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PRE- FEASIBILITY

REPORT

Prefeasibility Report

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1.1: Executive Summary The leather industry occupies a place of prominence in the Indian economy in view of its

massive potential for employment, growth and exports. The government of India is seriously

concentrating on its planned development, aimed at optimum utilization of available raw

materials for maximizing the returns, particularly from exports. The exports of leather and

leather products gained momentum during the past two decades. India’s export of leather &

leather products has increased from US$ 239.88 million in 1972 to US$ 3.40 Billion in 2009-10.

The projected figure is US$ 8.25 Billion for the year 2013-14. During the period April-December

2010 exports of Leather and Leather related products touched US$ 2754.86 million as against

US$ 2486.70 million in the corresponding period last year, recording a positive trend of 10.78%.

Indian leather industry today has attained well merited recognition in international markets

besides occupying a prominent place among the top seven foreign exchange earners of the

country.

The leather industry has undergone a dramatic transformation from a mere exporter of raw

materials in the sixties to that of value added finished products. Policy initiatives taken by the

Government of India since 1973 have been instrumental to such a transformation

In the wake of globalization of Indian economy supported with liberalized economic and trade

policies since 1991, leather industry is poised for further growth to achieve greater share in the

global trade. India possesses one of the largest livestock wealth in the world. India has 53%

of world Buffalo population, 15% of world cattle population and 17% of world Goat population. In

terms of sheep population, India ranks fifth in the world. The leather industry can provide up to

10 % of the global leather demand but at present we are supplying only 3% of total global

leather requirement. So as to meet the global demands we need more leather plants in our

country so as to tap the potential of market both globally as well as domestically.

Proponent Rajesh Nagora is planning to set up Leather Finishing Unit at Village Chawandiya,

Khasra No. 1492/5 Tehsil Malpura District Tonk, Rajasthan, for finishing of Leather for which

they will procure suppliers from domestic as well as from global markets. The proposed capacity

of the plant is 2,500 pieces of raw skins/ hides. Main stages for Operations of Raw

skins/Hides to Wet blue are Desalting, Soaking, Paint Liming, Reliming, Deliming, Pickling,

Chrome Tanning and the processes for wet blue to Finish leather are sammying and saving,

rechroming, neutralization, dyeing, fat liquoring and retanning.. This project will be financed by

term loan and personal contribution from the company’s proprietor. This project will also create

good employment opportunities for the people residing in the nearby villages.


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1.2: Salient Features of the Project

Project Name: Nagora Leathers

Proponent Name Nagora Leather

Location Khasra No. 1492/5 Village-Chawandiya, Tehsil- Malpura,

District –Tonk, Rajasthan.

Latitude 260 27’ 06.54” N

Longitude 750 27’ 09.37” E

Land Use Agricultural. Shall be converted for Industrial use

Nearest Habitate/ Town Jaipur – 61 Kms (72 kms by Road) Tonk – 46 kms (95 kms by Road)

Nearest Railway Station Makrana Junction – 3.3 km

Nearest Airport Jaipur – 52 Km (62 kms by road)

Nearest Highway Jaipur- Bhilwada – 3 km

Water Demand and Supply source 93 KLD Source- Ground water

Nearest Tourism Place Jaipur – 61 Km (72 km by road)

Seismic Zone Zone – II

Altitude 315 m

Proposed Production Process Processing of Leather (Raw to Finished) 2500 raw skins/ hides per day

Project Cost 2.30 Crore

Working Days 330 days per annum.

Man Power 30


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2.0: Introduction to the project

2.1 Identification of the project

M/S Nagora Leathers have proposed to set up a new Leather Processing Unit having office at

206, Vasundhara Colony, Tonk Road, Jaipur. Mr. Rajesh Nagora who is the prop. of the

proposed company is interested in the processing of Raw skins/Hides to Finished Leather at

the proposed unit. The proposed plant will be located at Village Chawandiya, Khasra No. 1492/5

Tehsil Malpura District Tonk Rajasthan.

2.2 Brief description of the nature of the project

The proposed project at Tonk will be primarily indulged in the Leather processing. The

production of finished leather from raw skins/hides may broadly be divided in two processes viz.

i) Raw Skins/Hides to Wet Blue and ii) Wet Blue to Finished Leather.

Finishing operations of raw skins/hides to wet blue comprises desalting, soaking, paint liming,

reliming, deliming, pickling and chrome tanning and the wet blue to Finished Leather comprises

Sammying and Shaving, Rechroming, Neutralization, Dyeing, Fat liquoring and Retaining.

However the operations vary depending upon the final product. A brief description of unit

processes adopted and chemical additives handled by the tannery are presented in the

following sections:

i) RAW SKINS/HIDES TO WET BLUE :

Desalting: The wet cured skins are drawn from the bins. They are ripped open

and desalted either manually or mechanically. Dusted salts are collected

separately for reuse. Then the head and tail portions of the skin are trimmed to

remove the unwanted ends and weighted. Weight of each skin is noted.

Soaking: The main object of soaking is rehydration and cleaning of the skin to

remove salt, dirt, dung, blood, etc. The soaking operation is carried out in three

stages in paddles for 4- 6 hours. In each stage about 180% of water by weight of

the skin is used. At initial stage 0.1% preservative and 0.2% wetting agent are

added along with water. A sizeable percentage of salt goes into solution as

waste.

Paint Liming: Soaked skins are piled up on the floor with flesh side up and hair

side down for 3 to 4 hours for complete draining of water. Based on the soaked

weight 2.5% sodium sulphide and 0.2% wetting agent are dissolved in 20% water

at 60oC. Then 10% lime solution is added and mixed well to form paint like

substance.

Reliming: The unhaired skins are taken for reliming operation in paddle with

10% lime, 0.25% NaOH and 180% water for 2 days. The paddle is run for 10

minutes every hour. On the third day fleshing operation is carried out by

machine. Then pelt weight is noted.


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Deliming: The pelts are washed in the drums with 120% water for 10 minutes.

Then deliming operation is carried out in the drum with 120% water and 1%

ammonium chloride for 1 hour. The skins are degreased with 2-3% degreasing

agent. 1% bate is added and run for 1 hour by running the drum for one hour.

Then washed with 120% water for 10 min. The purpose of deliming is to destroy

the alkanity by removing lime chemically bound to collagen. As a result, the

plumping and permeability in the skin are achieved. At this stage the pH of the

skin is 7-8.

Pickling: Pickling is the process of deliming pelt with a mixed solution of

sulphuric acid and common salt to bring it to a state fit for tanning process.

Pickling is carried out in drum with 60% water, 10% salt, 1% sulphuric acid and

0.5% formic acid for 1-2 hrs. At this stage the pH of the skin is 3.0 – 3.5. Skins

are left overnight in the drum.

Chrome Tanning: Next day one half of the pickle liquor is drained out and 8%

basic chromium sulphate is added in the drum and drum is run for 3 to 4 hours.

Then basification is carried out with 30% water, 1% sodium formate and 1%

sodium formate and 1% sodium bicarbonate by adding the solution in 10 or 15

instalements in 10 – 15 min. frequency. After completing the addition, pH of the

skin is checked (3.8 to 4.0) and again run for 1 hour. The contents are left

overnight in the drum. Next day 0.1% preservative and 60% water are added and

run for 10 min. Then skins are removed from drum and piled.

ii) WET BLUE TO FINISH LEATHER:

Various unit processes are Sammying and Shaving, Rechroming, Neutralization,

Dyeing, Fat liquoring and Retanning

Sammying and Shaving: The wet blue skins are sammed (dewatering) in

sammying machine. The sammed skins are shaved to required thickness in

the shaving machine. Based on the shaved weight, water and chemicals are

used for subsequent processes.

Rechroming: The shaven skins are washed with water in 10 min. The basic

chromium sulphate (5 °A)) in water (90%) is added. The tanned wet blue leather

is tumbled for 1 hour. In the next hour, sodium formate (1%) and sodium

bicarbonate (1%) are added to the drums. The rechromed wet blues are piled on

the horse for overnight.

Neutralization: The objective of neutralization is to remove the excessive

acid present on the leather and also to condition leather for subsequent

dyeing and fat liquoring operation. The rechromed wet blues are washed

in drum with water (120%) for 10 min. The -washed wet blue is completely


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neutralized at pH 4.8 - 5.2. This is affected with addition of water (120%) in

the presence of sodium formate (1%) and sodium bicarbonate (1 %).

Dyeing, Fat Liquoring and Retanning: The neutralized skins are washed

with water (120%) for about 10 min to make them fit for dyeing. Hot water is

used. Water (120%) at 60°C and appropriate dye (4%) are mixed together

and added to the chromed tanned skins and drummed for 1 hour.

Subsequently fat liquor (12%) is added to improve the softness, flexibility and

strength. Dyes and fat liquor are fixed by using the 2% formic acid for 20 min

then retanning is carried out with 10% synthetic tanning to improve the

fullness quality of the leather and again washed with water (120%) and piled

on the horse

Table 1: Chemical used in various processes in Tanneries

PROCESS MAIN CHEMICALS

SOAKING Wetting Agents (detergents) Preservatives (biocides)

LIMING Sodium Sulphides Lime Water Wetting Agent

Liquid gel formed

RELIMING Lime NaOH

DELIMING NH4SO4

PICKLING NaCl H2SO4 10% Formic Acid

CHROME TANNING Basic Chromium Sulphate NaHCO3 Sodium Formate Preservative (biocides)

RECHROMING Basic Chromium Sulphate NaHCO3 Sodium Formate

NEUTRALIZATION NaHCO3 Sodium Formate


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2.3 Need for the project and its importance to the region

The leather industry occupies a place of prominence in the Indian economy in view of its

massive potential for employment, growth and exports. There has been an increasing emphasis

on its planned development, aimed at optimum utilization of available raw materials for

maximizing the returns, particularly from exports. The exports of leather and leather products

gained momentum during the past two decades. There has been a phenomenal growth in

exports from Rs.320 million in the year 1965-66 to Rs.69558 million in 1996-97. India’s export

of leather & leather products has increased to US$ 3.40 Billion in 2009-10. The projected figure

is US$ 8.25 Billion for the year 2013-14. Indian leather industry today has attained well

merited recognition in international markets besides occupying a prominent place among the top

industries.

The leather industry has undergone a dramatic transformation from a mere exporter of raw

materials in the sixties to that of value added finished products. Policy initiatives taken by the

Government of India since 1973 have been instrumental to such a transformation. In the wake

of globalization of Indian economy supported with liberalized economic and trade policies since

1991, the industry is poised for further growth to achieve greater share in the global trade.

Apart from a significant foreign exchange earner, leather industry has tremendous potential for

employment generation. Direct and indirect employment of the industry is around 2.5 million.

The skilled and semi-skilled workers constitute nearly 50% of the total work force. There exists a

large raw material base. India possesses one of the largest livestock wealth in the world.

India has 53% of world Buffalo population and 15% of world cattle population and 17% of

world Goat population. In terms of sheep population, India ranks fifth in the world. Cow/

Buffalo/Sheep/Goat, these four species provide the basic raw material for the leather industry.

Some of the goat/sheep skins available in India are regarded as specialty products commanding

a good market. Abundance of traditional skills in finishing and manufacturing downstream

products and relatively low wage rates are the two other factors of comparative advantage for

India. All the above stated facts lead to the conclusion that we need more Leather projects in

our country.

2.4 Demand and Supply Gap

With rising GDP and a consumption pattern increasingly favoring leather products, the demand

for leather products in India is expected to grow at 3-4% per annum in the near future. The

export of leather products is growing in view of the increasing preference for products made of

leather.

The value output of this leather processing sector in the year 2014 is estimated at over Rs.

250,000 million per annum. Of this, export accounted for Rs. 134,920 millions in 2005-07 and

the remainder, by the domestic market


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A close look at the statistics of council for leather export reveals the fact that out of huge

international demand, India’s share is about 3%. The leather industry can provide up to 10 % of

the global leather demand but at present we are supplying only 3% of total global leather

requirement. This exhibits huge gap in the demand and supply. So there exist huge gap

between the global demand and the supplying capacity of India.

Table 2: India’s export share in the global market for 5 years

(In Million US$)

2010 2011 2012 2013 2014

Global import 19784.34 19893.53 21700.85 23151.85 20631.73

India's export 607.73 636.27 724.00 807.19 673.37

% Share of India 3.07% 3.20% 3.34% 3.49% 3.26%

2.5 Import vs. Indigenous Production

The tanning and finishing segment in India has benefited immensely from the large raw material

base available domestically. India possesses one of the largest livestock wealth in the world.

India has 53% of world Buffalo population, 15% of world cattle population and 17% of world

Goat population. In terms of sheep population, India ranks fifth in the world .Some of the

goat/sheep skins available in India are regarded as specialty products commanding a good

market. Abundance of traditional skills in tanning, finishing and manufacturing downstream

products and relatively low wage rates are the two other factors of comparative advantage for

India.

With tanning and finishing capacity for processing 1,192 million pieces of hides and skins per

annum spread over different parts of the country, the capability of India to sustain a much larger

industry with its raw material resource is evident. In order to augment the domestic raw material

availability, the Government of India has allowed duty free import of hides and skins from

anywhere in the world. India produces 2 billion sq. ft. of leather annually.


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Table 3: Indian livestock population

Livestock Population in India by Species

(In Million Numbers)

Species 1967 1972 1977 1982 1987 1992 1997 2002 2007 2011 2014

Cattle 155.3 158.7 175.6 176.2 178.3 180.0 192.5 199.7 204.6 198.9 185.2

Adult

Female

Cattle

54.4 47.3 51.0 51.8 53.4 54.6 59.2 62.1 64.4 64.4 64.5

Buffalo 43.4 44.9 51.2 53.0 57.4 62.0 69.8 76.0 84.2 89.9 97.9

Adult

Female

Buffalo

21.0 21.7 24.3 25.4 28.6 31.3 32.5 39.1 43.8 46.8 51.0

Total

Bovines 198.7 203.6 226.8 229.2 235.7 242.0 262.2 275.7 288.8 288.8 283.1

Sheep 39.1 39.3 40.2 42.4 40.0 41.0 48.8 45.7 50.8 57.5 61.5

Goat 47.2 55.4 60.9 64.6 67.5 75.6 95.3 110.2 115.3 122.7 124.4

Horses

and

Ponies

1.5 1.5 1.3 1.1 0.9 0.9 0.9 0.8 0.8 0.8 0.8

Camels 0.6 0.8 0.9 1.0 1.1 1.1 1.1 1.0 1.0 0.9 0.6

Pigs 4.4 4.9 5.2 5.0 6.9 7.6 10.1 10.6 12.8 13.3 13.5

Mules 0.1 0.0 0.1 0.1 0.1 0.1 0.1 0.2 0.2 0.2 0.2

Donkeys 1.3 1.1 1.1 1.1 1.0 1.0 1.0 1.0 1.0 0.9 0.7

Yak NC NC 0.0 0.0 0.0 0.1 0.1 0.0 0.1 0.1 0.1

Mithun NA NA NA NA NA NA NA NA 0.2 0.2 0.3

Total

Livestock 292.9 306.6 336.5 344.5 353.2 369.4 419.6 445.2 470.9 485.4 485.0

Poultry * 73.5 94.8 114.2 115.4 138.5 159.2 207.7 275.3 307.1 347.6 489.0

Dogs NC NC NC NC NC NC 18.5 18.0 21.8 25.5 29.0

NC : Not Collected; NA: Not Available * Includes Chicken, ducks, turkey & other birds

Source : Livestock Census 2003


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The main production centers for leather and leather products are the following:

Table 4: Leather cluster in India

Region Cities Cities/Cluster

,

South

Tamil Nadu Chennai, Ambur, Ranipet,

Vaniyambadi, Tiruchirappalli

Dindigul, Puducherry

Karnataka Bengaluru

Andhra Pradesh Hyderabad

North Delhi Delhi

Uttar Pradesh Agra, Noida, Kanpur, Unnao,

Banther

Punjab Chandigarh, Jalandhar

Haryana Ambala, Karnal, Panchkula,

Gurgaon, Sonepat, Faridabad

East West Bengal Kolkata

West Maharashtra Mumbai

Source: Council for leather exports

2.6 Export possibility.

Leather exports from India could touch $8.25 billion by 2019-20. More than double the $ 3.40 billion it exported in 2012-13 according to Council for Leather Exports (CLE). India's export of leather & leather products during April-February 2013-14 touched US$ 3071.01 mn as against US$ 2750.56 mn in the corresponding period last year, recording a growth of 11.65%. The Indian Leather industry has capacity of supplying high quality leather for the global market with over 2 billion sq. feet of leather produced annually and can fulfill 10 % of the global leather requirement but at present we are have only 3% share in the global market. The major markets for Indian finished leather are Hong Kong, Italy, Germany, Spain, China, Korea Rep, Indonesia, France and Portugal. Nearly 73.17% of India’s export of finished leather is to the above countries


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Table 5: Statement showing India’s Export of Finished Leather to different countries:

(Value in Million US$)

COUNTRY

APR-MAR % share

2011-12 2012-13 2013-14

Germany 26.16 32.72 4.27% 25.08%

USA 10.71 8.22 1.07% -23.25%

UK 2.69 2.71 0.35% 0.82%

Italy 121.00 133.46 17.40% 10.30%

France 12.07 9.73 1.27% -19.40%

Hong Kong 271.62 256.09 33.39% -5.72%

Spain 22.02 26.61 3.47% 20.84%

Russia 12.31 9.02 1.18% -26.69%

Netherlands 6.22 7.93 1.03% 27.54%

Australia 2.09 2.08 0.27% -0.65%

New Zealand 0.48 0.36 0.05% -25.30%

Denmark 0.47 1.30 0.17% 176.08%

Greece 0.65 0.77 0.10% 19.16%

Canada 1.19 1.92 0.25% 61.29%

Switzerland 0.04 0.24 0.03% 456.82%

Sweden 0.03 0.93 0.12% 3280.80%

South Africa 16.63 12.93 1.69% -22.24%

Austria 0.62 0.90 0.12% 44.46%

Belgium 0.54 0.51 0.07% -4.50%

Japan 5.27 5.74 0.75% 8.88%

Portugal 8.76 12.56 1.64% 43.37%

China 38.86 48.22 6.29% 24.08%

Ireland 0.01 0.00 0.00% -100.00%


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UAE 2.82 6.16 0.80% 118.50%

Indonesia 9.57 14.13 1.84% 47.72%

Korea Rep. 34.73 27.62 3.60% -20.48%

Finland 0.49 0.38 0.05% -23.52%

Saudi Arabia 0.23 0.03 0.00% -86.81%

Others 115.72 143.66 18.73% 24.15%

Total 724.00 766.93 100.00% 5.93%

Source: DGCIS

2.7 Domestic and Export Market.

The global leather market is on the upbeat owing to an upsurge in the demand for various kinds

of leather, leather garments, footwear and goods. The world over, leather fashion has caught

people's fancy again and most of the European buyers are now looking at India for Finished

Leather, Goat Leather, Cow Leather and Sheep Leather. In the domestic front, there is an

increasing demand for leather from the Indian automobile sector, especially for car seats, and

there is also a marked increase in demand from the indigenous furniture market as well.

Major export markets for Indian Finished Leather are Germany, USA, Italy, France, Hong Kong,

Spain, Russia, Netherlands, South Africa, Portugal, China, Indonesia and Korea Rep. These 13

countries account for a share of about 75% in India’s total finished leather export.

In 2014 value of output of this industrial sector in India was estimated at over Rs. 250,000

million per annum. Of this, export accounted for Rs. 134,920 millions in 2012-13 and the

remainder by the domestic market i.e. Rs 115,080 million per annum. The main products of

leather sold in the domestic market are footwear and assorted leather goods. It may be noted

that whereas the export figures are accurate, based on customs data, the domestic

consumption figures are estimates.


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Table 6: Performance of Indian leather industry (in S $)

2006 2008 2010 2012 2014

Total export 239.88 552.10 1752.38 2421.51 2982

Domestic

market

162.50 320.00 1145.00 2045.00 2600

Total

turnover

402.38 872.10 2897.38 4466.59 5582

Global

export

4000 16000 54350 75260 Na

India’s %in

global export

4 3.4 3.22 3.22

Table 7: Current export basket of Indian leather industry

(Value in Million US$

Product Apr-Feb Apr-Feb % Variation

2012-13 2013-14

Finished leather 543.29 644.67 18.66%

Leather footwear 1003.31 1155.37 15.16%

Footwear

components 216.36 207.86 -3.93%

Leather garments 336.95 360.36 6.95%

Leather goods 596.81 647.58 8.51%

Saddlery and harness 38.67 38.00 -1.73%

Non leather footwear 15.17 17.17 13.21%

Total 2750.56 3071.01 11.65%

Source: Members Reporting / Monthly Customs


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2.8 Employment generation due to project.

Total manpower requirement is about 30, In the recruitment process of the organization, local

people will be given preference.

2.8.1. Current employment pattern in Indian subcontinent

The leather industry as a whole employs around 2.5 million persons. The skilled and

semiskilled workers constitute nearly 50% of the total work force. Key production units are

located in Tamil Nadu, West Bengal, Uttar Pradesh, Punjab, Karnataka, Andhra Pradesh,

Haryana and Delhi. The industry uses primarily indigenous natural resources with little

dependence on imported resources. Indian leather sector includes a complex grid of artisans,

tiny, cottage, small and medium enterprises.

Table 8: Employment in various segments in leather industry

Industry segment Workforce (all over India)

million

Percentage of total

Flaying, curing, handling and

transport etc of raw material

(self-employment)

1.00 40%

Tanning& finishing(organized) 0.10 4%

Footwear & footwear components

(organized)

0.20 8%

Footwear & footwear components

(cottage ,household and rural

artisans in unorganized sector)

0.9 36%

Leather garments ,goods

etc(organized sector)

0.30 12%

Total 2.50 100%

Source: CLE

2.8.2. Regional and state wise distribution of human resource.

In this section we will look at the regional and state wise distribution of human resource

employment in the leather finishing Industry.


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Table 9: Regional distribution of human resource

Region Percentage breakup

South 47%

West 35%

North 10%

East 8%

total 100%

Source: Annual survey of industries and IMaCS analysis

Looking at the state wise employment of human resource in the leather product industry, the top five states where Haryana is one of them account for the 84% of total employment with Tamil Nadu account for the 42% of the workforce.

Table 10: Percentage of population employed state wise

Sl. No. State % of population

employed

1 Tamil Nadu 42%

2 Uttar Pradesh 26%

3 West Bengal 7%

4 Haryana 5%

5 Punjab 4%

6 Delhi 3%

7 Maharashtra 2%

8 Karnataka 25

9 Rajasthan 2%

10 Andhra Pradesh 1%

11 Others 6%

12 Total 100%

Source: Annual survey of industries and IMaCS analysis

The distribution of workforce across major functions in finished leather segment is provided

below,


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Table 11: Distribution of human resource across various functions in finished

leather segment

Function Percentage of people

Manufacturing/Production 80-90%

Sales and procurement 2-3%

Other support function 10-12%

Total 100%

Source: Primary research and IMaCS analysis Includes Finance, HR, Administration

3.0: PROJECT DESCRIPTION

3.1: Type of Project including Interlinked and Interdependent Projects, if any

There is no interlinked and /or interdependent project linked with it. No other allied activities and/

or services will be carried out with this project.

3.2: Location (map showing general location, specific location and project boundary &

project site layout) with coordinates.

The unit is situated at Khasra No. 1492/5, Chawandiya village, Malpura Tehsil, Tonk District,

Rajasthan.

Location on Google map with longitude & latitude is given below:


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Longitude: 260 27’ 06.54” N

Latitude: 750 27’ 09.37” E

Connectivity:

Railway Station : Makrana Junction at 3.3 Km

Airport : Jaipur International Airport – 52 Kms (62 Kms by Road)

State Highway : SH- 12 – 3 Km

Buffer zone with a radius 10 Km w.r.t. the Project site:

The key plan, Conceptual plot plan ant the plant layout has been attached at

the end page of the PFR.


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3.3: Details of alternate sites considered and the basis of selecting the proposed site

particularly the environment consideration gone into should be highlighted

No alternate site.

3.4: Size and Magnitude of the Operation

The operation has a capacity unit of 2500 pcs of skins/ hides per day.

3.5: Project description with process details: The proposed project at Tonk will be primarily indulged in the Leather processing. The

production of finished leather from raw skins/hides may broadly be divided in two processes viz.

i) Raw Skin/Hides to Wet Blue and ii) Wet Blue to Finished Leather.

Finishing operations of Raw skins/hides to wet blue comprises desalting, soaking, paint liming,

reliming, deliming, pickling and chrome tanning and the wet blue to Finished Leather comprises

Sammying and Shaving, Rechroming, Neutralization, Dyeing, Fat liquoring and Retaining.

However the operations vary depending upon the final product. A brief description of unit

processes adopted and chemical additives handled by the tannery are presented in the

following sections:

ii) RAW SKINS/HIDES TO WET BLUE :

Desalting: The wet cured skins are drawn from the bins. They are ripped open

and desalted either manually or mechanically. Dusted salts are collected

separately for reuse. Then the head and tail portions of the skin are trimmed to

remove the unwanted ends and weighted. Weight of each skin is noted.

Soaking: The main object of soaking is rehydration and cleaning of the skin to

remove salt, dirt, dung, blood, etc. The soaking operation is carried out in three

stages in paddles for 4- 6 hours. In each stage about 180% of water by weight of

the skin is used. At initial stage 0.1% preservative and 0.2% wetting agent are

added along with water. A sizeable percentage of salt goes into solution as

waste.

Paint Liming: Soaked skins are piled up on the floor with flesh side up and hair

side down for 3 to 4 hours for complete draining of water. Based on the soaked

weight 2.5% sodium sulphide and 0.2% wetting agent are dissolved in 20% water

at 60oC. Then 10% lime solution is added and mixed well to form paint like

substance.


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Reliming: The unhaired skins are taken for reliming operation in paddle with

10% lime, 0.25% NaOH and 180% water for 2 days. The paddle is run for 10

minutes every hour. On the third day fleshing operation is carried out by

machine. Then pelt weight is noted.

Deliming: The pelts are washed in the drums with 120% water for 10 minutes.

Then deliming operation is carried out in the drum with 120% water and 1%

ammonium chloride for 1 hour. The skins are degreased with 2-3% degreasing

agent. 1% bate is added and run for 1 hour by running the drum for one hour.

Then washed with 120% water for 10 min. The purpose of deliming is to destroy

the alkanity by removing lime chemically bound to collagen. As a result, the

plumping and permeability in the skin are achieved. At this stage the pH of the

skin is 7-8.

Pickling: Pickling is the process of deliming pelt with a mixed solution of

sulphuric acid and common salt to bring it to a state fit for tanning process.

Pickling is carried out in drum with 100% water, 10% salt, 1% sulphuric acid and

0.5% formic acid for 1-2 hrs. At this stage the pH of the skin is 3.0 – 3.5. Skins

are left overnight in the drum.

Chrome Tanning: Next day one half of the pickle liquor is drained out and 8%

basic chromium sulphate is added in the drum and drum is run for 3to 4 hours.

Then basification is carried out with 30% water, 1% sodium formate and 1%

sodium formate and 1% sodium bicarbonate by adding the solution in 10 or 15

installments in 10 – 15 min. frequency. After completing the addition, pH of the

skin is checked (3.8 to 4.0) and again run for 1 hour. The contents are left

overnight in the drum. Next day 0.1% preservative and 100% water are added

and run for 10 min. Then skins are removed from drum and piled.

ii) WET BLUE TO FINISH LEATHER:

Various unit processes are Sammying and Shaving, Rechroming, Neutralization,

Dyeing, Fat liquoring and Retanning

Sammying and Shaving: The wet blue skins are sammed (dewatering) in

sammying machine. The sammed skins are shaved to required thickness in

the shaving machine. Based on the shaved weight, water and chemicals are

used for subsequent processes.

Rechroming: The shaven skins are washed with water in 10 min. The basic

chromium sulphate (5 °A) in water (54%) is added. The tanned wet blue

leather is tumbled for 1 hour. In the next hour, sodium formate (1%) and


19

sodium bicarbonate (1%) are added to the drums. The rechromed wet

blues are piled on the horse for overnight.

Neutralization: The objective of neutralization is to remove the excessive

acid present on the leather and also to condition leather for subsequent

dyeing and fat liquoring operation. The rechromed wet blues are washed

in drum with water (120%) for 10 min. The -washed wet blue is completely

neutralized at pH 4.8 - 5.2. This is affected with addition of water (120%) in

the presence of sodium formate (1%) and sodium bicarbonate (1 %).

Dyeing, Fat Liquoring and Retanning: The neutralized skins are washed

with water (120%) for about 10 min to make them fit for dyeing. Hot water is

used. Water (120%) at 60°C and appropriate dye (4%) are mixed together

and added to the chromed tanned skins and drummed for 1 hour.

Subsequently fat liquor (12%) is added to improve the softness, flexibility and

strength. Dyes and fat liquor are fixed by using the 2 % formic acid for 20 min

then retanning is carried out with 10 % synthetic tanning to improve the

fullness quality of the leather and again washed with water (120%) and piled

on the horse

The process flow chart of showing all the manufacturing process i.e. raw skins/hides to wet blue and from Wet blue to Finished leather has been shown below:


20

PROCESS FLOW DIAGRAM of WET BLUE from RAW SKINS/ HIDES

TRIMMING WEIGHING UNHAIRING FLESHING WEIGHING WASHING BATING DECREASING WASHING PRESERVATIVE TREATMENT

RAW SKINS/ HIDES DESALTING

SOAKING

PAINT LIMING

RELIMING

DELIMING

PICKLING

CHROME TANNING

WET BLUE


21

Process Flow Diagram of Manufacturing of FINISHED LEATHER from WET BLUE

WET BLUE

WEIGHING

WASHING

WASHING

WASHING

FIXING, RINSING

PILING, SETTING, DRYING

STAKING, TOGGLING, TRIMMING

BUFFING, DEDUSTING

SAMMYING & SHAVING

RECHROMING

NEUTRALISATION

RETAINING

DYEING

FAT LIQUORING

FINISHING


22

3.6: Raw material required: The raw material requirements are as follows:

Table 12: Daily raw material Requirement- Raw skins/hides to wet blue

S. NO Raw Material Qty. per ton of wet salted skin

1 Bactericade 2.5 kg

2 Sodium Carbonate (Soda ash) 9.5 kg

3 Hydrated lime 106 kg

4 Sodium Sulphide 43 kg

5 Lactic acid 4.3 kg

6 Bate 8.7 kg

7 Ammonium chloride 1.1 kg

8 Sodium chloride 51.9 kg

9 Sulphuric acid 18.2 kg

10 Basic Chronium Sulphate (BCS) 103.8 kg

11 Syntan ‘A’ 21.6 kg

12 Sodium formate 7.7 kg

13 Syntan ‘B’ 35.5 kg

Total

413.8 kg

Table 13: Daily raw material requirements – Wet blue to Finished Leather

S. NO Particulars QTY(kg/day)

1 Wet blue hides and skins , semi-finished leather

2500 raw skins/hides per day

2 Fat Liquor 220.00

3 Pigments 60.00

4 Binders 125.00

5 Feel Modifiers 3.00

6 Feelers 10.00

7 Lacquer 50.00

8 Dyes 100.00


23

3.7: Availability of raw water About 93 kld of raw water is required daily and its main source is Ground water. 3.7.1: Energy requirements: The total power requirement for proposed plant and machinery will be approximately 80 KW .It

will be taken from grid supply. For backup, 20 kVA DG set will be used.

3.8: Waste water generation:

The waste water will be generated from the dyeing and fat liquoring operation. About 92 kld of

waste water will be generated daily. 1 kld water shall be used for domestic purpose from

process.

Table 14: Water inputs for tannery operation

Unit process Cum/Ton of wet salted skin

Cum/day

Soaking Prewash Process water Rinse water

2.58 1.14 1.26

7.74 3.42 3.78

Unhairing /Liming Process water Rinse water Soak water(Reliming) Rinse water

1.14 6.6 1.14

1.26

3.42 19.8 3.42 3.78

Deliming /Bating

Pre rinse water Process water

Rinse water

2.184 0.522 0.72

6.552 1.566 2.16

Pickling Brine water Acid dilution water

0.132 0.042

0.396 0.126

Chrome Tanning Process water Rinsing

0.306 2.34

0.918 7.02

Pressing

0.108 0.324

Wet blue to Finish Leather

9.0 27.0

Total 30.474 91.422 say 92.000


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3.8.1: Solid and hazardous waste generation: 150 Mt/month solid wastes will be generated from ETP sludge which is hazardous and shall be

disposed to authorize TSDF.

3.8.2: Waste management at the plant: Industrial waste generated at project site will be segregated and the recyclable waste will be

sold to authorized vendors while the other waste will be sent to the designated landfill site.

The salt dust from hand shaking is proposed to be reused for wet salting the raw skins/hides.

Hairs and wool from unhairing process can be sold to carpet manufactures. Fleshing’s can be

sold to glue manufactures. Trimmings are taken by the small shoemakers. In this way all the

solid waste generated during the process is utilized for manufacturing of different market

products.

The solid waste from ETP, after drying on sludge drying bed shall be sent to approve landfill

site.

.

However, the biological solid waste i.e. Fleshing’s, Trimmings & Bio-sludge from ETP are

proposed to be pyrolysed in a pyrolytic gassifier where the biological waste generates hot

producer gas (CO + H2) and the residue a high quality activated carbon having good

commercial value.

During operation phase the generated waste of shaved leather will be sold to the concerned

vendors like card board manufacturer. Chrome shall be recovered and reused in the process.

The sludge generated from the ETP of the plant will be dried and stored in leak proof storage

pits within the factory .Hazardous waste generated at the project site will be reused in the

Hazardous Chrome recovery plant which is at Udaipur Rajasthan.

Used batteries from DG sets will be sold to concerned vendors.

Waste water generated in the leather finishing unit is treated through biological process then

secondary physico-chemical process followed by tertiary treatment of filtration &absorption with

chlorination. This treated effluent will confirm SPCB norms and finally it will be recycled partially

to the process and partially for green belt irrigation.


25

Table 15: Average characteristic of effluent

S.

No. Parameter

Stream 1 Stream 2 Stream 3 Domestic Effluent

Soaking & Pickling

Unhairing, Liming, Reliming,

Deliming & Bating

Chrome Tanning &

Press Liquor

1. pH 4.5 to 5.5 10.5 to 11.5 8.5 to 9.5 6.5 to 8.0

2. BOD 1671 3125 968 450

3. COD 4326 7813 2419 750

4. TSS 3408 757 475 650

5. Total Solids 22500 to

26500

4450 to

6200

2670 to

3670

2450 to

2700

6. Sulphides - 692 - 55

7. Total Chromium - - 280 -

Table 16: RPCB standards for finally treated effluent

Parameter Standards

pH 6.0 - 9.0

Suspended Solids 200

BOD (3 days at 270 C) 100

Chlorides 200

Source: www.rpcb.rajasthan.gov.in - Schedule 1 (Rule 3)

http://www.rpcb.rajasthan.gov.in/


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4.0: Site Analysis

4.1: Connectivity:

I. Railways: Nearest railway station is Jaipur located 62 kms (75 kms by road).

II. Roadways bus: State highway (SH-12) is 3 km away from industrial area.

III. Airport: Nearest airport is Jaipur International Airport , Jaipur -52 km (62 kms by road).

4.2: Land form, Land use and land ownership:

The proponent Mr. Rajesh Nagora owns the plot Village Chawandiya, Khasra No. 1492/5 Tehsil Malpura District Tonk Rajasthan. Land is vacant with no structure over it. The proposed leather processing unit will be commissioned there. Land is agricultural land and conversion to Industrial use is in process.

4.3: Topography (along with map):

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27

The District Tonk is situated on National Highway No. 12 at distance of 100 kms from Jaipur. It

is located at 26.16330 N and 75.78690 E. It is bounded in the north by Jaipur district, in the east

by Swai Madhopur districts and in the west by the Ajmer district. The total geographical area of

Tonk district is 7.16 lac hectares, but for land utilization purpose the area is reported to be 7.19

lacs hectares in 2002-03 as per land record papers. Tonk district occupies 20th position among

the existing 33 districts of the state; so far its area is concerned. The total area of the District is

7194 sq kms. It is surrounded by 5 districts i.e. in north Jaipur, in South Bundi & Bhilwara, in

East Ajmer and in West Sawai Madhopur districts. Average rain fall is 62 mm. Agriculture and

animal husbandry is the main occupation of the people.

4.4: PHYSIOGRAPHY

Tonk district has the shape of kite or rhombus with its eastern and western sides bending

somewhat inward and the south-eastern portion protruding between Sawai Madhopur and Bundi

districts. The district is flat at a general elevation of about 214.32 meters above sea level with

rocky but scrubby hills. The soils are fertile but somewhat sandy and the subsoil water too is

limited. The distinguishing feature of Tonk district is the Aravali system, which starts from

Bhilwara district and running along the boundaries of Bhilwara and Bundi districts, enters Tonk

district in the south near Rajkot and countinues in a north eastern direction until it leaves the

district near Banetha, A second chain lies in Tehsil Todaraisingh between the head quarter of

the Tehsil Rajmahal where the Banas river flow through this hill. Another important hill is near

Malpura and a small hillock near the border of Tehsil Sarwar of district Ajmer.

The rivers and streams of this district belong to the Banas system, which is more or less non

perennial. During Monson and for a few months thereafter new streams appear and retain water

in hollows at some places. Though is not of much use direct irrigation but help irrigation by

raising the sub-soil water level of wells. Banas River enters Tonk district at Negdia in Deoli

Tehsil and from this place it takes serpentine course, diving the district in roughly two third to its

west and north and one third to its east and south. Its total length is 400 Kms. It is fordable

during winter and summer but during the rains becomes a swift and angry torrent. Negdia ,

Bisalpur, Rajmahal, Deopura ,Mahendwas and Shopuri are the important villages on the bank of

this river . Manshi the principal tributary of Banas travels along the borders of Jaipur and Tonk

district between the Tehsils of Malpura and Phagi until it turns south to join the Banas at Galod

village. The Sohadra is another important river as it feeds the Tordi sagar Tank, the biggest

irrigation tank in Rajasthan. It joins Mashi near village Dundia and thereafter meets, Banas

River near village Galod. Other small rivers are khari, Daian, Bandi and Galwa which join Banas

and Mashi River at Negdia, Bisalpur, Chaturpura and Chouth-ka-Barwara respectively.

There is no natural lake in the in the district. However, several tanks formed by harnessing the

feeders of the Mashi and the Banas are available. The biggest of such tanks is Tordi sagar in

Tehsil Malpura irrigation an area of more than 5 thousands hectares, followed by bhairon sagar

irrigating an area of about 1295 hectares. Others are very small tanks which are individually a

very small area.


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BISALPUR DAM 17 Km. from Deoli. The water storage capacity of this dam is 115.50 meter.

Besides providing water to Jaipur, Ajmer, Nasirabad, Beawar, Kishangarh etc. This dam will

provide irrigation facilities to Deoli, Tonk, & Uniara Tehsils. Due to dam subsoil water level also

rise in Deoli, Tonk, Malpura & Toda Raisingh which will result in increasing the Agricultural

produce.

4.5: SOIL CLASSIFICATION:

The type of soil and vegetation vary with the availability of water. Interestingly some evidence

testifies that Rajasthan was once filled with lush green vegetation and had numerous streamlets

running through the land. But those days have elapsed and presently a major portion of

Rajasthan is desiccated. This is due to the continuous soil erosion and the recurrence of

droughts.

The ground water level is very low due to over-exploitation and the limited, erratic rainfall

averaging 360mm per year allows the growth of scanty, shrub -like thorny vegetation. Grasses

and species like P. cineraria grow in the regions where little water is available. Water level is

available only at a depth of 30 to 61m. However food crops are grown in the plains that are

drained by the rivers and streamlets owing to the alluvial and clay soil deposits. The hilly tracts

of the Aravali are characterized by the black, lava soils that sustain the growth of cotton and

sugarcane.

The types of soil available in Rajasthan are mostly sandy, saline, alkaline and chalky

(calcareous). Clay, loamy, black lava soil and nitrogenous soils are also found.

The following are the Soil and Vegetation belts in Rajasthan that are classified owing to the

topographical divisions of the state-

1. Western Desert Regions

2. Irrigated North western plain

3. Semi - Arid Eastern Plains

4. Flood Prone Eastern Plains

5. The Aravali Hills & Sub-humid Southern Plains

4.6: CLIMATE AND RAINFALL:

The climate of Tonk district is generally dry in short south-west monsoon season which starts

from the month of June and continues till the middle of September to November is the post-

monsoon season commences and between December and February is winter. In March,

summer commences and extends till middle of June. A metrological observatory was

established very late at Tonk and according to the observation. In summers the temperature

goes as high as 45 degree Celsius while in winters it remain at 22 degrees Celsius. After

http://www.mapsofindia.com/rajasthan/


29

monsoon, the temperature falls but the relief 6 heat is not marked because of the added

discomfort from the increase in humidity. In summer months humidity remains relatively very low

as compared to average humidity of 59.30 C. The average annual rainfall in the whole of the

district is 61.36 cm, but is generally decrease from the south-east to north–west. About 93% of

annual is during June to September, of which July and August are the rainiest months. The

rainfall data is available from Six station, which show the large variation in rainfall from year.

4.7: AVAILABILITY OF MINERALS:

Aravali system and the Deoli system are main geological formation in the region. Aravali

system running from north east to south west and is made of schist’s lying over reddish, jointed

and altered quartzite’s at Bonli, highly crystalline withlarge Pink garnets at Duni and alteration of

Mica schist’s and thin rusty quartzite’s runs through Tonk city . Several detached hills between

Tonk and Jaipur belong to Deoli system. Besides, Newai, Renwal and Chaksu there is a large

hill of compact quartzite, resembling in colour and quality with the Alwar series. Garnites ate the

important intrusive rocks of igneous origin in the Aravali system of this area and the variety

available is genesis granite and coarsely prophylactic. Tonk district endowed with a number of

non-metallic of which garnet, Silica sand, quartz and soap are found in abundance. Besides

theses minerals, felspar, mica and corundum are also found but in small quantities. In addition

to these major minerals, the minor minerals viz. bricks clay masonry stone, patti-Katla etc. are

also mined in Tonk district. The details as some of the minerals are given below-

(a) GARNET Garnet is found near village Rajmahal Gaonari, Devkhera and Kushalpura

of Tehsil Deoli. Occurrence of garnet at Rajmahal is of very good quantity garnets are used in cheaper variety of gemstones and abrasives. Garnet is used as semi-precious stones and also as abrasives for garnet papers, garnet cloth, gems, beads etc. production of garnet (Gem & Abrasive).

(b) GRANITE Survey permits were also issued to explore the area to know more

deposit of the minerals and as a results deposit of granite have been found near village Deve and Rajpura of Tehsil Malpura.

(c) QUARTZ & FELSPAR Felspar and quartz are generally used in the manufacture of glass,

pottery, ceramics enamels porcelain and glassware. (d) SILICA SAND Silica sand at present is missed near village Bartha, Noheta, Gangapura,

Behad of Tehsil Newai of the indicated reserves of 36.8 million tones at Newai 3.68 million tones are expected to be fried variety. Estimated deposit are Siwad Silica sand during 2002-03 in Tonk district was 11551 tones, providing employment for an average number of 125 persons.


30

(e) CORUNDUM It is found in village Jawai of Tehsil Tonk and the production of corundum

during 193-94 was about 0.60 tones. The average of person employed was 6.

(f) BUILDING STONE Building stone is found in abundance at places, Saraj Modiya, Chipoli,

Baheer and Karola in Tehsil Tonk. 384300 tones excavated during 2008-09 providing employment to 119 persons. It is generally used building purpose.

(g) PATTI-KATLA Amli of Tehsil Uniyara and Toda Raising, Ladpura, Thedoli of Toda

Raising Tehsil and Bislpur of Deoli Tehsil are these important places where patti is found. Besides these minerals, Kankar, Bajari, Bricks earth etc. are also found in Tonk district.

4.8: Social Infrastructure: The present population of the Chawandiya village is 2663. (Source: State Census 2011).

5.0: Planning Brief

5.1: Planning Concept: The proponent has wide experience in leather processing industry

and owns a large piece of land in Tonk district. The land at present is declared as agricultural

land however due to scarcity of water it is not being utilized for this purpose. In order to utilize

the present land and improve the social status of the area, the proponent proposes to put

leather processing industry.

5.2: Population Projection: The estimated population of Chawandiya village is 2663.

(Source: State Census 2011)

5.3: Land use Planning: At present it is agriculture land and request for conversion to

industrial use is in progress.

5.4: Assessment of Infrastructure Demand: No addition infrastructure shall be required as

total number of employees shall be 30. Maximum employment shall be given to local people.

Hardly 5 to 10 trained persons shall be brought from other district.

5.5: Amenities/Facilities: Increase of 5 to 10 trained workers in the area will not have any

impact on amenities/facilities.


31

6.0 Proposed Infrastructure 6.1: Industrial Area: The processing Area of the proposed plant is 19000 sq.mt.

6.2: Residential Area: As only local person will be given employment, no residential

area/housing is proposed. Increase of 5 to 10 trained workers will have negligible effect on the

infrastructure.

6.3: Green Belt: It is proposed to provide the green area up to 33%.

6.4: Social Infrastructure: Increase of 5 to 10 trained workers will have negligible effect on

the infrastructure.

6.5: Connectivity:

I. Railways: Nearest railway station is Jaipur located 62 kms (75kms by road).

II. Roadways bus: State highway (SH-12) is 3 km away from industrial area.

III. Airport: Nearest airport is Jaipur International Airport , Jaipur -52 km (62kms by

road).

6.6: Drinking Water Management: About 93 kld of raw water is required daily and its main

source is Ground water.

6.7: Sewerage System: Soak pit and septic tank arrangement shall be done.

6.8: Industrial Waste Management: Effluent treatment plant is proposed to be provided.

6.9: Solid Waste Management: Industrial waste generated at project site will be segregated

and the recyclable waste will be sold to authorized vendors while the other waste will be sent to

the designated landfill site.

The salt dust from hand shaking is proposed to be reused for wet salting the raw skins/hides.

Hairs and wool from unhairing process can be sold to carpet manufactures. Fleshing’s can be

sold to glue manufactures. Trimmings are taken by the small shoemakers. In this way all the

solid waste generated during the process is utilized for manufacturing of different market

products.

The solid waste from ETP, after drying on sludge drying bed shall be sent to approve landfill

site.

6.10: Power Requirement & Supply/source: The total power requirement for proposed plant

and machinery will be approximately 80 KW .It will be taken from grid supply. For backup, 20

kVA DG set will be used.

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32

7.1: Rehabilitation and Resettlement (R&R) Plan

Land is empty and no rehabilitation is there and there will be increase of 5 to 10 trained workers

in the area. No rehabilitation and resettlement plan is applicable.

8.1: Project schedule and cost estimates

COST OF THE PROJECT

Sl. No. Particulars Amount (Rs.)

1. Building 50 lakhs

2. Plant and Machinery 1.5 Crore

3. Environment Management Cost covering ETP ,Green Belt Development etc.

30 lakhs

4. Total 2.30 Crore

8.2: MEANS OF FINANCE:

Personal as prop Contribution + Term Loan: Rs. 2.30 Crore

9.1: Analysis of Proposal (Final Recommendations)

Utilization of the barren land shall be done. Employment to local people will be given, thus the

socio- economic status of society will be improved.


33

Key Plan of the Project Site


34

Conceptual Plot Plan


35

Plant Layout

Documents

PRE- FEASIBILITY REPORT - environmentclearance.nic.inenvironmentclearance.nic.in/.../0...PrefeasibilityReport(PFR)File.pdf · global trade. India possesses one ... country so as to