Welspun Ec PCB PDF

Prefeasibility Report Welspun Flooring Limited
FOR
Proposed Green filed project

For manufacturing of
Bulk Continuous Filament (BCF) Yarn and Partially Oriented Yarn,
“MANMADE FIBER - (OTHER THAN RAYON)”

Activity: 5(d), Category: B2
BY
M/s. Welspun Flooring Ltd
Unit proposed location :

Survey No. 190, Village : Chandanvalli ,
Shabad (Mandal), Ranga Reddy District,
State : Telangana.
EXECUTIVE SUMMARY
Name of the Project: M/S Welspun Flooring Limited

Location: Survey No. 190, Chandanvelli Village,
Shabad (M), Rangareddy District
Telangana
Project
 M/s. Welspun Flooring limited proposed to and has set up its industrial establish Tufted
carpet & synthetic floor tiles at Survey No. 190, Village: Chandanvelli, Shabad ( Mandal),
Rangareddy District, Telangana state
 The unit obtained CFE ( Consent for establishment) for manufacture of Tufted carpet and Floor
Tiles unit from Telangana State Pollution Control Board.
 Now the company has planned to establish synthetic yarn unit ( Non Rayon and Non
polymerization route) to manufacture Bulk Continuous Filament ( BCF) yarn and Partially
oriented yarn (POY) . Both these materials will be raw materials for manufacture of Tufted
Carpet and Floor tiles.
 Proposed Project Cost: Rs. 344.75 Crores
Applicability of EIA notification – 2006

 As per the EIA notification- 2006 as amended: Activity-5(d)– “Manmade fiber other than Rayon
”.
 Manufacturing of “Manmade fiber other than Rayon”falls under Category-B . As per the Office
Memorandum No. J-13012/12/2013 – IA -II (I) dated 24th December,2013, this is categorized as
B2 project as these fibres are manufactured from Chips and no polymerization reactions are
involved
Project Proponent
• Indian Limited company with diversified activities with its presence in more than 50 countries
• Large Scale Unit
LIST OF FINISHED PRODUCTS ( Proposed)
S.No Name Of the Product Capacity (MT/Annum)

17,500
(i) 1 Bulk Continuous Filament Yarn (BCF)
(ii) (iii)
2 Partially Oriented Yard (POY) 7500
Total 25,000
Note: Both Bulk continuous Filament Yarn & Partially Oriented Yarn (POY) is used as raw
material for tufted carpets and wall tiles which is downstream unit. The unit already obtained CFE
(Consent for establishment) from Telangana State Pollution Control Board for manufacture of tufted
floor carpets and tiles , as it does not attract EC Requirement.
Manufacturing : Manmade Fiber Industry

1
Resource Requirement
• Product wise Raw material Consumption
Consumption in
Sr. No Input material MT/Annum
BCF – 17,500 MT/Annum
1 Base white polymer( PP/ 17790.5
PET/ RPET/ PA6 Chips
2 Chips for Colorization 700
3 Spin finish oil 175

Total 18665.5
POY – 7500 MT/Annum
1 Base white polymer Chips 7615.55
(PET/ RPET/ PA6)
2 Chips for colorization 350
3 spin finish oil 35
Total 8000.15
• Utilities
Components Requirement Sourced from

TSPDCL ( State Electricity
Power 8.7 MW
Distribution Company)
D.G. Sets - DG sets are common for Tufted
(As Standby 3x 1500 KVA carpet plant and BCF & POY
Power source) plant
2 x 10TPH coal/Rice Husk
Boilers one stand by and one
Steam Boilers 90.0 TPD working. These boilers are
common for both Tufted plant
and BCF&POY plants
5,00,000 M3/hour air handling
HVAC system To be established for plant
capacity
Cooling tower (
1x 3900 TR To be established for this plant
with 3 units)
Water and Waste Water Management

 Total fresh water requirement will be @ 688 KL/Day. The same will be sourced from
Government supply through pipeline (Surface water source).
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 6.5 KLD of wastewater is generated from Monomer washer and Burnout.

 Industrial waste water in the form of washings from process, will be treated in the Effluent
Treatment Plant & ZLD system and treated effluent will be re -used back
 Blow downs from utilities will be treated in RO system followed by MEE
 Domestic waste water will be treated in STP and will be re-used for plantation purpose
 ZLD system is common for both this plant and Tufted carpet plant with the following capacities
25 KLD ETP , 50 KLD STP, 170 KLD of RO , 50 KLD MEE
Air Emission and its Control Measures

 Proposed to install two nos. Of Steam boilers with 10 TPH capacity ( One stand by and one
running) with Coal/Husk as fuel. This will be established in Tufted carpet plant and steam is
taken from that plant. Bag filters will be control equipment
 Three no. of D.G. Set (1500 KVA each) will be installed for proposed Tufted carpet plant and
this project as common resource . This will be only standby power supply.
 Adequate stack heights will be providing to boilers and D.G.Sets.
 There are no chemical reactions involved hence there are no process gas emission.
Solid & Hazardous Wastes and its Management
Types of Total
Source of
Waste & Quantity per Storage Methods Method of Disposal
Generation
Category Year
MEE (28.8 of From MEE 0.9 MT/Day Will be stored at a Will be sent to TSDF
Sch.IV) separate storage near Hyderabad
area
ETP Sludge From ETP 0.4 MT/day Will be stored in Will be sent to TSDF
(32.1 Sch. IV) drums near Hyderabad.
Empty Spin finish 25No/month Will be stored at a sold to authorized
drums Oil oil drums separate storage scrap vendor
Drums area
(33.3)
Yarn waste From 1710 Kg/Day Will be packed in Sold authorized
Solid waste process bags and stored at Recyclers
a designated area
Multi colored From 2500 Kgs/day Will be stored on Sold to secondary yarn
Yarn left Process bobbins users as bi product
outs on
bobbins
Details of Hazardous Chemicals

There are no hazardous chemicals used in the manufacturing process.

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1. INTRODUCTION
(i) Identification of Project and proponent.
Name of the project Proponent: M/s. WELSPUN Flooring Limited., proposed to set up Synthetic floor
carpets and carpet floor tiles at Sy. NO 190, Chandanvelli (V), Shabad (M), Ranga Reddy District.
Telangana. Government of Telangana allotted 600 acres of land to Welspun group for all their
upcoming units in this complex.
Welspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun Group
is one of India’s fastest growing conglomerates, registered at a CAGR of more than 20% over the last
decade. Welspun is a fully integrated player within the Pipes, Plates & Coils and Home Textiles
sector, while it also has a presence in the other business verticals such as Steel and Infrastructure.
As a globally recognized leader in the fields of Line Pipes and Home Textiles, Welspun Group has
captured a strong foothold in more than 50 Countries, it employs over 26,000 people and has as
many as 100,000+ shareholders.
Welspun Flooring Limited is a new venture of Welspun Group to provide specialized Flooring
solutions for both domestic and International Market. The facility shall be manufacturing
specialized carpet tiles, wall to wall carpet solution, hard flooring, artificial grass and other products
to be used for Commercial, Residential, Hospitality and Infrastructure sector.
The Company is managed by Board of Directors. The names of the Directors and their
addresses are given below.
Table 1.0 List of Directors of the company
Sl. No. Name of Directors Designation Address
1. Mukesh Sawalani CEO & Director Boulevard I 205, The Address,
LBS Marg Ghatkopar West
Mumbai 400086
2. Dipali Goenka Director “Rocky Isle”, 46/C, B.Desai Road,

Breach Candy Mumbai - 400 26,
Maharashtra, India
3. Altaf Jiwani Director 2/1706/Tower 2, 17th Floor,
Casa Grande CHS Ltd, S.B. Marg,
Lower Parel (W) Mumbai
400013, Maharashtra
4. Devendra Patil Director B/13, Yojna Co-Operative

Housing Society Ltd., Natwar
Nagar Road No. 5,Jogeshwari
(East), Mumbai-400060
5. Pradeep Poddar Independent Flat No. 2, Mont Blanc, 22nd

Director Floor, August Kranti Marg, Off
Kemps Corner, Mumbai – 400036

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(ii) Brief description of nature of the Project

M/S Welspun Floorings Limited proposed to set up a manufacturing unit at Survey No190,
Village – Chandanvelli, in Rangareddy District of Telangana State, for manufacturing Bulk
Continuous Filament Yarn and Partially Oriented Yarn @ 17,500 TPA and 7,500 TPA
respectively (covered under manmade fiber)
Both Bulk continuous Filament Yarn & Partially Oriented Yarn (POY) is used as raw material
for tufted carpets and wall tiles which is downstream unit. Both these materials are proposed
to use internally. The unit already obtained CFE (Consent for establishment) from Telangana
State Pollution Control Board for manufacture of tufted floor carpets and tiles
Now the company is going for back ward integration to manufacture BCF and POY yarn for
internal consumption
For the proposed project, the company intends to procure the available latest technology for
manufacturing the products listed.

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Business Model (Manufacturing Flow chart)

Figure 1.0 Process Flow Diagram BCF
Bringing the Chips Melting the Mixture Stretching
The melts pump is arrangement of spur gears in planetary The strand of filaments is then drawn by stretching
fashion with special design which acts as metering the between pair of rollers in draw zone in tune of 1.1 to
mechanism for polymer & forces this metered polymer to 3.5 times of their original length. Surface of rollers are
Storage of Chips spin packs which have fine hair like capillaries for filament heated to facilitate drawing process as well as set
formation. molecular orientation.
Conveying of Chips, Spin pack - heart of spinning.

conditioning of chips in case Texturizing process
PET/ PA6 & to metering zone
Quenching Cooled strand of fibres is then lifted off from

Mixing of Chips and colour chips cooling drum, Interlaced & wound on paper-tubes
under appropriate tension.
Extruder Spin Finish Application

Winding on winders

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(iii) Need for the project and its importance to the country and or region
The proposed project provides key raw materials i.e. BCF and POY for tufted Wall carpet and
carpet tiles which is final product of this company
The domestic demand for PFY stood at 10, 14,755 Tons during the year 2003. The demand for PFY
grew at CAGR of 4.21% to reach an estimated 12, 88,523 Tons by the years 2008. PFY industry, as
we know, had faced difficult market conditions during the years 1999-2002 due to excess capacity
over demand which lead to cut throat unhealthy competition causing substantial erosion in
profitability of these companies. However, as now new capacities came up during this period, the
gap between supply and demand got gradually bridged up and POY manufacturing
units/companies are doing reasonably well since beginning of 2002 and are expected to do much
better during the next few years in view of the sustained demand growth. As per detailed survey
conducted by 'CRISINFAC' the domestic Polyester industry is likely to witness robust demand
growth and higher profit margins in the next five years due to the following positive factors
favoring Polyester industry.
Demand Push:
Increase of PFY in non-appeal segments: In India, fiber is mostly used for textile applications
i.e. 93% and only 7% for non-apparel applications like home textiles, automotive an industrial
segments as against 59% worldwide. The demand of non-apparel segment is expected to grow @
20% p.a. as Polyester offers high tenacity and strength which is most suitable for such
applications.
Lower per capita consumption: The average per capita consumption (PCC) of fabric in India is
much lower than in its neighboring countries. India has a huge potential market, given that its PCC
is as low as 1.4 kg as compared China (5 kgs), Pakistan (3 kgs) and Indonesia (5 kgs). India has the
advantage of a large growing domestic market, and a good GDP growth.
Tufted carpets and wall tiles are gaining lot of market with growing infrastructure projects
such air ports and retail malls.
Manufacturing of manmade fibers globally is getting shifted mainly to China and India. As
China's domestic consumption almost matches its production, India will be able to increase its
presence in the International market. Keeping in view the strong fundamentals mentioned above,
CRISINFAC has projected the POY industry grows at a healthy 7.8% Compounded Annual Growth
Rate (CAGR).
Various Categories: Indian textile industry can be divided into several segments, some of which
can be listed as below:
• Partially Oriented Yarn
• Fully Drawn Yarn
• Nylon Filament Yarn

• Bulk Continuous Filament
• Texturized Yarn, Twisted Yarn, Monofilament Yarn, Splitting Yarn, Intermingled Yarn
(iv) Demand –Supply Gap
The products have very high demand for the process of weaving and knitting carpets and wall
tiles
(v) Imports vs. Indigenous production

Existing products manufacturing in the country will be very much economical compare to Imports
of the same. The growing crude prices and pushing international price for filament yarn
(vi) Export Possibility / Domestic / export Markets

There is a huge demand of synthetic filament yarn in the export market.
Employment Generation (Direct and Indirect) due to the project
There will be very good opportunity of employment generation directly and indirectly due to
proposed expansion. Directly about 270 no. of persons. It will also generate employment in
transport and other support sectors.

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2. PROJECT DESCRIPTION
(i) Type of Project including interlinked and interdependent projects, If any :

The project is interdependent project of the company. The down stream project of Tufted wall to
wall carpets and Carpet tiles unit is under implementation in the same complex
(ii) Location (map showing general location, Specific location, and project boundary & project
site layout) with coordinates:
The map showing general location, specific location and project boundary and project site layout
of Welspun Flooring Limited Located at Survey No. 190, Chandanvelli (V), Shabad (M) ,
Rangareddy District, Telangana
Figure 2.0: Location map showing the Project site and features within 10 Kms radius

10
Figure 3.0 Topo Map of The Plant and 10 KM radius

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(iii) Profile of Project Site:

Table 2.0 Salient features of Project site and surroundings
Sr. No. Nearest Infrastructure Feature Distance from Project Site (Aerial Distance)
N 17 13 08.3 , E 78 10 30.8
N 17 13 08.7 , E 78 10 59.4
1 Geographical Position
N 17 12 55.4 , E 78 10 59.1
N 17 12 55.2 , E 78 10 31.0
2 Elevation above Sea Level 520 Meters above MSL (Approx.)
Anthareddyguda – 0.5 KM – South-West
Chandanvelli – 1.45 KM - North
3 Nearest Village
Machanpali - 1.2 KM - South - West
4 Nearest Town Shabad– 8 Km SW (Approx.)

5 Nearest National Highway NH 8: 15.7km (Approx.) in West (Approx.)
6 Nearest State Highway SH No 5.87 Km West (Approx.)
7 Nearer Railway Station Thimmapur - 13 KM
8 Nearest Airport Samshabad - 26 KM
Polaram cheruvu 0.64(SW), Machanpalli cheruvu
Nearest Surface water
9 1.08 Kms(SW), Nagarkunta tank2.16 Kms(SW),
Resource/Reservoir
Musa River – about 3 KM in the North
10 Forest Land Mudimial RF-8.92 Kms(NE)
Location of Archaeologically
11 None
/Historically important places
National Park/Sanctuary or
12 None
Ecologically sensitive Area
13 National or State Boundary None
14 Tourist Places None
• Area Statement
Table 3.0 Area statement of the project
S.No Description Area in Sq.Mtrs
1 Tufted wall carpet & Tiles plant 53799

2 Ware house 25200
3 Utilities 5300
4 Administrative office 1800
5 Area for future expansion 570209
6 Canteen Building 150
7 Security 100
8 Waste water treatment plant 1600
9 Scrap yard 500
10 Green belt 113547
11 Parking 19056
12 BCF & POY 17939
Total area 809200

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➢ Out of 600 acres of land allotted by Telangana State Industrial Infrastructure corporation
(TSIIC), 200 acres of land is allocated for Tufted carpets and BCF & POY plant.
➢ This project will be implemented within the existing premises procured at the initial stage of
unit with required civil construction and installation of required plant and machineries.
➢ There is no requirement of additional land for the implementation of proposed change in
product profile.
Site Layout Plan:
Figure 4.0 Site Lay out plan

13
Figure 5.0 Plant lay out plan

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(iv) Details of alternate sites considered and the basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted :
Proposed change in product profile will be implemented in the existing developed site only hence
alternate site consideration is not envisaged.
(v) Size or magnitude of operation :

As per the proposed project cost the project is covered under Large Scale category of
manufacturing industries.
(vi) Project description with process details :
• LIST OF FINISHED PRODUCTS
Proposed products & capacity
S.No Production Details Quantity In MT

1 Bulk Continuous Filament (BCF) 17,500 MT/Annum
2 Partially Oriented Yarn (POY) 7, 500 MT/Annum
• INFRASTRUCTURE, MACHINERIES, EQUIPMENT & TECHNOLOGIES

 Within the existing premises with required civil work for manufacturing of the these
products
 Within the existing premises and infrastructure the installation of required plant and
machineries will be required.
 List of critical machinery involved in manufacture of Synthetic Filament yarn
Table 4.0 Critical Machinery Proposed
Sr. No. Description of Equipment Sr. No. Description of Equipment

BCF Manufacturing – Key equipment For POY Line
I Chips conveying system 1 Chips Silos and Conveyor system
1. Chips Crystallizer 2 Chips Crystallizers
2. Chips Dryer 3 Chips Dryer
3. Master batch metering and 4 Metering and mixing unit
mixing device
4. Extruder 5 Melting and Extruder
5. Spinning beam arrangement 6 Spinning machine
6. Spin packs 7 Quenching unit
7. Dow therm Heating system 8 Winding unit
8 Quench air unit with 9 Process control room
humidifier
9 Texturising machine
10 Chilled water system
11 Process control room

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• MANUFACTURING PROCESS
The company is using the latest available process technology for the production. This chapter
Includes the manufacturing process of the product and material mass balance for the product.
01. Product: Bulk Continuous Filament Yarn (BCF)
a. Manufacturing Process:
BCF process is combination of two processes of drawing and texturising combined together at
high speed of manufacturing. This process is used to make coarser denier (single strand) directly
between 1000 denier to 4000. Primarily three Raw material i.e. Polyester, Nylon, PP are used in
the form of Chips. Majority of yarns will be coloured at melt stage involving no use of water in
coloration.
Step wise process is as follows:

Chips drying and crystallizing
• Chips are stored in silo as per fibres, grades, supplier, lustres etc. Special storage conditions of
dry air / nitrogen purging are required for PA6. This is required for preventing hydrolysis of
PA6 polymer
• For PET as mentioned crystallizing and drying is required. This is done using hot air circuit
and desiccant dryers. In this process PET chip moisture content is reduced to less than 30
PPM.
Extrusion process
• Dried chips are fed into extruder for melting, compression and mixing (homogenization by a
moving spiral barrier type screw. Screw barrel is treated in five different constant
temperature zones.
• From outlet of extruder, melt is transferred to spin beam via melt transfer line Spin which is
electrically heated
Spin Beam Process
• Spin beam is a jacket sump which includes static mixtures, manifold and melt pump. Here
melts is further homogenize due to presence of static mixtures in polymer lines. Spin beam is
heated using thermic fluid vapor
Metering
Positive displacement pump of different capacity speed controlled by inverter, decides.
Melt comes to pack contains various filters and spinneret which decides number of filament in
yarn.

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Quenching:
These hot melt steam projecting out of spinneret capillaries are greeted by conditioned air in
quench zone. The temperature of quench zone is positively controlled for temperature as well as
humidity.
Typical quench temp range between 14-21 deg. Velocity of air for quench ranges from 0.2 m/s to
0.8 m/s. Relative humidity is also a critical parameter along with temp in Pa6 as Shrinkage values
Spin finish application:
• Cooled strands of fibers is applied spin finish oil in metered quantity to overcome friction in
next process & keep fibrous bundle in cohesive form.
• Unlike POY / FDY process here we apply neat oil. Oil application is done in two stages and has
migration nozzles which blow air a low pressure to evenly spread oil applied.
Stretching:
• The strand of filaments is then drawn by stretching them between pair of rollers in draw zone
in tune of 1.1 to 3.5 times of their original length. This value varies for fiber to fiber. DPF has
important role in deciding the stretch.( D.R). This is important parameter which resilience of
yarn to an extend.
• We have series of 5 rollers in drawing arrangements. Surface of rollers are heated to facilitate
drawing process as well as set molecular orientation. Temperatures are different for fibres
spun. PP needs temp of 130-140 deg, Pa6 up to 180 & PET up to 190 deg
Texturizing
• The strand of filaments is then subjected to texturizing process. This is heart of BCF process
were flat drawn filaments are processed to apply bulk using hot compressed air and then
cooled off on cooling drum.
• As seen in photo yarn moves straight in nozzle grove at steady tension and jet of hot air at
high pressure hits the yarn at angle, creates vortex .This creates yarn to loose it straight form
and gains bulk
• Further yarn enters lamella chamber which form a conical space used for pluck formation.
Geometry of nozzle & lamella dimensions are demonstrated in next step
Winding :
• The Yarn is ready. It will be wound on the tubes using a very accurate winding speed.
• It’s a complex robotic mechanism yet very accurate & precise in terms of speed and length. We
need to set length of yarn to be wound on package. This is automatic machine which
automatically changes and doffs bobbin once set length is achieved

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Inspection, packing and Dispatch

Inspection & Testing and Grading will be done and material is ready for Packing and dispatch.
Material will be send to downstream plant of the unit i.e., Tufted carpet plant, located in the
same premises
b. Process Flow Diagram
Polyester/Nylon chips / colour master batches conveying pneumatically
Drying in Fluidized bed crystallizer cum dryer
Dried chips melting, compression and mixing in extruder
Filtration through C.P.F and METERING
Spinning of Yarn as per required denier and QUENCHING
Spin finish oil application to Yarn
Texturising
Winding of Yarn by high speed spindle driven auto turret winder
Packing and dispatch to Tufted carpet division

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c. Material mass balance :

Table 5.0 Typical Material Balance of BCF
Sr. Consumption Quantity in
No Input material in MTPA Output material MTPA
1 Base white polymer( 17790.5 BCF Fibre 17500
PP/ PET/ RPET/ PA6
Chips
2 Colour pigments 700 2nd quality of Fibre ( Bi- 612.50

compounded with product)
base polymer
3 Spin finish oil 175 Yarn waste 416.50
Hard Flushing waste 49.00
Moisture and other system 87.50
losses
Total 18665.5 18665.5
02. Product: Partially Oriented Yarn ( POY )
a. Manufacturing Process:
The process is very similar to BCF manufacturing except that PET ( Poly Ehylene Tetra ) chips are
first crystallised and dried as chips need to be modified from amorphous to Crystallised form
amorphous form to crystallised form and to avoid shrinkage of chips in the extruder. The moisture
need to be removed from chips then they will go to extruder.
Another major difference in POY is, it is process where fibre is manufactured material which neither
drawn nor texturized . material is drawn and textured on different machine which is called as Draw
texturizing process. So its using two stage process. Here due to process speeds we can make a finer
DPF product ranging between 0.5 to 2.5
Poy is dimensionally unstable product with higher % elongation ranging between 120-150 % and
characterised by low strength and high shrinkage making it unsuitable to use in direct tufting/ heat
setting or tufting process.
The poy yarn is drawn and texturized on friction texturising machines and then Bundled together ( On
parallel winding machines or texturising machine itself) to form a coarser denier to be used in
Twisting/ heat setting or direct tufting.
Feel of yarn manufactured By Poy route are much softer as compare to BCF yarns and hence poy route
process is applied to manufacture carpet yarn suitable for certain applications of carpets like bath mats
or area rugs.
Carpet manufactured out of POY route yarn may have lower resilience and high wear under high traffic
areas and hence BCF yarns are preferred in areas of high traffic.

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b. Process Flow Diagram
Base White Polymer Chips ( PET, RPET, PA6) , Master Batch & other
Additives
Crystalliser & Dryer
Extrusion
Spinning
Quenching
Winding
Inspection and Dispatch
c. Material mass balance :
Table 6.0 Typical Material Balance for POY Fibre – Production capacity of 7500 MT
Sr. Consumption in Quantity in

No Input material MTPA Output material MTPA
1 Base white polymer Chips 7615.55 POY Fiber 7500
(PET/ RPET/ PA6)
2 Colored Chips for (colored 350 Un useable fiber on 262.50

chips made in our RM plant . It bobbins ( Bi-
uses color pigments product)
compounded with base
polymers)
3 spin finish oil 35 Yarn waste 179.55
Hard Flushing waste 21.00
Moisture and other 37.50
system losses
Total 8000.55 8000.55

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(vii) Raw material required along with estimated quantity, likely source, marketing area of final
products/s, mode of transport of raw Material and finished product :
Detailed raw material requirement along with estimated quantity, likely source, marketing are of
final products mode of transport of raw material and finish product
• Raw material requirements:

Table 7.0
List of Raw-materials
S.No Raw material Per Ton of Quantity
BCF required for in
production TPA ( Tons per
in Tons annum)
For BCF Production

1 Base white polymer( PP/ 1.0166 17790.5
PET/ RPET/ PA6 Chips
2 Color pigments 0.04 700

3 Spin finish Oil 0.01 175
FOR POY Production
1 Base white polymer Chips 1.0154 7615.55
(PET/ RPET/ PA6)
2 Colored Chips with 0.0467 350

Additives
3 Spin Finish Oil 0.00467 35
• Marketing area of final products:

Company is manufacturing Bulk Continuous Filament yarn and Partially Oriented Yarn (FDY)” which
is used in the process of manufacture of Tufted wall to wall carpet and floor tiles unit established in
house
• Transport of Raw material and Finish products:
Table 8.0 Storage and Transportation of Raw materials
Sr. Name Storage Means of Mode Of Source

No. Capacity Storage transport
1. Chips for POY / FDY 500 MT Ware house By road in truck Manufacturer
2. Spin finish oil 50 MT Storage Tank By road in Manufacturer
3. Pigments 10 MT Ware house tanker
By road in truck Manufacturer
4. Waxes 5 MT Ware house By road in truck Manufacturer
(viii) Resource optimization/ recycling and reuse envisaged in the project , if any , should briefly
outlined :
 By adoption continuous improvement in technology and process the reduction in process

waste generation will be achieved.

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 Efficient handling of raw materials the wastages of raw materials will be reduced.
(ix) Availability of water its source, Energy/power requirement and source should be given:
Availability of water its source, Energy/power required and its source.
• Water Requirement
Table 9.0 Water requirement
S.No. Stream Fresh Water Recycled Total

requirement in KLD KLD
KLD
1 Process
Monomer washer 3.5 0 3.5

(BCF)
Spin Finish 1.5 0 1.5
Preparation (POY)
Burn out (BCF & 4 0 4
POY)
2 Cooling tower 445 27.5 472.5
make up
2 (a) HVAC Make up 120 34 154
3 Boiler * 99 0 99
4 Domestic 24 0 24
5 Gardening & 0 19 66
Landscaping
Total 688 80.5 768.5
* Steam requirement is met from common boiler for both plants. Quantity given here for steam
requirement of this plant
Source of water : Supplied through TSIIC Pipeline
• Energy Requirements and its source:

Table 10.0 Energy Requirement
Sr. No. Particulars Existing Proposed Source

1 Steam Nil 3750 Kgs/Hr Two nos. of Steam Boiler having
requirement (max) steam generation.
capacity of 10 T/hour will be
established as common resource for
this plant and Tufted carpet plant One
will be stand by. Fuel will be either
coal or Rice Husk

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• Power Requirements and its source:

Table 11.0 Power requirement
Sr.
Particulars Requirement Source
No.
Power –Electricity
1 8.7 MW TS PDCL
requirement
(x) Quantity of waste to be generated (liquid and solid) and scheme for their
Management/disposal:
Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal.
• Quantity of Waste Water (liquid waste) generation and its management :
Table 12.0 Waster water generation & Management
S.No. Stream Waste water Treatment &

generation in Point of Disposal
KLD
1 Process
Monomer washer (BCF) 2.5 Will be treated in

Spin Finish Preparation 0 ETP, RO and MEE
(POY) and re-used for
Burn out (BCF & POY) 4.0 cooling tower
2 Cooling tower blow down 50.0 Blow down water
Will be treated in
RO and re-used
2 (a) HVAC system blow down 3.0
3 Boiler blow down 2.0 Will treated in RO

and re-used
4 Domestic 19 Treated in STP
and re-used for
plantations
Total 80.5
• The Domestic waste water generated will be treated in STP and reused for plantation purpose
• Industrial waste water in the form of washing are treated in ETP and then send to RO. RO rejects
will be send to MEE and RO Permeat will be used back for utilities
• Blow downs from utilities will be treated in RO and rejects will be sent to MEE and permeate will
be re-used
• Hence, there is no discharge of treated effluent

23
Water Balance Diagram: considering proposed
Figure 6.0 Water Balance diagram
Fresh water
(688 KL/day)
24.00 KL/day 9.00 KL/day 301.5 KL/day
Domestic Boiler, Cooling Tower

Process
15.00 KL/day & HVAC
9.00 KL/day
655KL/day
19.00 KL/day 6.5 KL/day 55 KL/day
STP
Total Effluent (61.5 KL/day) (
Process effluents will be treated in
ETP followed by RO and MEE Reused for
Utility blow downs will be directly Condensate utilities
Gardening send to RO from MEE
19.0 KL/day
Detailed of Effluent Treatment Plant
• Design Criteria:
• Product : Synthetic Filament Yarn
• Source of Effluent : Process Washings & Process effluents from Tufted carpet plant
• Design Flow of Effluent : 25 KL/day Max.
• Design Parameter : As under
Table 13.0
Effluent Characteristics
Sr. Test Parameters Untreated effluent Treated Effluent

No.
1. pH 6 to 8 6.5 to 8.5
2. Suspended Solids (mg/lit) 250 to 350 <100
3. Total Dissolved Solids (mg/lit) 1500 to 2000 <2100
4. COD Value (mg/lit) 2000 to 3000 <100
5. BOD Value ( 3 days at 27o c) (mg/lit) 900 to 1300 <30
6. Oil & Grease (mg/lit) 10 to 25 <10

24
EFFLUENT TREATMENT SCHEME
1. PRIMARY TREATMENT
UNITS : Oil & Grease removal Tank

Collection Cum Neutralization / Reaction Tank
Primary settling and sludge removal
The effluent coming from the plant is initially passed through the Oil & Grease removal system. The oil
free effluent is then collected into the collection cum reaction tank. In the collection cum reaction tank
various chemicals like None Ferric Alum, Caustic soda/acid and polyelectrolyte (coagulant) are added
to ensure proper settling which reduces the suspended solid concentration, colour and COD in the
effluent. The treated effluent is then fed into the primary clarifier. Clear effluent from primary settling
tank is charged into the secondary treatment tank (Aeration tank) and settled sludge is discharged into
the sludge drying beds and leached of the sludge drying beds is going back to collection tank.
2. SECONDARY TREATMENT (BIOLOGICAL TREATMENT)
UNITS: Aeration Tank & Secondary clarifier

The primary treated clear effluent is passed through the aeration tank where the biodegradation of the
organic matter is taken place in presence of active microorganism and required Dissolved Oxygen level.
During the biological treatment BOD Value and COD Value are reduced. After the biological treatment
(aeration tank) the effluent with the biomass is passed through secondary settling tank where biomass
is settled and settled biomass is recycle back to aeration tank or if excess is discharged into the sludge
drying beds. And clear effluent is collected into the holding tank.
3. TERTIARY TREATMENT
UNIT: Sand Filter & Ultra Filtration

After secondary treatment the effluent is passed through sand filtration and ultra filtration along with
utilities blow downs . Treated water sent to RO System. The Rejects from RO will be sent to MEE for
evaporation. Concentrate from MEE will be send to dryer and Dried salts are disposed to TSDF facility.
The condensate from MEE will be send back to units for utilization in utilities.
The company will monitor the characteristics of the effluent and as required by state pollution Control
Board
The Process flow sheet of proposed ETP is given hereunder

25
Figure 7.0 ETP Flow Diagram
Effluent Treatment Plant
Tufted Carpets Collection Tank Waste Water BCF & POI Plant
Plant 10 KLD 9.0 KLD
Preliminary Treatment
Oil & Grease trap, Flocculation, Clarifier,
Biological Treatment
Aeration system and secondary clarifier
19KLD
Tertiary treatment
Blow downs from utilities From BCF plant ( 55KLD)
Sand & Ultra Filtration & RO

Blow downs from tufted carpet plant (84 KLD)
45 KLD
Recycled back
MEE
Condensate Condensate
42 KLD 3 KLD ( concentrate

Dryer TSDF
Salts
• Utility Emission & Control Measures :
❖ Utility Emissions & Control Measures as per existing permissions and proposed project:

26
Table 14.0 Emission sources and controls
Details Fuel & its Probable Emission Control Remark

consumption Pollutants Rate Measures
Stand by HSD = 12 PM <100mg/Nm3 Stack Ht: Will be
D.G. Sets: KL/Month SO2 < 100 ppm 20 meters. common
3 x1500 KVA NOx < 50 ppm With resource for
Acoustic both this
enclosure plant Tufted
carpet plant
Steam Boiler: 2 Coal /Hsuk PM <115 Stack Ht: Will be
Nos. If Coal – 20 SO2 mg/Nm3 30 meters common
Capacity: TPD NOx < 100 ppm With Bag resource for
2x 10 TPH Capacity If Husk – 35 < 50 ppm filter as both this
TPD control plant Tufted
equipment carpet plant .
Monomer washer Nil PM <100 Stack Ht: Water trap
mg/Nm3 15 meters.
The company is installing 3 D.G. Sets of 1500 KVA capacity each. The D.G. Sets will act as standby
unit and will be only utilized in case of power failure. The company has valid consent to operate
under the air act to operate D.G. Sets. Flue gas stack monitoring reports are enclosed for the same.
The company will provide adequate chimney height to the utilities in order to control the utility
emissions. Apart from the above mentioned utilities, there will be Cooling Tower, DM Water Plant
and Chillers. The company will use Coal/Husk for boiler as fuel and HSD for DG sets.
• Quantity of Solid Waste generation and its management :
The hazardous waste will be generated from process, ETP, machinery and raw material
consumption. All the wastes will be stored separately in a designated storage area safely and
properly. The company will send its ETP waste to Ramkey TSDF facilities near Hyderabad
for final disposal.
Yarn waste from process will be sold to other users. Used oil from machinery will be sold to
registered recycler/re-processor. Empty drums and bags will be sold to authorized re-
conditioner & authorized scrap vendor. The following wastes will be generated from the
operational activities.

27
Table 15.0 Hazardous and Non hazardous waste generation and Disposal
Types of
Source of Total Quantity
Waste & Storage Methods Method of Disposal
Generation per Year
Category
ETP Waste From ETP 1 MT/Day Will be stored at a Will be sent to TSDF Site
(32.1) separate storage area of Ramkey near
Hyderabad.
MEE Salts From MEE 0.9 T/day Will be stored at a Will be sent to TSDF Site
separate storage area of Ramkey near
Hyderabad.
Used oil (5.1) From 1.5 TPA Will be stored in Will be sold to registered
process drums recycler/ re-processor.
Empty Raw 10000 Will be stored at a Will be reused internally
drums/ material Nos./Year separate storage area and sold to authorized
bags/Liners cons. scrap vendor or reused.
(33.3)
Left over yarn From 2500 Kgs/day Will be packed in bags Will be recycled back
on bobbins process and stored at a /sold to other users
designated area
Yarn soft From 1710 Kgs/day Will be packed in bags Will be sold to other
waste process and stored at a users/Authorised re-
designated area processors
Hard Flush From 200 Kgs/day Will be packed in bags Will be sold to other
Waste ( process and stored at a users/Authorised re-
Generated designated area processors
when there
are power
failures )
Other From 7000 Kg/day Will be stored in Will be given to scrap
packaging Stores designated area dealer
Waste
Coal/Husk From Boiler 10 T/Day Will be stored in Will be sold to brick
Ash section closed shed manufacturers
Details of Hazardous Chemicals
There are no hazardous chemicals used in the existing manufacturing process. Also, there will be
no hazardous chemicals involved in the process in the proposed expansion project.
Health & safety
The company is concerned about the occupational health and safety among its work force as the
man power is the biggest asset to the industry. The On-site Emergency Plan is prepared and
implemented for existing activities and will be modified as per proposed change in product mix and
will be implemented. The Off-site Emergency Plan is available with the District Collector Office, RR
district.
The following safety measures are implemented and will be followed:
➢ Safety Training will be provided to the employees.

28
➢ Safety Alarm Systems are installed for use, in case of emergency.

➢ Emergency Control Room with emergency sirens is established.
➢ Assembly point is provided.
➢ Fire Hydrant System proposed .
➢ Fire Extinguishers are provided.
➢ Mock drills are periodically conducted and factors like response time are evaluated.
➢ Fire squad team is formed for handling any emergency situation & regular training of squad
team will be conducted.
➢ First Aid Facility and training is provided.
➢ Personal protective gears and equipment’s is provided to the employees.
➢ Health checkups are organized at regular intervals.
➢ Safety / Health records and MSDS will be maintained.

29
(xi) Schematic representations of the feasibility drawing which give information of EIA
purpose:
Type of Industry
Proposed mfg. unit of “Man Made fiber-other than Rayon”
Type of category as per EIA

notification:Man Made fiber (Activity -5(d)-
Category-B)
Proposed Activity:
The proposed project involves the production of "Synthetic Site Location:
Filaments Yarn- Manmade fibers" manufactured from Chips The company proposed this unit at SY. No 190,
Chandanvalle (V), Shabad (M), Ranga Reddy
District of Telangana
Public consultation: Not required it is B2 project as per As per the

Submission of Form-1, Pre-Feasibility Office Memorandum No. J-13012/12/2013 – IA -II (I) dated 24th
Report as it is category B2 as per the OM December,2013
Resource requirements Presentation before the EAC for TOR

• Raw Material: Sourced from Manufacturer / Traders of the same.
• Land: Expansion within existing premises.
• Water: Will be sourced from TSIIC from surface water source
• Power: power will be sourced through TS PDCL
• Fuel : Local dealer
Env. Mgt. Plan (EMP)

• Air Pollution Control Measures: Air Pollution control system will be
provided.
• About 33% of the Total Area will be developed as Greenbelt.
• Health & Safety measures will be followed properly
• STP for domestic water and treated water to go for plantation

• ETP will be provided for Industrial waste water with ZLD concept
• Flue Gas emissions: Bag filters for boilers Adequate chimney height
will be provided.
• Fugitive emission: There is no generation of fugitive emissions.

30
3. SITE ANALYSES
3.0 Site Analysis
(i) Connectivity:
The project is located in Chandanvalle (V) which is very well connected to National Highway no.7
which is about 14.3 KM from the site. And the nearest air port Hyderabad Air port which is about
26 KM from site.
(ii) Land Form, Land use and Land ownership:
1. The land is owned by M/s. Welspun Flooring Limited , allotted by TSIIC
2. The land is near Chandanvalle(V) and not in notified industrial area
(iii) Topography (along with map) :
Base map showing the study area below
Figure 8.0 Base map of the study area

31
(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including
area under CRZ)), shortest distances from the periphery of the project to periphery of the
forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from
the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification
should be given:
Current land use is agricultural land and same is allotted by Telangana State Industrial
Infrastructural Corporation . Copy of letter from TSIIC is enclosed at Annexure. It does not come
under CRZ. No National parks, wild life sanctuaries, eco sensitive zones within 10 KM radius. The
site does not come under HFL of any river.
(v) Existing Infrastructure:

Total 600 acres of land is allotted to the company by TSIIC for various units to be established by
company. Out of this, 200 acres are allotted to Tufted carpet plant. Tufted carpet plant already
obtained CFE from state Pollution Control Board of Telangana and plant is under
implementation. This unit is back ward integration plant. Industrial infrastructure will be
developed as a part of this project
(vi) Soil classification:

General soil classification of the area is as under:
• Soil Characteristics & Land use classification: Most of the area cultivated depending on rain fed
and bore wells
• Surface color: black soils
• Depth of the soil: 0 - 25 cm (shallow to mod deep)
• Predominant Texture: Heavy Texture, predominantly clay.
(vii) Climate data from secondary sources:

Rainfall Data:
Rainfall data was taken from central Ground water board data , indicates that the mean spanning
the period 1999 -2011 is medium to high 51.6 to 110.13 cm rainfall
Climate data:
Rangareddy District is in Deccan Plato the mean temperature of the area is about 30 Deg C. Peak
summer temperature reaches up to 43 Deg C and winter lows will be around 12-13 deg C
(viii) Social Infrastructure available:

Social Infrastructure in RR District is here under
Education:
The educational quality of the local people is fairly good as the literacy rate of the area is
recorded to be 75.87%. Male literacy rate is 82.11 and female literacy rate is 69.4%
Health:
The region is served by 4 medical college hospitals, 4 General hospitals , 39 Primary Health
centers, another 30 dispencerties. The crude birth rate is 17.4 and infant mortality rate is 39 for
1000 live births

32
Education:
Basic educational facilities are well developed RR District. There are 126 degree colleges, 563
Junior colleges, 134 Engineering colleges, 4 medical colleges, 5263 Schools.
Tourism:
Rangareddy District is very close to Hyderabad City. Many mandals of the District are suburbs of
Hyderabad. There are many tourist destinations in Ranga reddy District which include old siva
temple in Maheswaram, Lord Venkateswara temple near Chilukur, Anantagiri Hills which is
having resorts, Ramoji Film City which is well known film city complex in the country, Sanghi
Temple complex in Sanghi nagar, Himayat sagar, Shamirpet lakes are few to mention. However
there are no tourist spots within 10 KM radius of the current project site

33
4. Planning Description
4.0 Planning Brief.
(i) Planning Concept (Type of industries, facilities, transportation etc) Town and Country
Planning /Development authority Classification:
There are few small scale units, primary agro based units are there within the vicinity.
(ii) Population Projection:
Rangareddy District is having total population of 52,96,741 people with population density of
707 people for square KM. The compound annual growth rate is 4.01 as per 2011 census data
(iii) Land use planning (breakup along with green belt etc):
Area Statement
Table 16.0 Area statement
Sr. No. Area Area Statement (Sq. mt.)
1. Total Plot Area 8,09,200
2. Total build up area for Tufted wall carpet plant 53.799
3 Total build up area for BCF& POY plant 17,939

4 Other utilities, ware house, parking etc. 53,706
3. Total Green belt Area 1,13,547
4. Open Plot Area for future expansion 5,70,209
Site Layout Plan

34
(iv) Assessment of Infrastructure demand (Physical & Social) :

There is no need for any additional infrastructure demand in terms of physical or social needs.
(v) Amenities/ Facilities:

TSIIC is providing all necessary infrastructure like power, water supply and road connectively to
site etc.

35
5. Infrastructure Details
5.0 Proposed Infrastructure:
(i) Industrial Area (Processing Area).
The proposed BCF and POY plant require shed and other support facilities which will be built.
Steam generation, ware house, stand by power generation , ETP , STP , parking facilities are
common to both Tufted carpet plant and this plant which are under development
(ii) Residential Area (Non Processing Area) :

No residential area is involved in the proposed expansion project.
(iii) Green Belt:

Green belt area will be provided and maintain at the tune of 33% of the total land area.
(iv) Social Infrastructure:

Facilities like road and communication are good. One can be sure of the uninterrupted power
supply and adequate water. There are plenty of hotels, Banks, ATM's and medical facilities are
also adequate within 10 KM radius of the plant
Amenities: Education- 30 schools including middle, secondary and higher secondary schools, 6
social welfare hostels, 2 libraries, 3 engineering colleges , 2 degree colleges are accessible to site .
Medical and Health- There is a Civil Hospital in Samshabad, Primary health center in Shabad and
other private dispenceries near by
Power and water- All the villages are electrified and drinking water facilities are extended to all
villages.
Rail and Road- The nearest railway station is Vikarabad which is 30 KM from the site. From there
the site is well connected through Shabad road which District road. NH 7 is at about 14.06 KM
(v) Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc) :
The project site is very well connected by road through National Highway no. 7 and South Central
Railway
(vi) Drinking Water management (Source& Supply of water) :

Water requirement will be fulfilled through TSIIC water supply line sourced from surface water
sources
(vii) Sewerage System:

There will be no discharge of industrial effluent (Zero Liquid Discharge). The treated effluent will
be utilized for utilities
Domestic waste water will be treated and re-used for plantation purpose
(viii) Industrial Waste Management:

Washings from process and blow downs from utilities will be treated in ZLD treatment plant and
re-ued
(ix) Solid Waste Management:

36
Table 17.0 Details of Solid Waste Management
Types of
Source of Total Quantity
Waste & Storage Methods Method of Disposal
Generation per Year
Category
ETP Waste From ETP 1 MT/Day Will be stored at a Will be sent to TSDF Site
(32.1) separate storage area of Ramkey near
Hyderabad.
MEE Salts From MEE 0.9 T/day Will be stored at a Will be sent to TSDF Site
separate storage area of Ramkey near
Hyderabad.
Used oil (5.1) From 1.5 TPA Will be stored in Will be sold to registered
process drums recycler/ re-processor.
Empty Raw 10000 Will be stored at a Will be reused internally
drums/ material Nos./Year separate storage area and sold to authorized
bags/Liners cons. scrap vendor or reused.
(33.3)
Left over yarn From 2500 Kgs/day Will be packed in bags Will be recycled back
on bobbins process and stored at a /sold to other users
designated area
Yarn soft From 1710 Kgs/day Will be packed in bags Will be sold to other
waste process and stored at a users/Authorised re-
designated area processors
Hard Flush From 200 Kgs/day Will be packed in bags Will be sold to other
Waste ( process and stored at a users/Authorised re-
Generated designated area processors
when there
are power
failures )
Other From 7000 Kg/day Will be stored in Will be given to scrap
packaging Stores designated area dealer
Waste
Coal/Husk From Boiler 10 T/Day Will be stored in Will be sold to brick
Ash section closed shed manufacturers
(x) Power Requirement & Supply / Source:
Power requirement for proposed project will be taken from TSPDCL and stand by DG sets are
proposed in case of any power outage

37
6. Rehabilitation and Resettlement (R&R) Plan:

(i) Policy to be adopted (Central/ State) in respect of the project affected persons including
home oustees, land oustees and landless laborers (a brief outline to be given):
There will be no rehabilitation and resettlement undertaken as labours and workers from local &
nearby areas for the proposed construction activity, which will be minor as the proposed plant
activity. The land is purchased from TSIIC
7. Project Schedule & Cost Estimates:

(i) Likely date of start of construction and likely date of completion (Time schedule for the
project to be given):
After obtaining Environmental clearance and Consent to Establish from PCC, the company shall
implement the proposed project.
(ii) Estimated project cost along with analysis in terms of economic viability of the project:
Estimated project cost along with the analysis in terms of economic viability of the project Plant &
Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the major heads
considered in the Capital Cost Projection for the proposed expansion project. Environment
Protection has also been considered in planning the Cost Projection, which will include Green belt
development, safety systems, etc.
Table 18.0
Capital Cost Projection
Project cost
Rs. In lakhs
Civil 5450
Contingency 1546
Imported Machinery 16939
Indigenous Machinery 954
Misc. Fixed Assets 7411
Preoperative 2175
Project cost 34475
The company will provide budgetary provision for the recurring expenses for environmental
issues while planning the allocation of funds during the annual budgetary planning.
Table 19.0
Budget for Environment & Safety
S.No Area Budget in Lakhs
1 Effluent Treatment Plant 250
2 Bag filters for boilers 40
3 Acoustic enclosures to DG sets 15
4 Greenbelt 25
Fire hydrant system and other
5 85
safety provisions
6 Rain water harvesting 50
Total 465

38
Table 20.0
Recurring costs
Sr. Proposed
Component
No. (Rs. in Lacs/annum)
Environment & Safety Management
1. System and environmental 50.00
monitoring.
2. Greenbelt Maintenance 10.00
Enterprise Social Contribution for @
3. 51.70
1.5% for 10 years
Total 111.0
8. Analysis of Proposal (Final Recommendations):
(i) Financial and social benefits with special emphasis on the befit to the local people
including tribal population, if any, in the area:
Proposed activity will provide benefits to the local people in terms of financial and social welfare.
• Local people will get direct financial benefit by way of employment.
• Local people will get some contracts of supply and services to get indirect income.
• Company will contribute in improving education and health facilities in nearby area.

39

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Prefeasibility Report Welspun Flooring Limited

Proposed Green filed project

“MANMADE FIBER - (OTHER THAN RAYON)”

M/s. Welspun Flooring Ltd

Unit proposed location :

Name of the Project: M/S Welspun Flooring Limited

Applicability of EIA notification – 2006

LIST OF FINISHED PRODUCTS ( Proposed)

S.No Name Of the Product Capacity (MT/Annum)

Manufacturing : Manmade Fiber Industry

• Product wise Raw material Consumption

2 Chips for Colorization 700

3 Spin finish oil 175

Components Requirement Sourced from

Water and Waste Water Management

 6.5 KLD of wastewater is generated from Monomer washer and Burnout.

Air Emission and its Control Measures

Solid & Hazardous Wastes and its Management

Details of Hazardous Chemicals

Manufacturing : Manmade Fiber Industry

2. Dipali Goenka Director “Rocky Isle”, 46/C, B.Desai Road,

4. Devendra Patil Director B/13, Yojna Co-Operative

5. Pradeep Poddar Independent Flat No. 2, Mont Blanc, 22nd

Manufacturing : Manmade Fiber Industry

(ii) Brief description of nature of the Project

Manufacturing : Manmade Fiber Industry

Business Model (Manufacturing Flow chart)

Bringing the Chips Melting the Mixture Stretching

Conveying of Chips, Spin pack - heart of spinning.

Quenching Cooled strand of fibres is then lifted off from

Extruder Spin Finish Application

Manufacturing : Manmade Fiber Industry

• Nylon Filament Yarn

(v) Imports vs. Indigenous production

(vi) Export Possibility / Domestic / export Markets

Employment Generation (Direct and Indirect) due to the project

Manufacturing : Manmade Fiber Industry

(i) Type of Project including interlinked and interdependent projects, If any :

Manufacturing : Manmade Fiber Industry

Figure 3.0 Topo Map of The Plant and 10 KM radius

Manufacturing : Manmade Fiber Industry

(iii) Profile of Project Site:

4 Nearest Town Shabad– 8 Km SW (Approx.)

1 Tufted wall carpet & Tiles plant 53799

Manufacturing : Manmade Fiber Industry

Site Layout Plan:

Figure 4.0 Site Lay out plan

Manufacturing : Manmade Fiber Industry

Figure 5.0 Plant lay out plan

Manufacturing : Manmade Fiber Industry

(v) Size or magnitude of operation :

(vi) Project description with process details :

• LIST OF FINISHED PRODUCTS

Proposed products & capacity

S.No Production Details Quantity In MT

2 Partially Oriented Yarn (POY) 7, 500 MT/Annum

• INFRASTRUCTURE, MACHINERIES, EQUIPMENT & TECHNOLOGIES

 List of critical machinery involved in manufacture of Synthetic Filament yarn

Table 4.0 Critical Machinery Proposed

Sr. No. Description of Equipment Sr. No. Description of Equipment

Manufacturing : Manmade Fiber Industry

01. Product: Bulk Continuous Filament Yarn (BCF)