Highway NH-58 is 3.45 km away from the site. The nearest Railway station

Haridwar is about 8.59 km away from the site.

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6.2 Population Projection:

Total Manpower engaged during operation of the PU insulation unit is 155. Apart

from this, 775 – 800 persons are indirectly benefited by this project during the

operation phase.

Employment Status:

Sl. No. Category No. of Employees

Proposed

01. Plant Head --


03. Supervisors 07



Total 155

6.3 Land Use:

The Project is over an area of 20265.00 Sq. m there is no forest land was involved in the

project site. The entire land is in the name of the plant and situated as Plot No. – 1, Sector

No. – 2, IIE, SIDCUL, Ranipur, Haridwar, Uttarakhand.

Green Belt Development

Local native species suitable for this region are planted in compliance of conditions of

environmental clearance. With a view to attenuate air pollutants, to resist noise propagation

from power generation units and uptake of treated effluent to some extent, the green belt all

around the periphery of project sites and in vacant areas (33% of the total acquired land) is

being developed. Tree plantation has been undertaken in a large scale on land vacated after

cessation of construction activities. Open spaces, where tree plantation is not possible are

planted with flowering herbs and grass which act as soil binders and also helpful in

preventing erosion of topsoil. Existing green belt is being strengthened regularly.

6.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL):

The social infrastructure likes Malls, Hotels and Primary Health Centre are developed in

this area. However, the following facilities are installed within the plant site;

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a. Electricity supply

b. Water supply

c. Administrative Building, Service Building

d. Construction offices and stores

e. Time and security offices

f. First Aid and firefighting station

g. Canteen

h. Toilets and change rooms

i. Car parks and cycle/ scooter stands

6.4.1 System Design for High Productivity:

The productivity of the Unit and associated auxiliary objectives are achieved by adopting

the following principles;

Use of equipment and systems of design, performance and high availability which has been

fully established by a considerable record of successful operation for similar service

conditions in all plant facilities. Use of only proven design concepts and conservative

designs. Strict implementation of quality assurance norms during design, manufacture as

well as installation and commissioning stage. Strict compliance with the project company

approved pre-commissioning and commissioning procedures as well as standard checklists

forming a part of commissioning documents for the project.

6.4.2 Sizing of Critical Equipment- Margins & Redundancy/Standby:

Adequate margins are provided while sizing all important auxiliaries and sub-systems to

ensure operation of the Unit at ultimate capacity under the worst conditions and taking into

consideration normal wear & tear.

6.4.3 Design for Efficient Operation:

Centralized maintenance system is followed. All repairs of capital nature, heavy

maintenance jobs, and plant civil maintenance are done by engaging specialized external

agencies.

Implementation of computer systems including local area network (LAN) with standard

user friendly software‟s in the field of financial management, personnel management,

materials management, order scheduling, sales and marketing management, management

information systems (MIS), production planning and control, maintenance and spares

planning, etc. has been considered to increase work efficiency and to reduce manpower

requirement.

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6.4.4 Operation Performance Management System (OPMS):

The operation of the plant will be optimized by implementation of OPMS. This system will

clearly define the responsibilities of all key O & M personnel including the shift-in-charge.

This will also cover the system of daily reporting to the project company Corporate Office

and monthly O&M review meetings.

6.4.5 Operation & Maintenance Philosophy:

Most of the key positions in operation and maintenance of the proposed plant at different

categories are manned by the qualified persons having experience in the similar field.

However, depending on the type of equipment /facilities along with the degree of

automation contemplated, the operation and maintenance personnel of the plant so

recruited will require specific need based training which is carried out on site by the

respective equipment supplier during equipment erection, start up and commissioning of

different plant units.

6.5 AMENITIES/FACILITIES:

6.5.1 In-Plant Facilities:

The following facilities are provided in the existing plant:

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

d. First Aid and firefighting station

e. Canteen

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

h. Training Centre

Office space has been provided as per good practice and canteens, toilets and restrooms

according to norms laid down in relevant factories act. The above facilities shall also be

adequately furnished and equipped.

6.5.2 Employment Generation:

Total Manpower engaged during operation of the PU Insulation Unit is 155.

Establishment of small and medium scale engineering ancillaries, with cascading

employment opportunities;

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Increased revenue to the state by way of taxes and duties;

Improved green cover;

Better communication and transport facilities;

The project has enhanced the prospects of employment. Recruitment for the unskilled

workers for the plant is from the nearby villages. The basic amenities viz. roads,

transportation, electricity, drinking water, proper sanitation, educational institutions,

medical facilities, entertainment, etc. are developed as far as possible.

6.5.3 Peripheral Developmental Activities:

M/s Cello Industries has undertaken various activities already made around the plant as a

mark of their Corporate Social Responsibilities viz. Education, Water Supply, including

Drinking Water, Health Care, Environment, Social Empowerment and Sports and

Culture.

7.0 PROPOSED INFRASTRUCTURE:

Not Applicable

8.0 REHABILITATION & RESETTLEMENT (R & R) PLAN:

Not Applicable

9.0 PROJECT COST ESTIMATES:

Initiated Project cost was estimated as under:

Table – 07: Cost of Project

Details Rs. in Lakh

Land : 0.00

Plant & Machinery : 80.00

Electrical installation 10.00

Furniture & Fixtures 2.00

Moulds & Dies 8.00

Others : 0.00

Total : 100.00

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Means of Finance:

Details Rs. in Lakh

Internal Accrual (Self) : 100.00

Total : 100.00

10.0 ANALYSIS OF PROPOSAL:

Project will create direct & indirect employment opportunities within the surrounding

region. Unit will use good faith efforts to employ local people from the nearby villages

depending upon the availability of skilled & un-skilled man-power surrounding the project

site.

In operation phase, the proposed project would require significant workforce of non-

technical and technical persons. Migration of highly education and skilled experience will

result in increase of literacy in the surrounding villages. In addition, the proposed project

shall enhance the prospects of employment.

Additional government revenue expected from royalty, taxes, duties and other fees. An

added benefit to the proposed project will result in considerable growth of stimulating the

industrial and commercial activities in the state.

11.0 STORM WATER/SEWER DETAILS:

The Factory Land is small with Plot area of just 20265.00 Sq. m. The open land

surrounding the building is paved with concrete, except for green belt & garden.

Being a small land, there is no storm water drain, as the rain water flows out into the

SIDCUL drain.

11.1 Sewer Drainage System:

The Company has provided the adequate sewerage facilities. Domestic effluent is being

treated in CETP, operated in SIDCUL.

11.2 Rain Water Harvesting:

Rainwater harvesting in the present scenario holds vast potential in controlling runoff and

resulting water logging problems besides assuring an alternative source of water and a

supplement to existing natural resources in a wide variety of circumstances.

A rainwater harvesting system comprises components of various stages namely-

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Transporting rainwater through pipes or drains.

Filtration

Storage in tanks for reuse or recharge.

\

Fig – 11: Design of Typical Recharge Pit

Two major systems that are ideal for industrial developed areas of are artificial ground

water recharge, and roof top rainwater harvesting (The mode NBC-2005). The mode of

harvesting are basically site specific and depends the amount of precipitation, availability of

total number of rainy days, nature of storage structures, nature of aquifers etc.

In general CGWB norm suggest not to artificially recharging if water table is less than 05 M.

Also recharging is not recommended for aquifers with TDS levels higher than 4000 mg/L or

high levels of chemical composition like Nitrate, Fluoride, and Arsenic etc.

In this project it has been planned to provide 02 Nos. rainwater harvesting recharge pit

(Trench) and 02 No. rain water harvesting tank. Rainwater collected from the rooftop

would be diverted by drain pipes to a settlement / filtration tank, from which it would flow

into the recharge pit. Water filters would be provided prior to the chamber to arrest and

separate any suspended matter present in the rain water. The recharge pits are designed with

three concentric circular chambers in which the outer chamber is filled with sand, the

middle one with coarse aggregate and the inner most layer with pebbles.

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Fig – 12: Cross section of Recharge Trench

Any surplus runoff which overflows the recharge pits would be collected in the unpaved

areas and allowed to get absorbed. Also there would be proper storm water drainage

network to collect the excess storm water runoff.

Rain Water Harvesting (RWH) System Calculation

Based on the area statement, the total roof/surface area receiving the rainfall is as follows:

Total Plot Area: 20265.00 m2

Ground coverage area of the unit receiving: 8752.22 m2

Paved area of the Unit 2289.78 m2

As per data available, the annual rainfall in Dehradun: 1174.30 mm

Total rainy days in a year: 80 days

Average rainfall per day: 1174.30/80 = 14.67 mm/day

The intensity of rainfall considered is 14.67 mm/hr, (Heavy rain fall) which generally occurs

in one hour (for the purpose of calculations, the higher value of rainfall intensity is being

considered in view of unpredictable nature of rainfall for arriving at total storage volume)

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Therefore, intensity of rainfall: 14.67 mm/hr

RUN-OFF (Discharge)

Q = 10*C*I*A

Where:

Q: run off in cubic meters/hr

C: Co-efficient/Impermeability factor of the surface

I: Intensity of rainfall (14.67 mm/hr)

A: Total drainage area in hectare

Co-efficient of Run off/Impermeability Factor [C]

S. No. Description of Surface Value of run off coefficient

factor of the surface (C)

1. Terraces, Hard paved surfaces 0.9-0.95

2. Paved Surfaces, roads 0.85-0.90

3. Gravel path, loosely paved walk, rocky surface 0.70-0.85

4. Brick paved, Compact ground 0.50-0.70

5. General Ground 0.50-0.60

6. Natural Ground, sloping ground 0.20-0.50

Run Off Calculation:

(i) Run off from ground coverage area of the unit

Q1 = 10*0.8*14.67*8752.22/10000 (since 1 hectare = 10000 m2)

= 102.71 m3/hr

Q2 = 10*0.9*14.67*2289.78/10000 (since 1 hectare = 10000 m2)

= 30.23 m3/hr

Total run off discharge (Q): = 132.94 m3/hr

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Considering the first flush of rainwater after a dry period shall be allowed to run to waste as

it will be contaminated with dust, bird droppings etc.

Total run off = 0.9 * 132.94 = 119.65 m3/hr

Considering retention storage of rain water harvesting is 30 min

Total capacity of RWH storage: 119.65 *30/60 = 59.82 m3

The total no. of RWH proposed: 2

Capacity of each RWH: 29.91 m3 (approx. 30 kl)

12.0 WASTE WATER MANAGEMENT:

The manufacturing Process doesn‟t generate any effluent. Bleed water from CT will be

reused into green belt. Waste water generated (6.10 KLD) from Domestic Purpose &

Miscellaneous i.e. Equipment/floor washings etc. will be treated in the CETP. Company


13.0 AIR / NOISE POLLUTION CONTROL MEASURE:

As Green insulated DG Set will be installed, although an acoustic enclosure will be

provided on the DG Set.

All noise producing equipment are enclosed in Acoustic hoods.

Ambient air quality and stack emissions will be regularly monitored to ensure ambient air

quality standards.

Dense Green belt is available and being strengthening around the boundary to reduce the

noise escape in surrounding area.

14.0 SOLID WASTE MANAGEMENT:

Little quantity of solid waste (Approx. 10.0 Kg/day) will be generated during material

sampling, dispensing, handling, production, processing and packing & eventually reuse into

process.

Approx. 5.0 kg / day solid waste will be generated from the proposed production process

such as cutting waste of Puff shall be sold to authorized recyclers for safe disposal.

Approx. 30.0 Kg/day solid waste will be generated as scrap of Empty sacs, Boxes, Plastic

Utensils, and Cans, which will be sold to the respective Dealers.

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15.0 HAZARDOUS WASTE MANAGEMENT:

Empty Barrels approx. 1500 Nos. / Annum will be generated and shall be manage as per

Hazardous & Other Waste (Management, Handling & Transboundary movement) Rule,

2016. Waste / Used Oil from Proposed DG Set will be sold to the authorized recyclers only.

16.0 SAFETY MEASURES:

Company will provided full proof fire hydrant system & all kinds of fire extinguishers to

ensure the safe working environment. The workers shall be provided with face-mask, hand

gloves, moreover the production halls shall be fitted with exhaust fans etc.

On site emergency management plan has been made. MSDS instruction shall be followed

while dealing with the raw materials. All Safety measures will be taken to ensure that there

would be no wastage of any manufactured or By - product. Due care & precautions would

be taken at every stage to ensure that no material will go down to the drain.

The Organization will establish, implement & maintain documented Occupational health &

safety objectives, at relevant functions & levels within the organization and training /

awareness program will be conducted on regular basis.

Documents

M/s CELLO INDUSTRIESenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/...INSULATION UNIT IN THE EXISTING COMPLEX BY M/S CELLO INDUSTRIES.-21 M/s CELLO INDUSTRIES PLOT NO. –