PRE FEASIBILITY REPORT

OF

M/s. Sayaji Laminates Pvt. Ltd.

Survey No. : 213,Village-Bahutha,

Ta. :Savli , Dist. : Baroda,

Gujrat-391770

Email: sayajilaminates@gmail.com

Prepared By:

T. R. Associates

C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump,

S. G. Highway, Ahmedabad.

Mo. No.: 98253 71099

Email ID: trassociates@hotmail.com

trassociates@ymail.com

1. Executive summary

M/s. Sayaji Laminates Pvt. Ltd. is proposing to manufacture P. F. Resin, M. F. Resin,

& U. F. Resin at Survey No. : 213,Village-Bahutha, Ta. :Savli , Dist. : Baroda, Gujrat-

391770 Proposed unit will manufacture resin for production within its premises as

well as sell purpose.

The total land area of company is 7611 m2 out of which 2525.33 Sq. Mt. land will be

used for greenbelt area development. The estimated cost of the Resin project is 1.0

Crore. Total budget allocation towards Environmental Management Facilities will be

Rs. 15 Lacs. Total 50 persons will be employed including skilled persons, unskilled

persons and office staff.

M/s. T. R. Associates is carried out EIA/EMP studies for Environmental Clearance.

Production details are given below:

No. Product Total Quantity

( MT/Month)

1. Phenol Formaldehyde Resin 400

2. Melamine Formaldehyde Resin 400

3. Urea Formaldehyde Resin 400

Salient Features with in 10 km radius surroundings area as follows:

S.No Important Features Description

1 Location Survey No. : 213,Village-Bahutha,

Ta. :Savli , Dist. : Baroda, Gujrat-391770

2 Topomap F43H7

3 Longitude 73°12'36.38"E

4 Latitude 22°30'37.66"N

5 MSL 45 m

6. Nearest power station MGVCL (Madhya Gujarat Vij Company Ltd.)

7 Proponent Name Mr. Dhirajbhai J. Patel - 9825043996

8 Corporate office address Survey No. : 213,Village-Bahutha,

Ta. :Savli , Dist. : Baroda,

Gujrat-391770

9 Temperature range 140 C to 430 C

10 Annual Rain fall 510 mm

11 Nearest Road NH 158 (0.57 Km)

12 Nearest Railway station Samlya Jn.– 9.95 Km

13 Nearest city Vadodara (21.0 km)

14 Nearest village Lasundra (1.95 km)

15 National HW NO NH 8 (13.41 Km)

16 State HW No SH – 158 (0.57 Km)

17 Seismic Zone Zone-III (Less Active)

18 National Parks / Sanctuary None within 10 Km radius.

2. Project Proponent and their back ground.

Mr. Dhirajbhai J. Patel has more than 5 years experience in field of manufacturing

Resin.

Brief description of nature of the project.

It is a small scale project for production of resin which is used for Laminated Sheets.

Need for the project and its importance to the country and or region.

Formaldehyde resins are used predominantly in the wood products industry as

adhesives. Growth of these resins 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) mainly used to produce Electrical Insulation Board and

H.P. Decorative Laminated Sheets. These sheets have good market demand to

develop the home and office for furniture.

Demand-Supply Gap.

The average production of decorative laminates has crossed approximately 130

million sheets inclusive of all thicknesses but the gap between installed capacity and

demand is growing bigger. During FY 2011-2012 phases that gap narrowed with

sudden demand in lower thickness segment but later capacities came in place and

the Decorative laminate market became a pressure driven market.

The below graph shows the gap which indicates more supply means pressure on

pricing, profits etc. It is caution for any new comer that if he enters, he should be

prepared for "More investments, more efforts and a long wait for margins".

The burgeoning market demands of urban and semi-urban India are estimated at Rs

5,00, 000 crore. The demand-supply gap has already attracted foreign players to

India; and the e-retailing boom offers immense business opportunities. But a mere

15% of India's woodworking industry is organized. Its semi-skilled carpenters, self-

styled interior decorators and small-scale local manufacturers will need to be

trained and organized to meet future market demands and exploit business

opportunities.

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 its no more a regional shift, it

is a global shift. Indian technology should be upgraded an updated at par with

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 only local market of resin. It is an intermediate product for manufacturing

of Laminated Sheets. Liquid resins are quite expensive for export. So we have only

local sale market for distribution.

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

This project will provide direct employment to 50 people whereas it will provide

employment to many others indirectly. Plywood and Laminated sheet 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 and Laminated sheets

Industries will be interdependent on resin Industries.

(ii) Location

Latitude: 20°37'3.16"N

Longitude: 72°58'5.89"E

Google Image of Proposed Location.

Key Plan of proposed site

(iii) Project description with process details

1. Phenol Formaldehyde Resin:

Manufacturing Process

First all raw materials like phenol, formaldehyde & caustic will be added into closed

vessel.

Stirring & heating will be done up to 60 C. After 60C stop heating.

Reflux is done for 30 minutes up to 98 C.

Vacuum distillation will be started.

Water will be removed from the vessel as per the batch size.

Cooling down to 40C.

Methanol will be added for dilution purpose.

Phenol Formaldehyde Resin will be ready for use in Laminate sheets.

Reaction Chemistry

Process Flow Diagram

Process Flow Diagram

Limped Reaction Vessel

Stirring and heating up

to 60 C

Reflux for 30 Minutes

Vacuum Distillation

Cooling

Dilution

Product: Phenol

Formaldehyde Resin

Phenol

Formaldehyde

Caustic Flakes

Methanol

Water

2. Melamine Formaldehyde Resin:

Manufacturing Process

First all the raw materials melamine & formaldehyde will be added in Limped

reaction vessel.

Stirring & heating will be done upto 95 C for 1 Hr.

Cooling down to 40 C.

Melamine Formaldehyde Resin will be ready for use in Laminate sheets.

Reaction Chemistry

N

N

N

NH2

NH2 NH2

+ CH2 ON

N

N

N

OH

CH2

OH

CH2

fast

melamine formaldehyde

melamine formaldehyde resin

Process Flow Diagram

Limped Reaction Vessel

Stirring and Heating up

to 95C for 1 hr

Cooling at 40C

Product: Melamine

Formaldehyde Resin

Melamine Formaldehyde

3. Urea Formaldehyde Resin:

Manufacturing Process

First all the raw materials Urea & Formaldehyde will be added in Limped

reaction vessel.

pH will be adjusted to pH 9.0 by adding acetic acid.

Stirring & heating will be done upto 95 C for 50 Minutes.

Heating will be continued until tolerance (10:40) is achieved.

pH will be adjusted to 9 by adding Caustic.

Cooling down to room temperature.

Urea Formaldehyde Resin will be ready for use and sale purpose.

Reaction Chemistry

Process Flow Diagram

Stirring and Heating up

to 95C for 50 Minutes

Cooling

Urea Formaldehyde

Resin

Limped Reaction Vessel

Urea Formaldehyde

pH adjusted to 9

Acetic Acid

pH adjusted to 9 Caustic

List of Raw Materials

Sr. No. Name of the

product

Name of Raw

Materials

Quantity in

MT/Month

1 Phenol

Formaldehyde

Resin

Phenol 377.2

Formaldehyde 148.8

Acetic acid 2.0

Caustic 2.0

2 Melamine

Resin

Formaldehyde 240

Melamine 160

3 Urea

Formaldehyde

Resin

Urea 160

Formaldehyde 240

Acetic Acid 2.0

Caustic 2.0

4. Resource optimization/ recycling and reuse envisaged in the project, if any,

should be briefly outlined.

Our main raw materials urea and formaldehyde are easily available from

developmental city like Baroda, Surat etc.

5. Availability of water its source, Energy/ power requirement and source

should be given.

Water source: Bore well

Energy/power requirement: 320 HP from MGVCL

6. Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal.

Solid waste generation and disposal

Sr.

No. Description Category Quantity Mode of Disposal

1 ETP Sludge 34.3 6.1

MT/Month

Collection, storage and

Disposal at TSDF Site

2 Used Oil 5.1

50

Lit./

Month

Collection, storage and

used within premises

as a lubricant / sold to

registered recycler.

3 Discarded

Plastic bags 33.3

6480

Nos./

Month.

Collection, storage &

sell to authorized

vendor

4 Edge Cutting

Waste 23.1

15

MT/Month

Collection, storage &

disposal at common

Incineration facility

Waste water generation and Disposal facility

4800 liter waste water will be generated from the washing activity.

Effluent treatment plant:

(1) 4000 liter/day: boiler Blow down

(2) 200 liter /day: washing

(3) 600 liter/day: cooling tower blow down

Flow Diagram of ETP.

Collection &

Neutralization

Tank

Holding Tank

(Photo Fenton

Reagent)

Evaporator

Primary

Settling Tank Industrial

effluent

7. Schematic representations of the feasibility drawing which give

information of EIA purpose.

4. Site Analysis

(i) Connectivity.

Nearest Railway

station

Samlya Jn. 9.95 Km

Nearest National

highway

NH 8 13.41 Km

Nearest Airport Baroda 20.0 Km

Nearest State highway SH no 158 0.57 km

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

This is a new unit manufacturing of Laminated Sheets.

Fig: 1 Land use pattern

Land possession document are attached as annexure: A.

(iii) Topography (along with map).

Fig: 2 legendry map of Baroda district

(iv) Existing land use pattern.

Existing land use pattern shown in fig no: 1

(v) Existing Infrastructure.

(1) Nearest railway station: Samlya Jn.– Railway station is 9.95 Km from the

project site

(2) Nearest Highway: state highway 158 is 0.57 km from the project site.

(3) Nearest Airport: Baroda is 20.0 km from the project site.

(4) Power: 320 HP from Madhya Gujarat Vij Company limited.

(5) Water : Source of the water is Ground water

(6) Basic amenities:

Educational facility: - Sigma Institute of Technology & Engineering, Waghodiya is 23.1 km from the project site.

Temple: Nilkanth Mahadev Temple is 7.1 km away from the project site.

Hotel: Anand Prakash hotel is 5.7 km away from the project site.

Project site

Post Office: - India post office,Manjusar is 8.8 km away from the project site.

Hospital: - Satyam Hospital, Baroda is 20 km away from the project site.

(vi) Soil classification of district mahesana

Madhya Gujarat region compries of Panchmahal, Dahod, Anand, Kheda, and Baroda

Districts. Dominantly the Soils are very deep, well drained and fine and medium

textured. They are slightly alkaline, slight to strong saline. Soil depth in Madhya Gujarat

is well distributed in two parts. The Soils in western side are dominantly very deep

followed by moderately deep and in eastern part soils are dominantly shallow followed

by moderately shallow. The Soils in Panchmahal, Dahod, Anand, Kheda, and Baroda

District dominantly distributed to very deep soil depth class followed by shallow depth

Moderately deep soil are also observed, Soil salinity in Madhya Gujarat varies from

slight to strong salinity class. In Baroda District soil salinity belongs to slight to

moderate and severe towards coastal. In these districts soil salinity is moderate.

(vii) Climatic data from secondary sources.

STATION:- BARODA YEAR: - 2014 MONTH: - MARCH

ELEMENTS: - (1) WIND DIRECTION & (2) WIND SPEED REPORTED IN KMPH

DA

TE

0830 HRS

IST

1730 HRS

IST

0230 HRS

IST

0530 HRS

IST

1130 HRS

IST

1430 HRS

IST

2030 HRS

IST

2330 HRS

IST

DIR SP

D DIR

SP

D DIR

SP

D DIR

SP

D DIR

SP

D DIR

SP

D DIR

SP

D DIR

SP

D

01 CA

LM 000 W 012 NW 006 NE 004

WN

W 014

SS

W 006

NN

E 006 SW 012

02 S 004 NW 008 SS

W 010 S 004 W 012 NW 014 NW 008 NW 008

03 S 006 N 008 NW 008 NE 006 NN

E 006 NW 008

CA

LM 000

WS

W 012

04 CA

LM 000 W 014

WS

W 008

CA

LM 000

CA

LM 000 W 008 NW 006 NW 006

05 SE 008 w 014 CA

LM 000 NW 006 SW 006 W 014

NN

E 006 SW 008

06 NW 006 NW 008 SW 008 W 010 W 006 W 018 NN

E 006 W 008

07 CA

LM 000 W 014 W 006 W 008 W 012 W 010 NW 008 NW 008

08 W 010 W 018 NW 006 W 010 W 010 NW 018 NW 006 NW 006

09 SE 006 N 012 NW 006 NN

E 006 E 008 NE 010 N 006 N 012

10 E 006 CA

LM 000 NE 010 NE 008 E 022 NE 012

NN

E 008

NN

E 008

11 NN

E 012 NW 008

CA

LM 000

NN

E 012

NN

E 012

NN

E 008 NW 010 NW 010

12 W 010 WN

W 022 N 008 W 010 W 008

WN

W 018 NW 012 NW 012

13 NE 004 NN

E 012

WN

W 008 NW 008 NE 012

NN

E 012

NN

E 010

NN

E 012

14 NN

E 006 NE 012 N 010

NN

E 006 E 018 NE 010

NN

E 010

NN

E 008

15 NN

E 012

CA

LM 000 NE 008

NN

E 014 S 008

CA

LM 000 NW 008 N 008

16 CA

LM 000 W 014 S 006

CA

LM 000

CA

LM 000 NW 008 NW 012 NW 010

17 NW 010 NW 004 N 010 NW 010 NN

E 010 NW 014 SE 004 W 012

18 CA

LM 000 W 010 NW 008

CA

LM 000 N 010 NW 012 E 006 E 006

19 E 006 W 014 S 006 NW 006 NN

E 006 W 012 S 004 W 012

20 W 004 NW 014 CA

LM 000 N 004 NW 004 NW 014

NN

W 006 NW 006

21 NN

W 008 N 012

NN

W 004

NN

W 008 N 006 NW 008 NW 012 NW 012

22 CA

LM 000 NE 010

CA

LM 000

CA

LM 000 E 012 NE 010 N 012 N 010

23 NN

E 012 NW 008

NN

E 008

NN

E 008 NE 010 NE 008 NW 012 N 012

24 CA

LM 000 NW 014

NN

E 012

CA

LM 000

CA

LM 000 NW 008 NW 012 NW 012

25 SW 006 NW 014 NE 008 NE 006 NW 006 NW 008 NW 010 N 012

26 NW 004 NN

W 010

CA

LM 000 NW 012 NW 012

NN

W 012 NW 006

NN

W 006

27 W 008 W 008 N 004 CA

LM 000

NN

E 006 W 008 W 006

CA

LM 000

28 N 012 NW 014 W 014 CA

LM 000 N 008

WN

W 010

WN

W 008 NW 006

29 NE 004 NW 014 WN

W 006 NE 006

NN

W 006 NW 014 W 012 NW 012

30 CA

LM 000

WN

W 012 NW 012 NW 010 NW 006

WN

W 006 SW 006 SW 014

31 SS

W 012 W 008 W 010

SS

W 014 SW 008 W 008 W 008 SW 008

DAILY METEOROLOGICAL DATA

STATION: - BARODA YEAR:- 2014 MONTH:- MARCH

ELEMENT: - RELATIVE HUMIDITY IN % (PERCENTAGE)

DATE 0830

HRS

IST

1730

HRS

IST

0230

HRS

IST

0530

HRS

IST

1130

HRS

IST

1430

HRS

IST

2030

HRS

IST

2330

HRS

IST

1 061 043 066 080 049 044 054 062

2 077 044 069 081 057 041 061 079

3 081 034 080 084 044 036 053 063

4 082 037 079 084 047 036 044 057

5 061 023 068 082 033 026 037 049

6 058 048 055 064 054 042 055 060

7 072 032 064 078 045 030 055 059

8 066 035 072 082 039 033 055 064

9 082 032 073 082 038 037 025 042

10 047 015 051 064 015 013 027 038

11 046 022 047 048 020 022 027 044

12 054 020 059 065 031 020 036 052

13 057 022 058 062 056 031 027 038

14 053 022 044 065 019 016 030 053

15 060 017 068 076 027 020 034 053

16 043 023 057 062 026 020 035 040

17 054 023 052 066 031 025 035 044

18 054 025 051 066 028 023 031 033

19 058 022 059 070 031 023 031 039

20 054 024 048 062 041 028 034 044

21 044 020 052 046 030 019 028 039

22 044 021 045 060 022 015 029 037

23 063 019 054 075 024 019 027 034

24 042 020 058 057 018 017 027 031

25 052 017 056 065 023 016 035 042

26 052 014 048 053 025 016 035 043

27 044 027 048 053 038 022 033 042

28 052 019 049 049 033 023 038 044

29 048 020 047 063 029 019 030 031

30 042 022 038 043 027 027 036 038

31 075 032 043 075 044 033 041 044

(viii) Social Infrastructure available.

Educational facility: - Sigma Institute of Technology & Engineering,

Waghodiya is 23.1 km from the project site.

Temple: Nilkanth Mahadev Temple is 7.1 km away from the project

site.

Hotel: Anand Prakash hotel is 5.7 km away from the project site.

Post Office: - India post office,Manjusar is 8.8 km away from the

project site.

Hospital: - Satyam Hospital, Baroda is 20 km away from the project

site.

5. Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town

and Country Planning/Development authority Classification.

It is Laminated sheet manufacturing industry located in Baroda district. Total

available area is 7611 sq. meter out of it 2525.33 sq. meter area will be

provided as a greenbelt area. Industry wants to manufacture different types

of resin used in laminated sheets manufacturing plant.

(ii) Population Projection

In 2011, Vadodara had population of 4,165,626 of which male and female

were 2,153,736 and 2,011,890 respectively. In 2001 census, Vadodara had a

population of 3,641,802 of which males were 1,897,368 and remaining

1,744,434 were females. Vadodara District population constituted 6.89

percent of total Maharashtra population. In 2001 census, this figure for

Vadodara District was at 7.19 percent of Maharashtra population.

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

1 Built Up Area 3303.75 Sq mt

2 Green belt area 2525.33 Sq. mt

3 Open/ Road area 1781.92 Sq. mt

Total Area 7611.00 Sq. mt

(iv) Assessment of Infrastructure Demand (Physical & Social).

Super Specialty and modern health facilities and medical stores are needed

around.

(v) Amenities/Facilities.

Industry will provide 2.5 % of total profit for CSR activity.

6. Proposed Infrastructure

(i) Industrial Area

Industry will provide 3303.75 square meters built up area for industrial

process activity. Which provide all needed facility including proper

ventilation, safe handling system, etc.

(ii) Residential Area

Industry will provide labor quarter for their labors and provide all basic

facilities to them.

(iii) Green Belt.

2525.33 sq. meter area will be proposed for greenbelt development. Approx

1262.66 sq. mt area will be proposed for tree cover area (approx 46 trees).

(iv) Social Infrastructure.

The PP proposes the following social infrastructure facilities within 10.0 km periphery 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.

Health Facilities:-The PP proposes to provide assistance to existing health facilities in Nearest Hospital, for improvement in health facilities or services.

(v) Connectivity

The nearest city is Vadodara. Approaching road state highway no 158 is 0.57 km

away from the project site.

(vi) Drinking Water Management

Out of 20362 liter/day water approx 6750 liter water will be consume for

domestic purpose; 4500 L/day water will be consume for green belt

development and 9112 liter/ day fresh water will be used for industrial purpose.

(vii) Sewerage System.

Domestic waste water 6500 liter/day will be disposed through soak pit system.

(viii) Industrial Waste Management.

9840 liter/day waste water will be generated from the process activity. It

will be treated in effluent treatment plant and evaporate after treatment.

(ix) Solid Waste Management

Used oil, ETP waste, discarded bags are the main solid hazardous waste

generated from the proposed unit. Used oil will be send to register recycler,

ETP sludge will collected from sludge drying bed, stored into solid waste

storage area and disposed to authorized TSDF site. Discarded bags will be

sold to approved vendor.

(x) Power Requirement & Supply / source

320 HP from MGVCL.

7. Project Schedule & Cost Estimates

(i) Likely date of start of construction and likely date of completion

Start construction work: 1st week of December, 2015

Completion of construction work: June, 2016

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

project.

Total project cost of resin is around 1 crore.