PFR of M/s.

Rebecca Laminates

PRE FEASIBILITY REPORT

FOR OBTAINING ENVIRONMENTAL CLEARANCE

For the Proposed Expansion project of Resins and
Laminated Sheets Manufacturing Unit of

M/s. Rebecca Laminates

Survey No. : 132/P1, N.H. 8 A, Village: Bahadurgadh,
Taluka & District: Morbi, Gujarat.
Contact No.: 9712962848
Email: rebeccaind@[Link]

Prepared By:

T. R. ASSOCIATES
C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump,
S. G. Highway, Ahmedabad
Contact No.: 98253 71099
Email: [Link]@[Link]

January 2017

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 PFR of M/s. Rebecca Laminates

1. Introduction

M/s. Rebecca Laminates is a partnership firm proposing to expand and set up a medium
scale Resin and Laminated Sheet Manufacturing unit at Survey No.: 132/P1, Village:
Bahadurgadh, Taluka & District: Morbi, Gujarat.

2. Project Proponent and their back ground

Company is promoted by its partner. Detail of partners is as given below.

Sr.
Name of the Partner Background
No.
[Link] with 38 years of business
1. Gopalbhai Mohanbhai Charola
experience.
12th pass with 25 years of business
2. Kanjibhai Parbatbhai Patel
experience.
8th pass with 15 years of business
3. Shaileshbhai Thakarshibhai Bavarva
experience.
9th pass with 20 years of business
4. Aravindbhai Jadavjibhai Charola
experience.
12th pass with 10 years of business
5. Jignesh Keshavjibhai Bavarva
experience.
6. Jethalal Valjibhai Vadsola D.S.A.C
12th pass with 30 years of business
7. Bharatbhai Jethabhai Vadsola
experience.

8. Manishaben Pareshbhai Vadsola B.A

8th pass with 30 years of business

9. Mavjibhai Popatbhai Rambhiya
experience.

3. Brief description of nature of the project:

M/.s Rebecca laminate is manufacturing Laminated sheet, Phenol formaldehyde resin and
melamine formaldehyde resin at Survey No.: 132/P1, N.H 8A, Village: Bahadurgadh,
Taluka & District: Morbi, Gujarat. Now they want to expand their production capacity and
add Urea formaldehyde resin in their existing plant due to higher market demand. This is
kind information to you that resin is used for manufacturing of laminate sheets as well as
sale purpose.

M/s. Rebecca Laminates is willing for expansion to manufacture Melamine Formaldehyde

Resin, Phenol Formaldehyde Resin & Urea Formaldehyde Resin as well as Laminated
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Sheets at Survey No.: 132/P1, N.H 8A, Village: Bahadurgadh, Taluka & District: Morbi,
Gujarat. The existing products are already used for captive consumption as well as for sale
purpose, where in the proposed products also shall be used in the same manner.

Manufacturing of Laminated sheets does not require environmental Clearance from the
ministry of Environment Forest and Climate change, New Delhi. But phenol
formaldehyde resin, melamine formaldehyde resin and urea formaldehyde resin
manufacturing process falls into 5(f) category (Synthetic organic chemicals) of the EIA
notification 2006 and their amendments required to obtain Environmental clearance from
the MOEF&CC. In exiting unit they have obtained EC for manufacturing of laminated
sheets, Phenol formaldehyde resin and Melamine formaldehyde resin vide letter no
SEIAA/GUJ/EC/5(f)/3075/2015 from State environmental impact assessment Authority,
Gandhinagar dated on 21-08-2015. M/s. T. R. Associates has been appointed to carry out
EIA/EMP studies for obtaining Environmental Clearance.

As per amendment in EIA notification dated on 15/01/17, industry have water

consumption 63.8 KLD, formaldehyde storage capacity is greater than 5 Kl, and fuel
consumption is 6.73 MT/day after expansion. Due to above said condition; company will
have to obtain EC for Proposed expansion capacity from the MoEF&CC, New Delhi.

The total land area of company is 14,569 m2 out of which 4810 m2 (33 % of total land) area
will be used for greenbelt development. The total cost of the project after proposed
expansion is 7 Crores (i.e. Existing project cost is 6.19 Crores & 0.81 Crores for proposed
project). Total budget allocation towards Environmental Management Facilities will be
approx. Rs. 48 Lacs (i.e. 18 Lacs for existing & 30 Lacs for Proposed expansion). Total 80
persons are already employed including skilled persons, unskilled persons and office
staff. For the proposed expansion 10 employees shall be appointed for the project, so the
total staff will be 90 employees.

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

Resins are used predominantly in the wood based product manufacturing industry as
adhesives. Growth of the resin market is strongly correlated to construction/remodeling
activity (which accounts for over 50% of consumption), and to a lesser degree, to the
automotive industry.

The proposed products like Resins (Melamine Formaldehyde, Urea Formaldehyde and
Phenol Formaldehyde Resins) mainly used to manufacture Laminated Sheets. These
sheets have good market demand to develop the home and office for furniture.

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Demand-Supply Gap:

Laminated sheets are becoming very popular particularly plastics, paper & wooden.
Wooden laminates are highly popular.

Laminations are used for industrial purposes as well as decorative purposes. Industrial
lamination is used mainly for packaging materials. To looking its uses we can say that
there is a good scope for any new entrants.

Indian market for laminates is mainly driven by increasing demand from housing market.
The demand has increased due to growing significance of new construction industry.
Laminates have become an indispensable part of big and evolving markets. The increased
demand in these markets triggers the demand in the laminates market. Apart from this,
increasing urban population, rising per capita income and a gradual shift towards non-
food industry are other key factors driving the growth of laminates industry in India. The
combined worth of the plywood and laminates industry is believed to be to the tune of
Rs.21,000 crore per year, with laminates accounting for a share of approximately Rs.3300
crore, and the industry is expected to keep on growing further in the years to come.

Global demand for decorative laminates is expected to rise 5.6 per cent per year to 10.7
billion square meters in 2018, valued at $40.8 billion. Demand will benefit from expected
increases in the manufacture of products such as cabinets, ready-to-assemble (RTA)
furniture, and flooring, which are often made from laminated engineered wood. Gains
will also be driven by increased market penetration at the expense of other surfacing
materials (wood veneer and paint) due to cost and performance benefits. Laminates will
benefit from the continued improvement in textures and in printing techniques that create
advanced graphics rivalling the aesthetics of alternative materials.

Imports v/s Indigenous production:

Indian market is open and big that is why every kind of import is booming. Indian
plywood and panel trade has become global place as the consumption of different
imported ply panels are on the rise. Unlike before Indians are now welcomed by plywood
manufacturer of China. Earlier India was a self-dependent country for commercial or high
quality plywood, but sharp drop in domestic manufacturing output has resulted in
material sourcing from countries like Burma, Malaysia, Indonesia, China, Vietnam etc.
Now Indian plywood market is somehow curtailed or competed by incoming panel
products from China. Be it film face, decorative, laminate or MR plywood everything is
now being imported partially or more and is sold. Indian industrialist must understand
the fact that it’s no more a regional shift, it is a global shift. Indian technology should be
upgraded and updated as per the international standards.

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The working environment in India has changed tremendously. Earlier the trade fairs were
hardly participated by foreign timber, lumber and plywood manufacturing companies
where as now it is flooded with global suppliers.

Export Possibility:
There is market of Resins as well apart from laminated sheets. Resins are intermediate
products for manufacturing of Laminated Sheets. Resins are quite expensive for export, as
compared to the export of laminated sheets. So we have only local market for sale for
resins.

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

This project has already provided direct employment to 50 persons whereas it will
provide employment to many others indirectly. Plywood and Laminated sheet
manufacturing industries provide employment to large number of people.

4. Project Description
(i) Type of project including interlinked and interdependent projects:
Resins including P.F. resin, M.F. resin & U.F. resin are used in production of laminated
sheets and plywood. So plywood industries, laminated sheets industries will be
interdependent on resin industries.

(ii) Location
Proposed project is to be located at Survey No.: 132/P1, N.H. 8A, Village: Bahadurgadh,
Taluka & District: Morbi, Gujarat
Geographic Coordinates - Latitude: 23°01'59.74"N and Longitude: 70°48'42.03"E
Google image showing proposed project site is given below;

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Salient features in the surroundings area of the proposed site within 10 km radius are as
follows:

Sr. No. Important Features Description

1 Location Survey No.: 132/P1, N.H. 8A, Village:
Bahadurgadh, Taluka & District: Morbi, Gujarat.
2 GPS Coordinates Latitude: 23° 2'1.10"N
Longitude: 70°48'37.90"E
3 Temperature Range 15˚C to 43˚C
4 Mean Sea Level 14 m
5 Annual Rain Fall 500 - 600 mm
6 Nearest Railway Station Aerial distance of Malia Railway Station – 9.50
km in NW direction
Road distance of Malia Railway Station – 12.5
km in NW direction
7 Nearest Airport Aerial distance of Rajkot Airport – 79.30 km in
South direction
Road distance of Rajkot Airport – 92 km in
South direction
8 Nearest Town Aerial distance of Jetpur, Morbi – 8.5 km in ESE
direction
Road distance of Jetpur, Morbi – 10.5 km in ESE
direction
9 Nearest Village Aerial distance of Bahadurgadh - 1 km in SSW
direction
Road distance of Bahadurgadh – 1.5 km in SSW
direction
10 Nearest National Highway NH 8A – 0.02 km in W direction
11 Nearest River/Water body Aerial distance of Macchu River – 4.8 km in
WNW direction
Road distance of Macchu River – 7.8 km in
WNW direction
Aerial distance of Narmada Canal – 5.20 km in
NNE direction
Road distance of Narmada Canal – 9.8 km in
NNE direction.
12 National Parks / Sanctuary Wild Ass Sanctuary is – 10.8 km radial distance
from the project site in North direction.

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Google Image of Proposed Location:

Sr. No. Latitude Longitude

Project Site 23° 1'59.74"N 70°48'41.94"E

A. 23° 2'1.10"N 70°48'37.90"E

B. 23° 1'58.42"N 70°48'38.39"E

C. 23° 1'58.89"N 70°48'45.69"E

D. 23° 2'0.98"N 70°48'45.32"E

E. 23° 2'0.70"N 70°48'43.17"E

F. 23° 2'0.66"N 70°48'40.98"E

(iii) Alternative Sites considered

No other sites were selected.

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(iv) Size or magnitude of operation

List of Products
Quantity (MT/Month)
Sr. Name of
No. Product Total after
Existing Proposed
Expansion
Phenol
1 Formaldehyde 87.5 412.5 500
Resin
Melamine
2 Formaldehyde 37.5 462.5 500
Resin
Urea
3 Formaldehyde 00 500 500
Resin

Laminated 69,000 1,81,000 2,50,000

4
Sheets Sheets/Month Sheets/Month Sheets/Month
Note: Resins will be used for captive consumption as well as sell purpose.

(v) Project description with process details

Details of manufacturing process are given in Annexure- 4 of Form- 1.
(vi) Raw material required along with estimated quantity.

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Production Capacity Raw materials Used

Total after
Sr. No. Name of the product Existing Proposed Total after expansion Name of the raw material Existing Proposed
expansion
Phenol 40 187 227

1 Phenol Formaldehyde resin 87.5 412.5 500 Formaldehyde (37%) 49 230 279

Caustic 5 22 27

Melamine 15 184 199

Melamine Formaldehyde
2 37.5 462.5 500 Formaldehyde (37%) 22 276 298
resin
Caustic 0.2 2.3 2.5

Urea 198 198

Formaldehyde (37%) 297 297

3 Urea Formaldehyde resin 0 500 500 0
Caustic 2.5 2.5

Acetic Acid 2.5 2.5

Kraft paper 109 285 394

Laminated Sheets Design Paper 15 40 55

4 69000 1,81,000 250000
(Sheets/Month)
Resin 186 489 675

Methanol 9 23 32

ALL UNITS ARE IN MT/Month

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(vii) Resource optimization/ recycling and reuse envisaged in the project, if any, should
be briefly outlined.
Latest Process technologies are adopted as available in market with optimum resources
requirement with highest yield and less waste and pollution generation. Treated industrial
effluent will be reused in cooling and other possible activities. In addition to this, all the
feasible cleaner production technologies will be adopted.

(viii) Availability of water its source, Energy/ power requirement and source should be
given.
Energy/power requirement will be 250 kVA which will be procured through Paschim
Gujarat Vij Company Limited.

Existing Proposed Total After Expansion

225 KVA 25 KVA 250 KVA
The total water requirement after expansion will be 42.3 kl/day which will be fulfilled by
GWIL.

(ix) Quantity of wastes to be generated (liquid and solid) and scheme for their
Management/disposal

 Hazardous Waste Generation and Disposal

Details of hazardous waste generation and its disposal are given in Annexure- 5 of
Form- 1.
 Wastewater Generation and Disposal Facility
Details of domestic as well as industrial wastewater generation and its disposal are
given in Annexure- 7 of Form- 1.

(x) Schematic representations of the feasibility drawing which give information of

EIA purpose

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1. Site Analysis
(i) Connectivity

Nearest railway station Malia 9.50 km

Nearest national highway NH 8A 0.02 km

Nearest airport Rajkot 79.30 km

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

Proposed Expansion project site has already been procured by proponent and it is a
constructed shed area where in presently the existing products are manufactured
according to the Environmental Clearance certificate.

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(iii) Existing Land Use Pattern

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(iv) Topography Map

The link to the topographical map is here.

(v) Existing Infrastructure

(1) Nearest railway station: Malia railway station is 9.5 km away from the project
site in the NW direction.
(2) Nearest highway: National Highway 8A is 0.02 km away from the project site.
(3) Nearest airport: Rajkot Airport is 79.30 km from the project site in the South
direction.
(4) Power: Total 250 kVA after expansion from Paschim Gujarat Vij Company
Limited.
(5) Water: Source of the water will be directly from Narmada pipeline (GWIL).
(6) Basic amenities: Good road connectivity with state and national highway.

(vi) Soil classification of Morbi District

The soils of Morbi district are of clayey loam to clay type. They are moderately deep to
deep and vary in colour from very dark brown to very dark greyish brown and reddish
brown. The EC of the soils is generally less than 1.0 mmhos/cm and cation exchange
capacity is between 40 and 60 me/100 gm of soil.

(vii) Climate data from secondary source

General climate of the district is sub-tropical and is characterized by three well-defined

seasons, i.e. summer - from April to June, monsoon - from July to September, and winter -
from October to March.

Temperature
Highest temperature is 43 to 46 degree centigrade in summer and lowest temperature
comes down to 7 to 15 degree in winter season.

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Humidity
The relative humidity is generally over 75 % in the south west monsoon. In the rest of the
year the air is comparatively dry, especially in the afternoons. During the period of
November to May the relative humidity varies between 40% and 50%.

Wind
In the south west monsoon season, the wind direction is towards west and south west. In
the post monsoon/cold season, wind blow from the north-north east direction. In summer
seasons the direction of the wind is mainly between north west and south west. The wind
speed gradually increases from February and reaches the peak in July when the south
west monsoon is most active. It again decreases from August and becomes low.

Rainfall
More than 90% of the rainfall occurs during the monsoon. Rainfall during the winter and
summer months is negligible. The average annual rainfall of the district is 489 mm and in
the year 2016 it is 366 mm only which is around 75 % of the average annual rainfall.

(viii) Social Infrastructure available.

 Industrialisation/Entrepreneurship:
On account of availability in huge quantity and suitable climatic condition in the
district has induced the growth of Ceramic industries hugely in Morbi taluka. At
present more than 700 enterprises in around Morbi are Manufacturing Ceramic
Tiles, Floor Tiles, Luster Wall Tiles, Glazed Wall Tiles, Vitrified Tiles, Laminated
sheets, Porcelain Tiles, 2D, 4 D Tiles, Spartek, Roofing and Mosaic Tiles. More than
100 enterprises are manufacturing specialized Vitrified Tiles which has great
demand in the region as well as all over the country. It is also hub of digital and
other types of watch and clocks manufacturing enterprises such as Ajanta, Samay,
Sonera and Sonam which are World leaders in this sector. After 2002, Paper
industries have grown rapidly as ancillary sector due to need of high quality craft
grade papers very suitable for packing of goods. There are number of export-
import houses working in the district. Besides, many enterprises deals in consumer
durables and engineering goods. Tourism also fetches significant income to the
economy of the district as many visitors visit the district having historic values.
Though the concept of avoiding risk factor for the Governmental regulations and
process causes adverse effect and resulted in weakened industrial growth.
Industrial Training Institutes, Productivity Development Centres, Small Scale
Enterprises Development Institute- Ahmedabad, District Industries Centre- Morbi
and other Non-Governmental organizations must come forward to promote more
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and more training programmes to increase and motivate the productivity of the
labour force available in the district.

 Marketing Potential:
There are well developed Market Yards in Morbi, Wankaner and Halvad taluka of
Morbi district for the distribution of the agricultural produces. Farmers can accrue
more competitive prices for their produce in these market yards by selling their
produces. There is good infrastructure in the district for the sale of industrial goods
and services manufactured and produced.
2. Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town and
Country Planning/Development authority Classification.

 Proposed project site is located near to National Highway 27 and well connected to
the internal roads and highways. The site is well connected to Wankaner, Morbi as
well as Rajkot region, where all the infrastructural and transportation facilities are
available.
 At present more than 700 enterprises in around Morbi are Manufacturing Ceramic
Tiles, Floor Tiles, Luster Wall Tiles, Glazed Wall Tiles, Vitrified Tiles, Porcelain Tiles,
2D, 4 D Tiles, Spartek, Roofing and Mosaic Tiles. More than 100 enterprises are
manufacturing specialized Vitrified Tiles which has great demand in the region as
well as all over the country. It is also hub of digital and other types of watch and
clocks manufacturing enterprises such as Ajanta, Samay, Sonera and Sonam which are
World leaders in this sector. After 2002, Paper industries have grown rapidly as
ancillary sector due to need of high quality craft grade papers very suitable for
packing of goods

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(ii) Population (Source : MSME, Morbi (2016-17))

Description No.

Population Total : 9,60,329 Person

Male : 4,94,726 Person

Female: : 4,65,603 Person

Population density 481 persons per sq. km.

Village Population Total: 6,01,909 Person

Urbanised Population Total: 3,58,420 Person

Population increase rate N.A

Male- Female ratio 1000 : 961

Scheduled Caste population 49,902persons

Scheduled Tribe population 4,036 persons

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

Sr. No. Particular Area (m2) % of Total Land

1 Built-up area 6,269 43

2 Greenbelt area 4,810 33

3 Open area 3,490 24

Total 14,569 100

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

Surrounded villages in 10 km area from the project site are having all the necessary
physical and social infrastructure facilities due to agricultural activities, animal husbandry
and industrial development within the area as well the nearby Morbi Town and
Wankaner Town & Rajkot City.

(v) Amenities/Facilities.
All the basic amenities/facilities such as power connection & power back-up, drinking
water, internal roads, water & wastewater treatment plant etc. will be provided.

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3. Proposed Infrastructure
a. Industrial Area
Industry has provided 6269 m2 built up area for industrial process/manufacturing
activity which provides all needed facility including proper ventilation, safe handling
system, etc.

b. Residential Area
Industry will provide labor quarter for their labors and provide all basic facilities to
them.

c. Green Belt.
4810 m2 area will be proposed for greenbelt development. In addition to this, project
proponent will participate in greenbelt development programs in nearby areas under
their CSR.

d. Social Infrastructure
The proponent will provide social infrastructure facilities within 10 km radius of the
proposed project.

Education Facilities:-Many Facilities for village schools like game kits, drawing kits,
table-chairs; school construction (classroom/toilet/school boundary), ceiling fans/
coolers or books for school library are proposed.

Health Facilities:-Assistance to existing health facilities in nearest Hospital, for

improvement in health facilities or services.

e. Connectivity (Traffic and Transportation Road / Rail / Metro / Water ways

Proposed project site is located adjacent to National Highway 27/8A and well
connected to the internal roads and highways. The site is well connected to Morbi
Town and Wankaner Town & Rajkot City.

f. Drinking Water Management

In proposed project, out of 42.3 kl/day water approx. 7.7 kl/day water will be
consumed for domestic purpose

g. Sewerage System.
Domestic wastewater 6 kl/day will be treated in the STP.

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h. Industrial Wastewater Management.

Industrial wastewater will be generated from process, boiler, cooling tower blow-
down, washing. Wastewater (washing and process) will be collected collection cum
neutralization tank. Then wastewater will be given Chemical Oxidation treatment.
After completion of chemical treatment, wastewater will be taken to Nutch Filter/Filter
Press for chemical sludge separation. Chemically treated process and washing water
will be mixed with, cooling tower blow down, boiler blow down in holding tank. ETP
sludge along with evaporation residue from evaporator will be will be disposed of at
TSDF site. Thus, unit will maintain Zero Effluent Discharge.

i. Solid/Hazardous Waste Management

ETP waste + evaporation residue, discarded bags/barrels, used oil & edge cutting waste
are the main solid hazardous waste that will be generated from the proposed unit. ETP
sludge will be collected, stored into solid waste storage area and disposed to
authorized TSDF site. Discarded bags and containers will be sold to approve vendor.
Edge cutting waste will be disposed off to the common incineration facility.

j. Power Requirement & Supply / source

Power requirement for the existing project is 225 kVA. Power requirement for the
proposed project is 25 kVA, so in total Power requirement will be 250 kVA after the
proposed expansion which will be obtained from PGVCL.

4. Rehabilitation and Resettlement (R & R) Plan

Not applicable.
5. Project Schedule & Cost Estimates

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

(Time schedule for the project to be given)
Construction is already completed. Construction work related to proposed
expansion of Resin manufacturing plant will be only started after obtaining EC.

(ii) Estimated project cost along with analysis in terms of economic viability of the
project.
 Total cost of the entire project is approx. 7 Crore after expansion.
______________________________________________________

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