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M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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CHAPTER 1: EXECUTIVE SUMMARY
M/s. Siddaganga Cements Pvt Ltd is situated at Sy.No. 61 Sadarahalli Village,
Chikkanayakana halli Taluk, Karnataka State. It is a progressive company engaged in the
Manufacturing of cement and is professionally managed by people who have vast
experience in the field of cement. The company is promoted by technically qualified and
professionally experienced technocrats who crave for innovation and value addition. We
recognize that our ability to excel in our core competences depends on the skill,
knowledge, creativity and hard work of our employees. A high standard of ethics,
integrity and responsibility towards our customers remains our top priority. The
company’s competitiveness is displayed not only in cost-effectiveness and fast time
frames but also in dependability, quality and respect for intellectual property rights and
strict procedural norms ensuring clients and associates absolute confidentiality.
Manufacturing with effective quality management is of paramount importance to our
success. Our manufacturing sites are regularly evaluated internally and inspected by
regulatory authorities to ensure that finished product have the identity, strength, quality
and purity they are required to have. Our line of products is vast and varied. With a
strong emphasis on innovative and efficient process development our products conform
to the highest standards of quality that we have set for ourselves. Apart from our core
competence in standard unit operations, process innovation and development to achieve
higher yields, we see ourselves as our customers long term and faithful partners,
motivated by the understanding that the customers success is our success.
With the assistance of qualified professionals including those who have already worked
in the renowned cement companies in India as well as abroad, they are able to provide
quality cement. The company in a short span of time has expanded its operations to offer
total turnkey solutions to the various Indian cement industries. large installation capacity,
cost effective supply and customized packaging, they have secured a remarkable position
in this domain in short time.
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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M/s Siddaganga Cements Pvt Ltd located in the district of Tumkur, and 123 Kms from
Bangalore. Mr. D.K. Prabhudevaiah is the Managing Director and already an
entrepreneur from 1976 having couple of SSI units and he is well experienced in Cement
industry.
The main objective of M/s. Siddaganga Cements private Limited is manufacturing
Ordinary Portland cement and planning to manufacture Porzonlona Portland cement and
Portland slag cement with a capacity of 30 TPD To 200 TPD.
1.1 Quality Policy:
Siddaganga Cements Pvt Ltd manufacturing products of high quality and creates an
environment where each employee contributes to all aspects of our business processes.
The company recognizes that quality is not just another goal, but an essential strategy for
growth. Towards this objective of quality we advocate continuous improvement in all our
activities by fostering teamwork, innovation, providing good working environment and
effective training to our employees to make them more competent and quality conscious.
1.2 Quality Assurance:
The company’s quality focus encompasses all areas of the manufacturing operations-from
procurement of raw materials to best possible manufacturing technology, from on time
delivery of the customer’s requirements to promotional help pushing its product to
become the market brand thus ensuring a rapid penetration in the domestic markets-
nationwide.
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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CHAPTER 2: INTRODUCTION OF THE PROJECT/BACKGROUND
INFORMATION
2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
M/s Siddaganga Cements Pvt Ltd. has proposed for expansion of existing production
capacity from 30 TPD to 200TPD. at Sy.No. 61 Sadarahalli Village, Chikkanayakana
halli Taluk Karnataka State which measures 4acres 38 Guntas
M/s Siddaganga Cements Pvt Ltd located in the district of Tumkur, and 123 Kms from
Bangalore. Mr. D.K. Prabhudevaiah is the Managing Director and already an
entrepreneur from 1976 having couple of SSI units and he is well experienced in Cement
industry.
2.2 BRIEF DESCRIPTION OF THE NATURE OF THE PROJECT.
Presently company is manufacturing Ordinary Portland cement and planning to
manufacture Porzonlona Portland cement and Portland slag cement with a capacity of 30
TPD To 200 TPD. To increase the capacity further with the existing infrastructure the
company is going to adopt good production methodologies as pointed out below,
Optimization of existing grinding to increase capacity from Proposed Expansion
of grinding capacity from 30TPD to 200TPD.
Flyash from thermal power plants as additive in our cement mill to increase the
output of the mill
To improve the grinding facility efficiency, the improved quality of grinding balls
will be used.
2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY
AND OR REGION.
Cement is one of the core industries which plays a very important role in the growth and
expansion of a nation. It is basically a mixture of compounds, consisting mainly of
silicates and aluminates of calcium, formed out of calcium oxide, silica, aluminium oxide
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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and iron oxide. The demand for cement depends primarily on the rate of activities in the
business, financial, real estate and infrastructure sectors of the economy.
2.4 DEMAND AND SUPPLY GAP
Demand for Cement is high and as soon as Cement is produced it will be supplied to the
contractors by trucks covered with tarpaulins.
2.5 IMPORTS V/S. INDIGENOUS PRODUCTION
The major raw materials for the grinding unit are Clinker, Gypsum, Flyash and Slag and
the quantities of raw materials imported and their sources are as follows,
Sl.No Raw Materials Maximum Quantity
TPD
Sources
1 Ordinary port
land cement 53
grade
70 BMM Cements
Hospet
2 Granulated
Slag GGBS
17.5 JSW Steel plant
Bellary
3 Flyash 30 JSW Steel plant
Bellary
4 Gypsum 7.5 The Fertilizers &
Chemicals Travancore
limited, Cochin
5 Clinker 75 Heidelberg cements
india limited, Tumkur
6 PP Bags 4200 nos Tumkur
2.6 EXPORT POSSIBILITY
Cement is considered preferred building material and is used worldwide for all
construction works such as housing and industrial construction, as well as for creation of
infrastructures like ports, roads, power plants, bridges, dams, stadiums, etc. Indian
cement industry is globally competitive because the industry has witnessed healthy trends
such as cost control and continuous technology upgradation.The Indian cement industry
is extremely energy intensive and is the third largest user of coal in the country.
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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2.7 DOMESTIC/EXPORT MARKETS
India is the second largest cement producing country in the world after China. The
country’s cement production was 330 million tonnes in 2013; the figure is expected to
double to reach almost 550 million tonnes by 2020, as per estimates by the Cement
Manufacturers Association(CMA).
2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE
PROJECT.
The total manpower in the present and for expansion of the plant is 45 no’s as Direct
employment & Indirect Employment will be about 20 persons.
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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CHAPTER 3: PROJECT DESCRIPTION
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND
INTERDEPENDENT PROJECT IF ANY.
The Project is proposed to increase production capacity from 30TPD to 200TPD in
existing infrastructure facility accompanied in existing factory shed. at Sy.No. 61
Sadarahalli Village, Chikkanayakana halli Taluk Karnataka State which measures 4acres
38 Guntas There is no any interlinked and intermediate project as the Project is an
individual one.
3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC
LOCATION, AND PROJECT BOUNDARY & PROJECT SITE LAYOUT) WITH
COORDINATES.
Figure 3.2.1: Google image of the proposed project site
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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Fig 3.2.2: PROJECT SITE LAYOUT MAP
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3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF
SELECTING THE PROPOSED SITE, PARTICULARLY THE
ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE
HIGHLIGHTED:
There is no any alternate site considered for the proposed project M/s Siddaganga
Cements Pvt Ltd. as it is existing unit.
3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATIC
DIAGRAM/ FLOW CHART SHOWING THE PROJECT LAYOUT,
COMPONENTS OF THE PROJECT ETC, SHOULD BE GIVEN)
The capacity of the mill will be
1. Cement mill 200 TPD
i. The use of grinding aids – the multipurpose cement mill additive which helps in
increasing the mill out put & reducing the electricity cost and increase the efficiency of
grinding.
ii. Use flyash from thermal power plants as additive in our cement mill to increase the out
put of the mill
iii. We also plan to use improved quality of grinding balls in cement mills to improve
grinding efficiency.
iv. Now a days Government of Karnataka is ensuring continuous / dedicated power supply
to industries to enhance the productivity.
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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MANUFACTURING PROCESS
Figure :3.4.1 Process Flow diagram of the OPC and PPC process.
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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A detailed description of the cement making process at M/s Siddaganga Cements
Pvt Ltd
Secondary Raw Materials
Depending on availability and chemical composition, additional components may be
added to the raw mix. These are referred to as “Secondary” raw materials. Examples are
fly ash from JSW steel plant.
SCPL .manufactures below mentioned products
Port land pozzolana cement can be manufactured by intimately and uniformly
blending Portland cement an fine pozzolana.the company is going to adopt
grinding mill and requisite machinery like classifiers( to produce fine pozzolana
)to ensure uniformity of guaranteed quality
Portland slag cement is obtained by separately grinding Portland cement clinker
and BF Slag with gypsum and physical properties are similar to those of ordinary
Portland cement as per IS 445
Ordinary Portland cement is obtained by grinding cement clinker with gypsum
Cement dispatch
Cement is dispatched in 5O kg bags and distributed from the manufacturing plant via
road. The cement is marketed in Karnataka ,.
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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Figure : 3.4.2 Process Flow diagram of the cement manufacturing process.
3.5 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY
LIKELY SOURCE MARKETING AREA OF FINAL PRODUCT/S,MODE OF
TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT.
The major raw materials for the grinding unit are Clinker, Gypsum, and Slag and the
quantities of raw materials imported and their sources are as follows,
Flyash/slag Clinker Gypsum
Horizontal Ball Mill
PPC/OPC/PSC Cement
Silo
Stationary packers
Dispatch
M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report
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Sl.No Raw Materials Maximum Quantity
TPD
Sources
Ordinary portland cement 43 grade - 50 TPD
1 Clinker 45 Heidelberg cements India
limited, Tumkur.
3 Gypsum 5.0 The Fertilizers & Chemicals
Travancore limited, Cochin
Portland slag cement – 50TPD
1 Clinker 30.0 Heidelberg cements India
limited,Tumkur.
2 Slag 17.5 JSW Steel Limited, Bellary
3 Gypsum 2.5 The Fertilizers & Chemicals
Travancore limited, Cochin
Porzonlona Portland cement – 100 TPD
1 OPC 53 grade 70 BMM Cements ltd, Hospet
2 Fly ash 30 JSW Steel Limited,Bellary
3.6 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN
THE PROJECT IF ANY SHOULD BE BRIEFLY OUTLINED:
There is no generation of wastewater from the proposed project. Domestic effluent will
be sent to septic tank followed by soak pit.
3.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY/ POWER
REQUIREMENT AND SOURCE SHOULD BE GIVEN.
Water source is from bore well in the project site, power requirement is 250 KVA
including existing work and power supply is from KPTCL
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CHAPTER 4: SITE ANALYSIS
(i) Connectivity: SH-19 is at a distance of around 5.4 Km towards west The
company has chosen this site mainly due to its proximity to raw material sources
and also better access to market.
(ii) Land Form, Land use and Land ownership:
Land is owned by the M/s Siddaganga Cements Pvt Ltd
(iii) Existing land use pattern (agriculture, non-agriculture, forest, water bodies
(including area under CRZ)), shortest distances from the periphery of the
project to periphery of the forests, national park, wild life sanctuary, eco
sensitive areas, water bodies (distance from the HFL of the river), CRZ, In
case of notified industrial area, a copy of the gazette:
Thirtharampura north west extension reserved forest. 1km east
(iv) Soil classification:
Red Sandy soil covers rest of the area except very small area in the
northwestern part of C.N. Halli Taluk where Mixed Red and Black soil occur. Red
soils have good drainage but poor in lime and bases.
(v) Existing Infrastructure.
Exiting infrastructure is shown in project site plan in fig 3.2.2
(vi) Climatic data from secondary sources:
The average temperature during the months of summer can reach up to 40 0C
and the minimum average temperature during the months of winter can be 12
0C. The average rainfall recorded is around 250 mm.
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CHAPTER 5: PLANNING BRIEF
Planning concept (type of industries, facilities, transportation etc) Town and
Country Planning/Development authority Classification:
The grinding & packing project will give the following benefits to State and Central
government:
Additional revenue by way of taxes like Vat, Excise Duty, Income Tax etc.
Provides direct 45 persons and indirect 20 persons employment to around people
from the nearby areas.
Enhances the per capita income and standard of lining of the local people.
i.Population Projection: the population projection of the nearby places are Tumkur
district
ii.Land use planning (breakup along with green belt etc):
Land utilization details are shown below.
SL No Land usage Area in acres
1. Buidup area 1.250
2. Road area 1.125
3. Greenbelt area 1.825
4. Vacant land 0.75
Total land area 4.95
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CHAPTER 6: PROPOSED INFRASTRUCTURE.
i. Industrial area: There is no any industrial area around the proposed Project site.
ii. Residential area: Nearest major residential area around the Project Site is
chikkanayakana halli which is at a distance of around 9.7 Km .south
iii. Green belt: Green belt will be developed around the proposed project site in an
effective way to check pollutants and their dispersion into surrounding areas. The
degree of pollution attenuation by a green belt depends on its height and width,
foliage surface area and density. The main objective of green belt is as follows:
i. Mitigation of impacts due to fugitive emissions caused by vehicles
ii. Attenuation of noise levels
iii. Ecological restoration
iv. Creation of aesthetic environment
iv Drinking Water Management (Source and Supply of Water) Water Resources:
WATER REQUIREMENT
No water is required for the grinding unit except for domestic usage. Water is required
only for employees use. The total water requirement after commencement of full
production is estimated to be 2.025 KLD Water requirements for the domestic purpose is
met from Borewell existing in the project site.
Table 6.1 Water Balance
iv. Sewerage System: There is no effluent generated from the proposed project.
Domestic effluent from toilets will be sent to septic tank followed by soak pit.
Description Water requirement in KLD
Domestic 2.025
Total 2.025
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v. Industrial Waste Management: There is no any industrial waste generated in the
premises.
vi. Solid Waste Management: There is no solid waste generation..
vii. Power Requirements and Supply and Source:
Description For plant
Power supply from
electricity board
250 kVA
Total 250 kVA
CHAPTER 7: REHABILITATION AND RESETTLEMENT (R & R) PLAN.
Rehabilitation and Resettlement Plan Not applicable.
CHAPTER 8: PROJECT SCHEDULE AND COST ESTIMATE
8.1: Likely date of start of construction and likely date of completion (Time schedule
for the project to be given)
As soon as we obtain Environmental Clearance we will go for expansion of the Cement
Industry.
8.2: Estimated project cost along with analysis in terms of economic viability of the
project.
The total project cost estimated is Rs.6.95 Crores.
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CHAPTER 9: ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
The Indian cement industry is the second largest producer of quality cement. Indian
Cement Industry is engaged in the production of several varieties of cement such as
Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC), Portland Blast
Furnace Slag Cement (PBFS), Oil Well Cement, Rapid Hardening Portland Cement,
Sulphate Resisting Portland Cement, White Cement, etc. They are regulated to produce
strictly as per the Bureau of Indian Standards (BIS) specifications and their quality is
comparable with the best in the world. The Indian cement industry is the second largest in
the world. The industry occupies an important place in the national economy as it shares
large links with other sectors like construction, transportation, coal and power. It also
provides employment to thousands of people.