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PFR of M/s. Welmica Laminates
Page 1 of 16
PRE FEASIBILITY REPORT
FOR OBTAINING ENVIRONMENTAL CLEARANCE
For the Proposed project of Resins and
Laminated Sheets Manufacturing Unit of
M/s. Welmica Laminates
Survey No. 98, Opp 66 KV Substation, Before Millennium tiles,
Old Rafaleshwar road, At Village: Bhadiyad,
Taluka & District: Morbi 363642, Gujarat.
Contact No.: 7802987670
Email: [email protected]
Prepared By:
T. R. ASSOCIATES
C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump,
S. G. Highway, Ahmedabad
Contact No.: 98253 71099
Email: [email protected]
JUNE 2017
PFR of M/s. Welmica Laminates
Page 2 of 16
1. Introduction
M/s. Welmica Laminates Pvt. Ltd. is a partnership firm proposing to set up a medium
scale Resin and Laminated Sheet Manufacturing unit at Survey No.: 98, Opp 66 KV
Substation, Before Millenium tiles, Old Rafaleshwar road, At Village: Bhadiyad, Taluka &
District : Morbi 363642, Gujarat. Project Proponent and their back ground
Company is promoted by its partner. Detail of partners is as given below.
Sr.
No. Name of the Partner Background
1. Mr. Ravi Dayalal Adroja
Chartered finance analyst, M.Sc. in
Finance, M.Com, Director of Calypso
Ceramics Pvt. Ltd.
2. Mr. Nilesh Dayalal Adroja
M.E (Civil) & Government Contractor in
AA class category. Director of Calypso
Ceramics Pvt. Ltd.
2. Brief description of nature of the project:
M/s. Welmica laminates Pvt. Ltd. is proposing to manufacture Laminated sheet, Phenol
formaldehyde resin and melamine formaldehyde resin at Survey No.: 98, Opp 66 KV
Substation, Before Millenium tiles, Old Rafaleshwar road, At Village: Bhadiyad, Taluka &
District: Morbi 363642, Gujarat. Now they want to propose this production capacity due to
higher market demand. This is kind information to you that resin will be used for
manufacturing of laminate sheets as well as sale purpose.
M/s. Welmica Laminates Pvt. Ltd is willing to manufacture Melamine Formaldehyde
Resin, Phenol Formaldehyde Resin & Urea Formaldehyde Resin as well as Laminated
Sheets. The products will be used for captive consumption as well as for sale purpose.
Manufacturing of Laminated sheets does not require environmental Clearance from the
ministry of Environment Forest and Climate change, New Delhi. But phenol
formaldehyde resin, melamine formaldehyde resin and urea formaldehyde resin
manufacturing process falls into 5(f) category (Synthetic organic chemicals) of the EIA
notification 2006 and their amendments required to obtain Environmental clearance from
the MOEF&CC. In order to obtain EC for manufacturing of laminated sheets, Phenol
formaldehyde resin, Melamine formaldehyde resin & Urea formaldehyde resin, M/s. T. R.
Associates has been appointed to carry out EIA/EMP studies for obtaining Environmental
Clearance.
As per amendment in EIA notification dated on 15/01/17, industry have water
consumption 33.7 KLD, formaldehyde (37%) storage capacity is greater than 5 Kl, and fuel
PFR of M/s. Welmica Laminates
Page 3 of 16
consumption proposed is 4.7 MT/day. Due to above said condition; company will have to
obtain EC for Proposed capacity from the MoEFCC, New Delhi.
The total land area of company is 13,456 m2 out of which 4470 m2 (33 % of total land) area
will be used for greenbelt development. The total cost of the project proposed is 1.3
Crores. Total budget allocation towards Environmental Management Facilities will be
approx. Rs. 30 Lacs. Total 100 persons will be employed including skilled persons,
unskilled persons and office staff.
Need for the project and its importance to the country and or region:
Resins are used predominantly in the wood based product manufacturing industry as
adhesives. Growth of the resin market is strongly correlated to construction/remodeling
activity (which accounts for over 50% of consumption), and to a lesser degree, to the
automotive industry.
The proposed products like Resins (Melamine Formaldehyde, Urea Formaldehyde and
Phenol Formaldehyde Resins) mainly used to manufacture Laminated Sheets. These
sheets have good market demand to develop the home and office for furniture.
Demand-Supply Gap:
Laminated sheets are becoming very popular particularly plastics, paper & wooden.
Wooden laminates are highly popular.
Laminations are used for industrial purposes as well as decorative purposes. Industrial
lamination is used mainly for packaging materials. To looking its uses we can say that
there is a good scope for any new entrants.
Indian market for laminates is mainly driven by increasing demand from housing market.
The demand has increased due to growing significance of new construction industry.
Laminates have become an indispensable part of big and evolving markets. The increased
demand in these markets triggers the demand in the laminates market. Apart from this,
increasing urban population, rising per capita income and a gradual shift towards non-
food industry are other key factors driving the growth of laminates industry in India. The
combined worth of the plywood and laminates industry is believed to be to the tune of
Rs.21,000 crore per year, with laminates accounting for a share of approximately Rs.3300
crore, and the industry is expected to keep on growing further in the years to come.
Global demand for decorative laminates is expected to rise 5.6 per cent per year to 10.7
billion square meters in 2018, valued at $40.8 billion. Demand will benefit from expected
increases in the manufacture of products such as cabinets, ready-to-assemble (RTA)
PFR of M/s. Welmica Laminates
Page 4 of 16
furniture, and flooring, which are often made from laminated engineered wood. Gains
will also be driven by increased market penetration at the expense of other surfacing
materials (wood veneer and paint) due to cost and performance benefits. Laminates will
benefit from the continued improvement in textures and in printing techniques that create
advanced graphics rivalling the aesthetics of alternative materials.
Imports v/s Indigenous production:
Indian market is open and big that is why every kind of import is booming. Indian
plywood and panel trade has become global place as the consumption of different
imported ply panels are on the rise. Unlike before Indians are now welcomed by plywood
manufacturer of China. Earlier India was a self-dependent country for commercial or high
quality plywood, but sharp drop in domestic manufacturing output has resulted in
material sourcing from countries like Burma, Malaysia, Indonesia, China, Vietnam etc.
Now Indian plywood market is somehow curtailed or competed by incoming panel
products from China. Be it film face, decorative, laminate or MR plywood everything is
now being imported partially or more and is sold. Indian industrialist must understand
the fact that it’s no more a regional shift, it is a global shift. Indian technology should be
upgraded and updated as per the international standards.
The working environment in India has changed tremendously. Earlier the trade fairs were
hardly participated by foreign timber, lumber and plywood manufacturing companies
where as now it is flooded with global suppliers.
Export Possibility:
There is market of Resins as well apart from laminated sheets. Resins are intermediate
products for manufacturing of Laminated Sheets. Resins are quite expensive for export, as
compared to the export of laminated sheets. So we have only local market for sale for
resins.
Employment Generation (Direct and Indirect) due to the project:
This project has already provided direct employment to 100 persons whereas it will
provide employment to many others indirectly. Plywood and Laminated sheet
manufacturing industries provide employment to large number of people.
3. Project Description
(i) Type of project including interlinked and interdependent projects:
Resins including P.F. resin, M.F. resin & U.F. resin are used in production of laminated
sheets and plywood. So plywood industries, laminated sheets industries will be
interdependent on resin industries.
PFR of M/s. Welmica Laminates
Page 5 of 16
(ii) Location
Proposed project is to be located at Survey No.: 98, Opp 66 KV Substation, Before
Millennium tiles, Old Rafaleshwar road, At Village: Bhadiyad, Taluka & District: Morbi
363642, Gujarat.
Geographic Coordinates - Latitude: 22°47'42.45"N and Longitude: 70°52'17.96"E
Google image showing proposed project site is given below;
Salient features in the surroundings area of the proposed site within 10 km radius are as
follows:
Sr. No. Important Features Description
1 Location Survey No.: 98, Opp 66 KV Substation, Before
Millennium tiles, Old Rafaleshwar road, At Village:
Bhadiyad, Taluka & District : Morbi 363642, Gujarat
2 GPS Coordinates Latitude: 22°47'42.45"N & Longitude: 70°52'17.96"E
3 Temperature Range 15˚C to 43˚C
4 Mean Sea Level 57 m
5 Annual Rain Fall 500 - 600 mm
6 Nearest Railway
Station
Nazarbaug Railway Station – 2.70 km in NW
direction
7 Nearest Airport Rajkot Airport – 53.6 km in South direction
8 Nearest Town Lakhdirpur– 3 km in NNE direction
9 Nearest Village Bhadiyad – 1.1 km in NW direction
10 Nearest National
Highway
NH 8A – 1.3 km in NE direction
11 Nearest River/Water
body
Macchu River – 1.8 km in West direction
12 National
Parks/Sanctuary
Paneli Reserved Forest – 4 km East. Open Jungle – 5
km – SSE direction. Wild Ass Sanctuary (Ghudkhar
Abhyaran) is approx. 52.85 km away in NE direction
from project site.
PFR of M/s. Welmica Laminates
Page 6 of 16
Google Image of Proposed Location:
Sr. No. Latitude Longitude
Project Site 22°47'42.45"N 70°52'17.96"E
(iii) Alternative Sites considered
No other sites were selected.
(iv) Size or magnitude of operation
List of Products
Sr. No.
Name of Product Proposed Quantity
(MT/Month)
1 Phenol Formaldehyde Resin 700
2 Melamine Formaldehyde Resin 400
3 Urea Formaldehyde Resin 400
4 Laminated Sheets 2,50,000 Sheets/Month Note: Resins will be used for captive consumption as well as sell purpose.
(v) Project description with process details
Details of manufacturing process are given in Annexure- 4 of Form- 1.
PFR of M/s. Welmica Laminates
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(vi) Raw material required along with estimated quantity.
RAW MATERIAL CALCULATIONS
Sr. No.
Name of the product Name of the raw
material
Proposed Quantity
(MT/Month)
1 Phenol
Formaldehyde resin
Phenol 323
Formaldehyde (37%) 418
Caustic 3.7
2 Melamine
Formaldehyde resin
Melamine 160
Formaldehyde (37%) 238
Caustic 2
3 Urea Formaldehyde
resin
Urea 160
Formaldehyde (37%) 236
Caustic 2
Acetic Acid 2
4 Laminated Sheets (Sheets/Month)
Kraft paper 360
Design Paper 56.3
Resin 675
Methanol 33.8
(vii) Resource optimization/ recycling and reuse envisaged in the project, if any, should
be briefly outlined.
Latest Process technologies are adopted as available in market with optimum resources
requirement with highest yield and less waste and pollution generation. Treated industrial
effluent will be reused in cooling and other possible activities. In addition to this, all the
feasible cleaner production technologies will be adopted.
(viii) Availability of water its source, Energy/ power requirement and source should be
given.
Energy/power requirement will be 200 kVA which will be procured through Paschim
Gujarat Vij Company Limited.
The total water requirement will be 33.7 kl/day which will be fulfilled by own borewell.
(ix) Quantity of wastes to be generated (liquid and solid) and scheme for their
Management/disposal
Hazardous Waste Generation and Disposal
Details of hazardous waste generation and its disposal are given in Annexure- 5 of
Form- 1.
PFR of M/s. Welmica Laminates
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Wastewater Generation and Disposal Facility
Details of domestic as well as industrial wastewater generation and its disposal are
given in Annexure- 7 of Form- 1.
(x) Schematic representations of the feasibility drawing which give information of
EIA purpose
1. Site Analysis
(i) Connectivity
Nearest railway station Nazarbaug 2.70 km in NW
Nearest national highway NH 8A 1.3 km in NE
Nearest airport Rajkot 53.6 km in South
(ii) Land Form, Land use and Land ownership.
Proposed project site has already been procured by proponent to obtain the
Environmental Clearance certificate.
(iii) Existing Land Use Pattern
PFR of M/s. Welmica Laminates
Page 9 of 16
(iv) Topography Map
The link to the topographical map is here.
PFR of M/s. Welmica Laminates
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(v) Existing Infrastructure
(1) Nearest railway station: Nazarbaug railway station is 2.7 km away from the
project site in the NW direction.
(2) Nearest highway: National Highway 8A is 1.3 km away from the project site in
NE direction.
(3) Nearest airport: Rajkot Airport is 53.6 km from the project site in the South
direction.
(4) Power: Total 200 kVA will be procured from Paschim Gujarat Vij Company
Limited.
(5) Water: Source of the water will be Borewell.
(6) Basic amenities: Good road connectivity with state and national highway.
(vi) Soil classification of Morbi District
The soils of Morbi district are of clayey loam to clay type. They are moderately deep to
deep and vary in colour from very dark brown to very dark greyish brown and reddish
brown. The EC of the soils is generally less than 1.0 mmhos/cm and cation exchange
capacity is between 40 and 60 me/100 gm of soil.
(vii) Climate data from secondary source
General climate of the district is sub-tropical and is characterized by three well-defined
seasons, i.e. summer - from April to June, monsoon - from July to September, and winter -
from October to March.
Temperature
Highest temperature is 43 to 46 degree centigrade in summer and lowest temperature
comes down to 7 to 15 degree in winter season.
Humidity
The relative humidity is generally over 75 % in the south west monsoon. In the rest of the
year the air is comparatively dry, especially in the afternoons. During the period of
November to May the relative humidity varies between 40% and 50%.
Wind
In the south west monsoon season, the wind direction is towards west and south west. In
the post monsoon/cold season, wind blow from the north-north east direction. In summer
seasons the direction of the wind is mainly between north west and south west. The wind
PFR of M/s. Welmica Laminates
Page 12 of 16
speed gradually increases from February and reaches the peak in July when the south
west monsoon is most active. It again decreases from August and becomes low.
Rainfall
More than 90% of the rainfall occurs during the monsoon. Rainfall during the winter and
summer months is negligible. The average annual rainfall of the district is 489 mm and in
the year 2016 it is 366 mm only which is around 75 % of the average annual rainfall.
(viii) Social Infrastructure available.
Industrialisation/Entrepreneurship:
On account of availability in huge quantity and suitable climatic condition in the
district has induced the growth of Ceramic industries hugely in Morbi taluka. At
present more than 700 enterprises in around Morbi are Manufacturing Ceramic
Tiles, Floor Tiles, Luster Wall Tiles, Glazed Wall Tiles, Vitrified Tiles, Laminated
sheets, Porcelain Tiles, 2D, 4 D Tiles, Spartek, Roofing and Mosaic Tiles. More than
100 enterprises are manufacturing specialized Vitrified Tiles which has great
demand in the region as well as all over the country. It is also hub of digital and
other types of watch and clocks manufacturing enterprises such as Ajanta, Samay,
Sonera and Sonam which are World leaders in this sector. After 2002, Paper
industries have grown rapidly as ancillary sector due to need of high quality craft
grade papers very suitable for packing of goods. There are number of export-
import houses working in the district. Besides, many enterprises deals in consumer
durables and engineering goods. Tourism also fetches significant income to the
economy of the district as many visitors visit the district having historic values.
Though the concept of avoiding risk factor for the Governmental regulations and
process causes adverse effect and resulted in weakened industrial growth.
Industrial Training Institutes, Productivity Development Centres, Small Scale
Enterprises Development Institute- Ahmedabad, District Industries Centre- Morbi
and other Non-Governmental organizations must come forward to promote more
and more training programmes to increase and motivate the productivity of the
labour force available in the district.
Marketing Potential:
There are well developed Market Yards in Morbi, Wankaner and Halvad taluka of
Morbi district for the distribution of the agricultural produces. Farmers can accrue
more competitive prices for their produce in these market yards by selling their
produces. There is good infrastructure in the district for the sale of industrial goods
and services manufactured and produced.
PFR of M/s. Welmica Laminates
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2. Planning Brief
(i) Planning Concept (type of industries, facilities transportation etc) Town and
Country Planning/Development authority Classification.
Proposed project site is located near to National Highway 8A and well connected to
the internal roads and highways. The site is well connected to Wankaner, Morbi as
well as Rajkot region, where all the infrastructural and transportation facilities are
available.
At present more than 700 enterprises in around Morbi are manufacturing various
types of Tiles. More than 100 enterprises are manufacturing specialized Vitrified Tiles
which has great demand in the region as well as all over the country. It is also hub of
digital and other types of watch and clocks manufacturing enterprises such as Ajanta,
Samay, Sonera and Sonam which are World leaders in this sector. After 2002, Paper
industries have grown rapidly as ancillary sector due to need of high quality craft
grade papers very suitable for packing of goods.
(ii) Population (Source : MSME, Morbi (2016-17))
Description No.
Population Total : 9,60,329 Person
Male : 4,94,726 Person
Female: : 4,65,603 Person
Population density 481 persons per sq. km.
Village Population Total: 6,01,909 Person
Urbanised Population Total: 3,58,420 Person
Population increase rate N.A
Male- Female ratio 1000 : 961
Scheduled Caste population 49,902persons
Scheduled Tribe population 4,036 persons
PFR of M/s. Welmica Laminates
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(iii) Land use planning (breakup along with green belt etc.).
Sr. No. Particular Area (m2) % of Total Land
1 Built-up area 5343 39.7
2 Greenbelt area 4470 33.2
3 Open area 3643 27
Total 13,456 100
(iv) Assessment of Infrastructure Demand (Physical & Social).
Surrounded villages in 10 km area from the project site are having all the necessary
physical and social infrastructure facilities due to agricultural activities, animal husbandry
and industrial development within the area as well the nearby Morbi Town and
Wankaner Town & Rajkot City.
(v) Amenities/Facilities.
All the basic amenities/facilities such as power connection & power back-up, drinking
water, internal roads, water & wastewater treatment plant etc. will be provided.
3. Proposed Infrastructure
a. Industrial Area
Industry has provided 5343 m2 built up area for industrial process/manufacturing
activity which provides all needed facility including proper ventilation, safe handling
system, etc.
b. Residential Area
Industry will provide labor quarter for their labors and provide all basic facilities to
them.
c. Green Belt.
4470 m2 area will be proposed for greenbelt development. In addition to this, project
proponent will participate in greenbelt development programs in nearby areas under
their CSR.
d. Social Infrastructure
The proponent will provide social infrastructure facilities within 10 km radius of the
proposed project.
Education Facilities:-Many Facilities for village schools like game kits, drawing kits,
table-chairs; school construction (classroom/toilet/school boundary), ceiling fans/
coolers or books for school library are proposed.
PFR of M/s. Welmica Laminates
Page 15 of 16
Health Facilities:-Assistance to existing health facilities in nearest Hospital, for
improvement in health facilities or services.
e. Connectivity (Traffic and Transportation Road / Rail / Metro / Water ways
Proposed project site is located adjacent to National Highway 8A and well connected
to the internal roads and highways. The site is well connected to Morbi Town and
Wankaner Town & Rajkot City.
f. Drinking Water Management
In proposed project, out of 33.7 kl/day water approx. 11.3 kl/day water will be
consumed for domestic purpose
g. Sewerage System.
Domestic wastewater 10.3 kl/day will be treated in the STP.
h. Industrial Wastewater Management.
Industrial wastewater will be generated from process, boiler, cooling tower blow-
down, washing. Wastewater (washing and process) will be collected collection cum
neutralization tank. Then wastewater will be given Chemical Oxidation treatment.
After completion of chemical treatment, wastewater will be taken to Nutch Filter/Filter
Press for chemical sludge separation. Chemically treated process and washing water
will be mixed with, cooling tower blow down, boiler blow down in holding tank. ETP
sludge along with evaporation residue from evaporator will be will be disposed of at
TSDF site. Thus, unit will maintain Zero Effluent Discharge.
i. Solid/Hazardous Waste Management
ETP waste + evaporation residue, discarded bags/barrels, used oil & edge cutting waste
are the main solid hazardous waste that will be generated from the proposed unit. ETP
sludge will be collected, stored into solid waste storage area and disposed to
authorized TSDF site. Discarded bags and containers will be sold to approve vendor.
Edge cutting waste will be disposed off to the common incineration facility.
j. Power Requirement & Supply / source
Power requirement for the proposed project is 200 kVA which will be obtained from
PGVCL.
4. Rehabilitation and Resettlement (R & R) Plan
Not applicable.
PFR of M/s. Welmica Laminates
Page 16 of 16
5. Project Schedule & Cost Estimates
(i) Likely date of start of construction and likely date of completion
(Time schedule for the project to be given)
Construction will be started after June 2018. Construction work related to proposed
project of Resin manufacturing plant will be only started after obtaining EC.
(ii) Estimated project cost along with analysis in terms of economic viability of the
project.
Total cost of the entire project is approx. 1.3 Crore.
______________________________________________________