PREFEASIBILITY REPORT FOR EASTERN ENTERPRISEenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/20102016W… · the proposed project as there is growing shift in fashion clothing

PREFEASIBILITY REPORT FOR EASTERN ENTERPRISE

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DETOX CORPORATION PVT. LTD

1.0 EXECUTIVE SUMMARY

Eastern Enterprise is manufacturer of filament yarn polyester/ Nylon yarn. Now, proponents

have proposed for a addition of new product FDY mother yarn polyester/ Nylon. Unit is

situated at Plot No 480 B, Hashmi estate, Baleshwar village, Palsana, Surat, Gujarat. Total

production capacity of new product would be 270 MT/month in two phase (each of 135

MT/month).

The proposed expansion will take place in same plant. Project site is well connected to

Palsana Baleshwar Road & NH 8. Nearest village is Baleshwar at 0.45 km away and nearest

city is Surat approx 10.5 km away. There is no national park, sanctuary or forest land in

surrounding 10 Km radius. The project doesn’t fall under CRZ boundaries.

Water will be sourced from Ground water. There is no process air emission and hazardous

waste generation from proposed project. This is zero discharge plant as all wastewater will

be utilized in project premises itself. Details are given in Pre-feasibility report.

Both direct and indirect employment shall be generated in nearby area of the project.

Project details including site specific data, raw material consumption, product details, water

consumption, socioeconomic structure etc is discussed in the upcoming sections.

2.0 INTRODUCTION OF THE PROJECT AND BACKGROUND INFORMATION

2.1 Identification of project

Currently Eastern Enterprise has valid NOC for production of Filament yarn & air textrised

yarn. Now as a move towards expansion, the promoters have decided to enter into new

manufacturing of Polyester/ Nylon mother Yarn. The detail break up of existing as well as

proposed production capacity is given in the Table 1.

Table 1: Detail of Existing & Proposed Project

SR.

NO

NAME OF PRODUCT PRODUCTION CAPACITY

Existing product

1. Filament yarn 55 MT/month

2. Air Textrised yarn 50 MT/month

Proposed product

First Phase Second phase Total

1. Polyester/ Nylon Mother yarn 135 MT/month 135 MT/month 270 MT/month


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2.2 Brief Description of Nature of the Project

The Project Fall under Category B2, Section 5(d) of EIA Notification September 2006 and

amendment thereof vide notification no. S.O 3067 (E) dated 1st December 2009.

Now, according to MoEF circular No. J-13012/12/2013-IA-II (I) dated 24th December, 2013,

proposed project will be considered in “B2” category, as yarn will be produced from Poly

Nylon Chips.

2.3 Need of the Project and its importance to the Country and/ or Region

The textile industry constitutes significant portion of the world trade and is highly

fragmented in terms of geography and size. Textile is the most favorable sector for

developing countries under multilateral trade liberalization. With the phasing out of the

Multi Fiber Arrangement and the removal of Quantitative Restriction, the industry has

become very competitive and global dynamics of this industry are fast changing. Owing to

its labour intensive nature, the industry is shifting base to the developing countries that

offer competitive cost structure for the labour oriented activities like spinning, weaving,

processing and garmenting. Hence there exist increasing opportunities for the developing

countries having both upstream and downstream facilities.

In India, the development process has gathered momentum due to opening up of the

economy and globalization. Overall consumer performances have been changing faster and

value addition on fabrics is achieved by mixing of new components in the manufacturing

process to produce better looking products at a relatively cheaper prices.

Textile Industry in Surat is showing continuous growth and it is being reported at number of

columns that this growth is going to continue. The various sectors of the industry being

spinning, texturising, weaving, warp knitting, embroidery, etc. are attracting new

investment opportunities and lots of expansion is under process in the textile industry.

Further with the various govt. incentives in the form of subsidies, the viability of the

industry is very good and this is resulting in growth prospects in the industry. Further the

fabrics produced in Surat are in great demand worldwide. Even in present scenario, lots of

fabrics are being regularly exported to different parts of the world.

Considering the overall position of the textile industry in India, there is huge potential for

the proposed project as there is growing shift in fashion clothing from cotton based wear to

synthetics fabrics. Further the demand for the non apparel segment is also in a growing

phase and with the change in the style and fashion and multi utility of the products

manufactured through Polyester/Nylon Filament Yarn, the overall demand of the PFY/ NFY

is expected to increase at a massive speed.


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2.4 Demand Supply Gap

PFY/ NFY has an excellent orientation and crystalline characteristics which imparts it with

good mechanical properties. PFY/ NFY has a good fatigue resistance and better resistance

to the effect of prolonged heating for applications at a temperature lower than its melting

point. It is highly resistant to chemical degradation and strains. PFY/ NFY's good bulk,

handle and drape have helped in capturing a good share of textile market. PFY/ NFY is used

in textile primarily for clothing, but is widely used in home furnishing and industrial

applications also. Its high abrasion resistance, strength and refractive power make it

especially suitable for some uses like hosiery, swim wear, upholstery, parachute cloth,

umbrella cloth, etc. As mentioned in previous section also that there are many applications

of the PFY/ NFY due to its high flexural strength and tenacity. Bulked continuous filament

Polyester/Nylon yarn is widely used in the manufacturing of carpets due to its excellent

bulk, wool like luster appearance and better resistance to stains, chemicals, insects, fungi

and abrasion as compared to wool.

Since the demand of the Polyester/Nylon Filament yarn is increasing at a massive speed

and there is very limited number of players in manufacturing of the PFY/ NFY and hence the

required PFY/ NFY is regularly being imported from different parts of the world providing

huge investment potential for the entrepreneurs in India. The major domestic producers of

PFY/ NFY are –

a) JCT Limited

b) GSFC Ltd.

c) Century Enka Ltd.

d) Prafful Overseas Pvt. Ltd.

e) Gujarat Polyfils Limited

f) Salasar Polytex Pvt. Ltd.

g) Garden Silk Mill Pvt. Ltd.

Almost all the PFY/ NFY manufacturing companies are multi product companies and there is

huge gap between the demand of Polyester/Nylon Filament Yarn in India and supply by the

domestic manufacturers. This gap is presently being minimized by import of PFY/ NFY from

Taiwan, China, Korea and many other European countries.

It is quite evident that while the demand has increased manifold, but there is no significant

increase in the domestic production capacity. The ever increasing demand –supply gap is

being met from imports. Even after the commissioning of the proposed plant, the gap will

not be completely met and will be met from imports only.


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Hence there is huge demand and potential for the proposed project and being in the trading

of Polyester/ Nylon Yarn since several years promoters do not feel any problem is

marketing the proposed capacity of the plant.

2.5 Export Possibility

The Textile Industry is also growing very fast with excellent growth in exports also.

Following the lifting of the textiles quota few years ago India has been able to increase its

exports to the US by 13% and to the European market by 27% as against growth in textiles

export of China to the US (6.5%) and EU (12%). Indian apparel exports are slated to grow

at 15-18% annually and capture 5% of the global apparel export market.

Overall the outlook for Textile industry is, therefore, considered bright. Further India has

traditionally enjoyed many competitive advantages in the textile industry which helps in

registering good growth rate in the industry as compared to other locations in the world.

As it can be concluded from the above referred reasons the demand is growing with a

greater speed, the marketing of the various segments of textile is absolutely no problem.

Besides, existing plants are not able to meet out their demand and therefore newly

established plants have very bright potentiality and future.

2.6 Employment Generation

The total employment generation due to proposed project will be as follow

Table 2: Employment Generation due to proposed project

Skilled Employment Generation Non-Skilled Employment Generation

55 27

3.0 PROJECT DESCRIPTION

3.1 Interdependent Project

There is no interlinked or interdependent project with the proposed project.

3.2 Location (map showing general location, specific location, and project

boundary & project site layout) with coordinates

Table 3: Site specific Salient Features

Project Block No. Block No. 480 B, Hashmi Estate


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Village

Taluka

District

State

Baleshwar,

Palsana,

Surat

Gujarat

Latitude 21º06'50.8'' N

Longitude 72º58'41.3'' E

Existing land use pattern Non Agriculture Land

Nearest railway station Chalthan 5.3 Km

Nearest khadi Baleshwar khadi (approx. 50 meter)

Highway NH 8 : ∼ 0.16 Km

Palsana Baleshwar Road: ∼ 0.2 Km

Human settlement from the site Baleshwar: 0.45 Km

The location of site with type of land and boundary coordinates is as below

Figure 1: Satellite image showing project location with surrounding figures


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Markation of location as per above image

1. Sangarila Raw house (in construction phase)

2. Eastern Enterprise Campus 3. Mudassar dying-Closed

4. Juned Plastic Factory 5. Crane and Ware houses, Transports,

6. Khyai Chemicals Factory

7. Salim Fashion Dying Mill-Closed

Figure 2: Site map of 10 km radius

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

site, particularly the environment considerations gone into should be

highlighted

This is expansion project within same premises.

Table 4: List of Industries Exist in 2 Km Radius

Sr.

No. Industry Name Type

1 Gujarat Eco Textile Park GIDC

2 Madhusudan Textile mill Textile

3 Spectrum Dye industry Dye ( chemical)

4 Juned Plastic factory Plastic


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3.4 Size or Magnitude of Operation

The company proposes for installing manufacturing facilities for Mother Polyester/ Nylon

yarn with the production capacity as mentioned in Table 1.

3.5 Project Description with Process Details

The process description for different products is as mentioned in the subsection

3.5.1 Raw Material

Existing Raw materials are as follow.

Raw materials CONSUMPTION, MT/MONTH Source Mode of

transportation

Polyester / Nylon

yarn

105 India Road

Nylon-6 / PET chips are the main raw material for spinning of Polyester/Nylon yarn. It is

easily available in India as well as international market; It is packed in approximately 1000/

820 Kg bags with moisture proof lining.

The details of other raw materials along with its quantity, source and mode of

transportation is given in table below:

Table 5: Proposed Raw Material details

Raw materials CONSUMPTION, MT/MONTH Source Mode of

transportation

Phase 1 Phase 2 Total

Polyester/ Nylon

Chips

132.7 132.7 265.4 India Road

Spin Finish oil 2.3 2.3 4.6 India Road

Based on process, Material Balance can be provide as follow


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Figure 3: Material Balance for proposed product

Input output

3.5.2 Manufacturing Process

Extruder

Polyamide chips are emptied in extruder

hopper under nitrogen atmosphere to prevent from oxidation and moisture pick up. In the

extruder the chips is melted with electrical heaters and proper mixing is done to form

molten polymer.

Spinning

Molten Polymer coming out of extruder is mixed again with static mixer fixed inside the

piping and is metered as per the requirement of denier, by metering pumps. Molten

metered polymer is pumped to spin packs which are having filters to remove the impurities

and then finally extruded through the various orifices of the spinnerets. Number of holes is

decided based on the requirement of filaments in the yarn.

Quenching

Filaments bundle coming out of spinneret is in the molten polymer form. Hence it is

quenched by cross flow cool air blowing from back side of bundle. Once the molten

filaments solidifies and their temperature comes down below their glass transition

temperature, spin finish oil emulsion is applied on the filament bundles for removing static

charges, proper cohesion and lubrication to form yarn.

Drawing

Nylon yarn coming out after quenching and oil application is passed through electrically

heated hot godets for orientation. The final yarn is popularly known as Polyester/ Nylon FDY

mother yarn.

Winding

The final yarn produced is wound on take up winders on paper tube. These final packages

are sold in market after proper inspection, testing and packing for weaving. During the

above processes sometimes abnormality occurs like filament break, resulting into

generation of yarn waste. Normally in Polyester/ Nylon FDY spinning process it is 1-2%.

Polyester/ Nylon 6 Yarn= 990 kg

Yarn waste = 10 kg

TOTAL =1000 kg

Polyester/ Nylon Chips = 884 kg

Spin Finish Oil = 17 kg

Water = 99 kg

TOTAL =1000 kg


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Figure 4 : Process flow Chart

Finished product


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Finished product shall be sold all over country and major portion shall be in and around

Surat. Some portion shall be exported also. Yarn waste price is normally at half the price of

raw material.

3.5.3 Utilities

1. Electric heaters

Four nos of Electric heaters are required each of 600 L capacity. Fuel will be electricity &

requirement is 30 KW each.

3.6 Raw Material Details

The raw material required along with quantity, likely source and mode of transportation is

given in section 3.5.1.

3.7 Resources optimization/ Recycling and Reuse envisaged in the project

100% of waste water generated due to proposed project will be reused within the plan

premises for washing and green belt development. Hence it’s a zero discharge plant.

3.8 Availability & source of water, availability & source ofelectricity

3.8.1 Source of water and its availability

The total water consumption would be 6.7 m3/day, which shall be obtained through Ground

water. The major consumption of water in proposed plant is given in Table 6. Please refer

annexure 2 for raw water characteristics.

Table 6: Water Consumption in Proposed Plant.

PURPOSE EXISTING

M3/DAY

PROPOSED

M3/DAY

TOTAL

M3/DAY

Cooling Water -- 5 5.0

RO & DM plant regeneration -- 1.0 1.0

Washing 0.2 -- 0.2

Drinking 0.2 0.1 0.3

Process -- 0.2 0.2

Total 0.4 6.3 6.7


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3.8.2 Source of electricity and its availability

Electricity shall be obtained from DGVCL (Dakshin Gujarat Vij Company Limited). The total

power requirement for the plant for proposed project will be 17000 KWH/ day in phase 1

and 10000 KWH/day in phase 2.

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

management/ disposal

3.9.1 Waste water generation & management plan

Domestic wastewater will be disposed of by septic tank.

The major waste water generates from reject from Water treatment plant.

Total quantity of wastewater will be as shown in Table 7.

Table 7: Wastewater generation

Sr.

No

Description Quantity generated Disposal plan

1 RO & DM reject 1.0 M3/DAY Greenbelt development

The characteristic of waste water generate is given below in table.

Table 8: Characteristic of wastewater

Sr.

No.

Description Units Reject from

water treatment

plant

1 pH -- 6-9

2 COD mg/l <50

3 Oil & grease mg/l <10

4 Total suspended

solid

mg/l <20

5 Total Dissolved

solid

mg/l 950


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3.9.2 Solid waste generation and Management plan

Empty bags and yarn waste will be major solid waste. Empty bags of raw material will be

used for waste yarn packing and rest of the bags will be sold in the market.

Table 9: details of Solid waste generation

Sr. No. Type of waste Quantity Disposal Plan

1 Waste yarn 2.70 MT/month Sold to retailed recyclers

3.9.3 Hazardous Waste

No hazardous waste generates from proposed plant

3.9.4 Stack details and air pollution measures

One stack will be installed to occasional operative DG set of 1000 KVA.

APC: Adequate stack height as per statutory norms.

4.0 SITE ANALYSIS

4.1 Connectivity

Site is well connected to Baleshwar- Palsana road & National highway 8, which connects the

site location with Surat and Mumbai city, is 160m away from site. The road connecting the

site with national highway is well developed for transportation facility. Nearest city is of

Surat, which is 10.5 km away. The nearby village Baleshwar (approx. 0.45 km away), is

equipped with all facilities.

4.2 Land form, land use and land ownership

Land & NA documents are attached herewith as annexure 3.

4.3 Topography (along with map)

The site is plain. Topography map will be provided at the time of presentation.


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4.4 Existing land use pattern (agriculture, non agriculture, forest, water bodies

– including CRZ), shortest distances from the periphery of the project to

periphery of the forests, national park, wild life, sanctuary, eco sensitive

areas, water bodies (distance from HFL of the river), CRZ. In case of

notified industrial area, a copy of Gazette notification should be given.

There is no forest, national park, wild life sanctuary, eco sensitive areas in surrounding 10

Km of the plant boundary. CRZ is not applicable to the project.

4.5 Existing infrastructure

Manufacturing Facilities for filament yarn & Air Textrised yarn has been installed.

4.6 Climatic data from secondary sources

The climatic data for month of March 2016 in the study are as below

Wind Speed: 0 – 17 m/s

Relative Humidity: 23 % to 82 %

Temperature: 23 ºC to 42 ºC

4.7 Social Infrastructure available

The project site is located close to village namely Baleshwar (0.55 km away) . Surat is

nearest town which is approx. 10.5 km away. Basic amenities of life are easily available in

the area. Primary health centre, school, drinking water, electricity, communication, road

network, Fire and safety equipments from nearby town and industries, transportation

facility is available in the vicinity.

The existing infrastructure is sufficient to cater the additional load due to the proposed

project.

5.0 PLANNING BRIEF

5.1 Planning concept (type of industries, facilities, transportation etc) town and

country planning/ development authority classification

The propose project in close proximity of City namely Surat. Also the related facilities like

road infrastructure, telecommunication and medical facilities etc. are already developed

hence no planning is envisaged. The nearby villages also have all the modern facilities.


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5.2 Detail Land Areas break up

The detailed land use planning and the area break up is as given in the table below.

Table 10: Land Area break up

Total Land Area acquired 20455.38 sq m

Total Built-up Area (Existing +

Proposed)

602.85

Future expansion 12984.72

Roads 731.20

Green belt 6136.61

The detailed lay out plan is attached as annexure 1.

5.3 Assessment of infrastructure demand (physical and social)

The basic infrastructure (Connective roads, Water resource vicinity) is required for the

proposed project is available at the project site.

5.4 Amenities/ facilities

Major basic facilities are available for the proposed project. Road, electricity, water,

transportation facility etc are well developed in the surrounding area. The major new

amenity for the proposed project will be installation of process equipment at site within the

premises along with all the necessary infrastructure for same like storage house, internal

access roads, office buildings, equipment sheds etc.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial area (processing area)

The total area acquired by the company is 20455.38 sq m. 602.85 sq m area will be

developed for proposed industrial activities.

6.2 Residential area (non processing area)

No labour colony is envisaged in the proposed project.

6.3 Green belt

Around 6136.61 sq m area has been developed as green belt.


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6.4 Social infrastructure

Basic amenities of life are easily available in the area. Primary health centre, school,

drinking water, electricity, communication, road network, transportation facility is available

in the vicinity.

6.5 Connectivity (traffic and transportation, road/ rail/ metro/ water ways etc)

The connectivity to the project site is given in table below.

Table 11: Connectivity

Description Distance

Transportation Road: Baleshwar Palsana 0.2 km

NH 8 (approx. 0.160 km away)

Railway Chalthan Railway station (5.3 km

away)

Airport (Surat Air port: Approx. 24.5 km

away)

Port (Magdalla Port: approx 32 km away)

Nearest Town/ Villages City : (Surat: 10.5 km away)

Villages: (Baleshwar: 0.45 km away)

6.6 Drinking water management (source & supply of water)

Ground water after RO water treatment shall be used for drinking purpose.

6.7 Sewerage system

Domestic waste water generated will be disposed off in septic tank and soak pits.

6.8 Solid waste management

The solid waste generated due to industrial operation along with its quantity and disposal

plan is discussed in detail in section 3.9.2.


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6.9 Power requirement & supply/ source

Electricity shall be obtained from DGVCL, Mandvi and the details of same are discussed in

section 3.8.2. one standby DG set of 1000 kva will be installed.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to be adopted (central/ state) in respect of the project affected

Persons including home oustees, land oustees and landless labourers

Not applicable

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Likely date of start of construction and likely date of completion

Likely date of start of construction:

Within two months after obtaining EC

8.2 Estimated project cost along with analysis in terms of economic viability of

the project

Total project cost: 7.39 crores

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.1 Financial and social benefits with special emphasis on the benefit to the

local people including tribal population, if any, in the area

The company is already engaged in many social welfare activities in the Surat region.

Company has allocated fund for various activities. Following CSR activities will be conducted

in nearby villages. Please provide (Example as below)

1. Tree plantation

2. For improving education standards in nearby area, Benches and Computers will be

provided in school on need basis.

3. Providing fund in Gram Panchayat for village development

The budgetary allocation for environment management plan is given in table below.


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Environmental Parameter Capital Cost (Rs. In Lacs)

Environmental Monitoring And

Management

0.10

Occupational Health 0.10

Green Belt 0.20

Total 0.40

10.0 SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING WHICHGIVE

INFORMATION OF EIA PURPOSE

The proposed activities of the industry; i.e. Man Made fiber fall under category B Sr. no. 5

(d) in the Government of India Notification no. 1533 dated 14thSeptember, 2006; which

require prior Environmental Clearance before starting construction, production or any other

allied activities related to the project.

Now, according to MoEF circular No. J-13012/12/2013-IA-II (I) dated 24th December, 2013,

proposed project will be considered in “B2” category, as yarn will be produced from Poly

Amide 6 Chips.

Environmental Clearance (EC) is a formal process used to predict how industrial

development will affect natural resources such as water, air, land, socioeconomic and bio

ecological environment.

An Environment Clearance process usually involves a sequence of steps:

(1) Screening to decide if a project requires assessment and to what level of detail.

(2) Preliminary assessment to identify key impacts, their magnitude, significance, and

importance.

Methodology

The methodology of this study can be schematized as detailed below:

• To gather information on present environmental conditions and relevant national

environmental guidelines and EC procedures.

• Scoping of impacts.

• Assessment of significant impacts.


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• Description of residual impacts

• To inform all relevant and involved authorities regarding the impact of the project on

environment and the proposed mitigation measures.

Annexure 1: Layout MapAnnexure 1: Layout MapAnnexure 1: Layout MapAnnexure 1: Layout Map

Annexure 2: Annexure 2: Annexure 2: Annexure 2: Water Water Water Water Analysis ReportAnalysis ReportAnalysis ReportAnalysis Report

Annexure 3: Land DocumentsAnnexure 3: Land DocumentsAnnexure 3: Land DocumentsAnnexure 3: Land Documents