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M/s. KANSAI NEROLAC
PAINTS LIMITED
Prefeasibility Report for
Environmental Clearance for
Expansion of Integrated Paint
Manufacturing Facility at Phase II,
Goindwal Industrial Complex,
Village- Goindwal Sahib, Tehsil-
Khadur Sahib, District- Tarn Taran,
Punjab
JANUARY 2018
Kadam
Environmental Consultants
www.kadamenviro.com
Environment for Development
PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB QUALITY SHEET
M/S. KANSAI NEROLAC PAINTS LIMITED
Prefeasibility Report for Environmental Clearance
for Expansion of Integrated Paint Manufacturing
Facility at Phase II, Goindwal Industrial Complex,
Village - Goindwal Sahib, Tehsil- Khadur Sahib,
District- Tarn Taran, Punjab
© Kadam Environmental Consultants (‘Kadam’), January 2018
This report is released for the use of the Kansai Nerolac Paints Limited (KNPL), Regulators and
relevant stakeholders solely as part of the subject project’s Environmental Clearance process.
Information provided (unless attributed to referenced third parties) is otherwise copyrighted and
shall not be used for any other purpose without the written consent of Kadam.
PROJECT DETAILS
Prefeasibility Report for Environmental Clearance for Expansion of Integrated Paint
Name of
Manufacturing Facility at Phase II, Goindwal Industrial Complex, Village- Goindwal
Publication
Sahib, Tehsil-Khadur Sahib, District - Tarn Taran, Punjab
January
Project Number 1731512310 Report No. 1 Version 1 Released
2018
Prepared &
Mitali Khuman Released By Sameer Kadam
Managed By
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: kadamenviro@kadamenviro.com; T:+91-265-613 1000
Delhi / NCR
SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall,
Sohna Road, Gurgaon -122 002 (Haryana)
E: delhi@kadamenviro.com;T: 0124-4242430
DISCLAIMER
Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan.
Kadam also believes that the facts presented in the report are accurate as on the date it was written.
However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore
specifically disclaims any liability resulting from the use or application of the information contained in this
report. The information is not intended to serve as legal advice related to the individual situation.
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 2
PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY
CONTENTS
1 EXECUTIVE SUMMARY ............................................................................ 6
1.1 INTRODUCTION ...................................................................................... 6
1.2 PLANT FEATURES AND PRODUCTION CAPACITY ..................................................... 6
1.3 ENVIRONMENT....................................................................................... 7
1.3.1 Air Emission .................................................................................. 7
1.3.2 Water ......................................................................................... 7
1.3.3 Hazardous Water Generation and Disposal ............................................. 7
1.4 SUBMISSION ......................................................................................... 7
2 INTRODUCTION ..................................................................................... 8
2.1 BRIEF DESCRIPTION OF NATURE OF THE PROJECT .................................................. 8
2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION ......................................... 8
2.3 DEMAND SUPPLY GAP ............................................................................... 8
2.3.1 Global Market ................................................................................ 9
2.4 IMPORT VS. INDIGENOUS PRODUCTION ............................................................. 9
2.5 EXPORT POSSIBILITY ................................................................................ 9
2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. ....................... 9
3 PROJECT DESCRIPTION ........................................................................ 10
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ............ 10
3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &
PROJECT LAY OUT) WITH COORDINATES.................................................................... 10
3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE,
PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ............ 14
3.4 SIZE OR MAGNITUDE OF OPERATION............................................................... 14
3.5 TECHNOLOGY AND PROCESS DESCRIPTION ........................................................ 14
3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA
OF FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ................. 18
3.6.1 Transportation details of Raw Materials ................................................ 20
3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE
BRIEFLY OUTLINED ......................................................................................... 20
3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE
GIVEN 21
3.8.1 Water consumption ........................................................................ 21
3.8.2 Power Requirement and Source ......................................................... 25
3.8.3 Fuel ........................................................................................... 25
3.9 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT
/DISPOSAL .................................................................................................. 26
3.10 DETAILS OF STACK .............................................................................. 27
4 SITE ANALYSIS .................................................................................... 28
4.1 CONNECTIVITY ..................................................................................... 28
By Road ................................................................................................ 28
By Rail .................................................................................................. 28
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 3
PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY
By Air ................................................................................................... 28
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP.................................................... 28
4.3 EXISTING LAND USE PATTERN ...................................................................... 28
4.1 EXISTING INFRASTRUCTURE ........................................................................ 29
4.1.1 Land .......................................................................................... 29
4.1.2 Buildings ..................................................................................... 29
4.1.3 Plant Machinery & Utilities ................................................................ 29
4.2 SOIL CLASSIFICATION .............................................................................. 30
4.3 CLIMATIC DATA FROM SECONDARY SOURCES ....................................................... 30
4.3.1 Temperature ................................................................................ 31
4.3.2 Wind ......................................................................................... 31
4.3.3 Rainfall ....................................................................................... 31
4.3.4 Cloud Cover ................................................................................. 32
4.3.5 Humidity ..................................................................................... 32
4.4 SOCIAL INFRASTRUCTURE AVAILABLE ............................................................... 32
5 PLANNING BRIEF ................................................................................. 33
5.1 PLANNING CONCEPT ................................................................................ 33
5.2 POPULATION PROJECTION .......................................................................... 33
5.3 LAND USE PLANNING (BREAKUP ALONGWITH GREENBELT ETC.) .................................... 33
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ............................ 33
5.5 AMENITIES/FACILITIES ............................................................................. 34
5.5.1 Greenbelt Development ................................................................... 34
5.5.2 Fire-fighting system ....................................................................... 34
5.5.3 Storm water management plan .......................................................... 35
5.5.4 Rainwater harvesting system ............................................................ 35
6 PROPOSED INFRASTRUCTURE ............................................................... 36
6.1 INDUSTRIAL AREA (PROCESSING AREA) ............................................................ 36
6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ..................................................... 36
6.3 GREEN BELT ........................................................................................ 36
6.4 SOCIAL INFRASTRUCTURE .......................................................................... 36
6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC.) ........ 36
6.5.1 By Road...................................................................................... 36
6.5.2 By Rail ....................................................................................... 36
6.5.3 By Air ........................................................................................ 36
6.6 SEWAGE SYSTEM ................................................................................... 37
6.7 INDUSTRIAL WASTE MANAGEMENT................................................................. 37
6.7.1 Details of ETP ............................................................................... 37
6.8 SOLID WASTE MANAGEMENT....................................................................... 38
6.9 POWER REQUIREMENT AND SUPPLY AND SOURCE.................................................. 38
7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN .............................. 39
7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS
INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS(A BRIEF OUTLINE TO BE GIVEN) . 39
8 PROJECT SCHEDULE AND COST ESTIMATE............................................... 40
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 4
PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR
THE PROJECT TO BE GIVEN) ................................................................................ 40
8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE
PROJECT. ................................................................................................... 40
9 ANALYSIS OF PROPOSAL ...................................................................... 41
9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE
INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA. .................................................... 41
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 5
PFR FOR EXPANSION OF INTEGRATED M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN LIMITED GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY 1 EXECUTIVE SUMMARY 1.1 Introduction This Pre-feasibility report is part of documentation filed by Kansai Nerolac Paints Limited as part of the Environment Clearance (EC) Process, a mandatory regulatory clearance required from the Ministry of Environment and Forests (MoEF) prior to commencement of construction at site. Kansai Nerolac Paints Limited (Hereafter will be referred as KNPL), incorporated on 2-09-1920, at Lower Parel in Bombay is one of the leading paint companies in India with gross sales of Rs.4936 Crores for the year 2016-17. KNPL is engaged in manufacturing/ marketing of & Architectural & Industrial coatings, Powder Coatings& High Performance Coatings. It has operations spread across the country with four strategically located factories & has 98 depots from where they service a vast base of customers both in decorative & industrial side. The plants are located at Lote Parshuram in Maharashtra, Jainpur in Kanpur Dehat of Uttar Pradesh, Bawal at Haryana and Hosur at Tamil Nadu. KNPL is a subsidiary of Kansai Paints Co., Japan’s number one coating company, who holds 74.99% equity. KNPL is targeting a growth significantly better than the expected industry growth rates, as aforesaid. Company enjoys thorough connectivity across its branches, factories & HO through V-SATS/ leased lines and functions on SAP platform, thus bringing transparency in operations & working on live data. Our Supply Chain department uses advance IT tools like APO for Forecast, production planning & scheduling. All its operations are thus computerized & it is truly IT enabled company KNPL is committed to creating value addition to customers by way of continuous up-gradation of technology resulting in reduction in paint consumption per vehicle, increasing the utility & life span of paints, reducing energy consumption and in manufacturing of environmental friendly paints. Latest technology application knowledge, technical sales service and knowledge of entire paint system are key factors in Auto paint market. With collaboration from world leaders across various continents and with wealth of experience over the years in running various auto lines, KNPL is well equipped to maintain and consolidate its position of strength, KNPL is proud to be the first company to introduce latest environmental friendly lead free Cathodic Electro Deposition (CED) paint in India and eco-friendly water based coatings like Acrylic CED in the Industrial segment as well as lead-free paints and special Low VOC odor free paints in Decorative paints segment. All of our plants have been certified with ISO 14001, OHSAS 18001, ISO 9001 & TS 16949 certification and the new facility too will go for such certification. We are the recipients of Golden Peacock & Greentech award for Environmental Management for various plants. We have also received Sustainability award from Frost & Sullivan and from our renowned customers like Tatas, Maruti, Honda and M & M. 1.2 Plant Features and Production Capacity The project is expansion of existing water based paints, powder coating paints and emulsion manufacturing facilities. The estimated cost of the proposed project is INR 370 Crores (including working capital). The Total Production capacity is given in Table 1-1. KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 6
PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY
Table 1-1: Production Details
Unit Production Proposed Total
S.No. Name of Products
capacity Expansion Capacity
1 Water based paints TPA 38000 74000 112000
2 Powder coating paints TPA 14400 nil 14400
3 Emulsion TPA 24000 12000 36000
1.3 Environment
1.3.1 Air Emission
Adequate stack height is provided to stacks of boiler and D.G Set. HSD is used as fuel.
1.3.2 Water
Total 711 KLD of water will be required after proposed production in which 165 KLD will be
recycled from RO and MEE condensate and 546 KLD fresh water will be required. Total 252 KLD
industrial wastewater will be treated in ETP followed by RO & MEE resulting zero liquid discharge
(ZLD).
1.3.3 Hazardous Water Generation and Disposal
Hazardous waste will be collected through TSDF and PPCB approved authorized recycler.
1.4 Submission
In the light of the above, we would like to state that the integrated water based Paint & powder
coating paints manufacturing facility in Goindwal Industrial Complex at Goindwal Sahib with a
production capacity under construction as well as expansion at same premises as per Table 1-1
would have in place systems, procedures and hardware to ensure that all guidelines for protecting
the environmental emission norms are followed and its operation has no adverse impact on
environment.
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 7
PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB INTRODUCTION
2 INTRODUCTION
2.1 Brief Description of nature of the Project
The Kansai Nerolac Paints Ltd, is planning for expansion of production capacity of integrated paint
manufacturing facility in Goindwal Sahib. The project site is located in an industrial area identified
by the “allotment order for plots” issued by the Punjab Small Industries & export Corporation Ltd
(PSIEC). The said allotment is in the Goindwal industrial area which is state notified industrial
area.
The estimated cost of the project is Rs. 370 crores approximately for the phase – I, which will be
borne out of internal accruals. The Total Production capacity after proposed expansion is given in
Table 2-1.
Table 2-1: Production Details
Production Proposed Total
S.No. Name of Products Unit
capacity Expansion Capacity
1 Water based paints TPA 38000 74000 112000
2 Powder coating paints TPA 14400 nil 14400
3 Emulsion TPA 24000 12000 36000
The entire product will be manufactured throughout the year. The various water based paints and
powder coating paints are traded by the names of Excel, Suraksha, lotus touch, Beauty
silver/Gold, Little Master, Beauty smooth, Nero coat Powders etc.
2.2 Need for the project and its importance to region
Indian Paint Industry is growing at the rate of 12-14% CAGR driven by strong growth in Industrial
and Real estate sector. Growing disposable income along with growing life style aspirations of
people have resulted into increased demand for decorative coatings for homes.
Kansai Nerolac Paints Ltd. currently holds 2nd position by sales turnover in Indian paints Industry.
Fueled by strong technological base, dynamic Management team, and aspirations to become the
market leader, KNPL wants to expand its manufacturing capacity by installing a new production
plant. This production plant shall cater to the growing market demand in North India esp. the
states of J&K, Punjab, Haryana, and Rajasthan.
The location has been shortlisted based upon various internal criteria to strike an optimum balance
of availability of resources and supply chain ease and cost. Major raw material required for paint
like Soapstone, Talc, Calcium carbonate, etc. is available in Rajasthan. Proximity to the national
highway shall provide easy access to the target destinations for the product. Skilled labor (ITI
trained) and Supervisory staff shall be sourced from nearby areas.
2.3 Demand Supply Gap
In the last ten years, the Indian Paint Industry has grown at a compounded annual growth rate
(CAGR) of 12-13%. The market for paints in India is expected to grow at 1.5 times to 2 times GDP
growth rate in the next five years. The paint industry is dominated by decorative paints. Emulsion,
which constitutes the majority share of decorative paints, is the fastest growing segment in the
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 8
PFR FOR EXPANSION OF INTEGRATED M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN LIMITED GOINDWAL SAHIB, PUNJAB INTRODUCTION paint industry. In order to cater to its growth rates, KNP is looking to expand the current manufacturing capacity by expanding existing manufacturing plant in Punjab. This is imperative to cater to the demand for the state of Punjab, and nearby areas. 2.3.1 Global Market All paints will be supplied in domestic market to meet the demand. 2.4 Import vs. Indigenous Production No import has been proposed for Raw Materials as Major raw material required for paint like Soapstone, Talc, Calcium carbonate etc. are available in adjacent state of Rajasthan. 2.5 Export Possibility There will not be any export. The product will meet the domestic requirement. 2.6 Employment Generation (Direct and Indirect) due to the project. The manpower requirement for the new plant is based on the number of persons required on each machine/ process. The paint manufacturing requires skillful handling thus it has been decided to have all apprentices/ workers who have a minimum qualification of ITI. For operating at the full capacity KNPL will require approximately 45 operators & 80 indirect workers. It will be the endeavor of the Company to utilize local manpower meeting the requirements of qualifications, to the extent possible. Fresh ITI passed outs shall be taken as apprentices for two years. People completing the apprenticeship successfully shall be absorbed as regular employees. Stipend/salary shall be keeping in mind prevailing labor laws. In addition about 20 numbers of Supervisory/Managerial staff will be required. The qualification requirement for these staff will be degree in Paint Technology or BSc/ MSc Chemistry for production /QC related work or Graduation in Engineering for Maintenance or Process engineering work. KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 9
PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
3 PROJECT DESCRIPTION
3.1 Type of Project including interlinked and interdependent projects, if any
This project is a capacity utilization of existing plant by M/S Kansai Nerolac Paints Ltd .The basic
information about the project is given in below table. There is no interlinked and interdependent
project.
Plot A, Phase II, Goindwal Industrial Complex, Taran
Location Taran District
Water based Paints: 38000 TPA
Present Sanction Capacity by MOEFCC & PPCB Powder Coating Paints: 14400 TPA
Emulsion: 24000 TPA
Water based Paints: 112000 TPA
Proposed expansion to Powder Coating Paints: 14400 TPA
Emulsion: 36000 TPA
Total Area Existing Plot Area: 1,42,179 m2
Achievement of Production Five years from Environment Clearance
3.2 Location (map showing general location, specific location and project
boundary & project lay out) with coordinates
Location:
Plot No.: A1, Phase II,
Area: Goindwal Industrial Complex,
Village: Goindwal Sahib
Tehsil : Khadur Sahib
District: Tarn Taran
Pin Code: 143 422
State: Punjab
The entire project area is about 35 Acres.
Project site location map is shown as Figure 3-1. The project site boundary with coordinates is
shown in Figure 3-2.
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 10PFR FOR EXPANSION OF INTEGRATED PAINT MANUFACTURING M/S. KANSAI NEROLAC PAINTS LIMITED FACILITY IN GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION Figure 3-1: Site Location Map KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 11
PFR FOR EXPANSION OF INTEGRATED PAINT MANUFACTURING M/S. KANSAI NEROLAC PAINTS LIMITED FACILITY IN GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION Figure 3-2: Project site Boundary with Coordinates KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 12
PFR FOR EXPANSION OF INTEGRATED PAINT MANUFACTURING M/S. KANSAI NEROLAC PAINTS LIMITED FACILITY IN GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION Figure 3-3: Satellite Imagery of 10 Km Radius KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 13
PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
3.3 Details of alternate sites considered and the basis of selecting the
proposed site, particularly the environmental considerations gone into
should be highlighted
The proposed project of KNPL is for expansion in already existing plot area so analysis of site
alternative is not applicable.
3.4 Size or Magnitude of Operation
Product details and production capacities are given in Table 3-1 .
Table 3-1: Production details
Unit Production Expansion Total Capacity
S.No. Name of Products
capacity capacity
1 Water based paints TPA 38000 74000 112000
2 Powder coating paints TPA 14400 nil 14400
3 Emulsion TPA 24000 12000 36000
3.5 Technology and Process Description
1. Manufacturing Paints
1. Water based Paint Manufacturing process:
Water Based Paints manufacturing process consists mainly of dispersion of Pigments (mainly TiO2)
& extenders (e.g. Talc, CaCO3, Clay, etc.) in water under vigorous agitation & followed by fine
grinding through Sand mill (whenever necessary). The slurry is diluted by adding Emulsion, water
& thickeners to get the required physical parameters. The final paint is filled in the containers &
dispatched.
The Process Steps consist of:
Dispersion – Pigments powders are wetted with optimum quantity of water along with wetting
agents. This is done in the equipment called Twin Shaft Disperse (TSD).
Grinding: This step is required in certain premium product only. The slurry is ground in high speed
sand Mills to achieve the desired particle size, which is at micron levels, to get desired finish.
Dilution- Slurry is transferred to Mixing vessel. The slurry is thinned by adding emulsion, Thickener
& water as per the recipe, to get desirable physical parameters.
Filling & Packing Filling is carried out in Bulk Packs (10, 20 lt.) or Small packs (1, 4 lt.).Automatic
filling machines are used for big batch sizes. Smaller batches are filled with manual machine. Small
packs containers are packed in cartons. Packed containers/Cartons are sent to BSR for storage &
onward dispatch.
The process flow diagram is given in Figure 3-4.
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 14PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
Figure 3-4: Process Flow Diagram – Water Based Paints
PROCESS FLOW CHART WATER BASED PAINTS
FROM POWDER
STORAGE SILO
PIGMENT/EXTENDER BATCH
ADDITIVES
SILO
WATER
TWIN SHAFT
DISPERSER
SAND MILL
EMULSION
WATER
ADDITIVE
THINNING/
TINTING
MIXER
FILTER
FILLING / BONDED DISPATCH TO
CARTONING STORE DEPOTS
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 15PFR FOR EXPANSION OF INTEGRATED M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN LIMITED GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION 2. Powder Coating Paint The production process consists of following stages. Premixing - The raw materials are in powder / flake form. These are weighed and added in a pre- mixer. The pre-mixer blends these materials mechanically Extrusion/ Melt Mixing- The ' Premix ' is fed into an extruder. The Extruder ensures uniform dispersion of the material at temperature of 1000 -1400C) and converts it into paste form. The paste coming out of the Extruder is squeezed between two rollers. Rollers are cooled using chilled water circulation inside the rollers. The paste on squeezing forms a thin uniform film. The film formed by squeezing is laid on a conveyor belt for cooling. Pre-breaking -The cooled film is crushed into small flakes of size approximately 1 sq.cm, by the pre-breaker. Blending - These flakes are charged into DCM (Double cone blender), small quantity of additive is added to the flakes, blending is done for proper mixing of additive. Micronizing -Blended flakes are then fed into a micro pulverizer (also known as air classifying mill). The micro pulverizer grinds the flakes into fine powder. The powder is then sieved and packed for dispatch. These micro-pulverizer are provided with dust collector & blowers to prevent dust pollution. Figure 3-5: Process Flow Chart - Powder Coating Paints Note: The flow diagram may change based on actual design considerations. 3. Emulsion manufacturing process Production process consists of following steps: Pre Emulsion Stage: De-ionized water, surfactants and Monomers are mixed at Room temperature in Pre Emulsion Vessel. Initiators and chain terminators solutions prepared in De mineralized water will be charged after thorough Emulsification of Monomers in Water. Reactor Charge Stage: De mineralized water and Surfactants are charged into reactor at 35-40 deg C followed by Initiator and buffer solution. Raise the Temperature to 50 deg C and charge 3% of Pre Emulsion from Pre Emulsion tank. Start Heating and after attaining 78 deg C take out KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 16
PFR FOR EXPANSION OF INTEGRATED M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN LIMITED GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION the sample and check for wetting. If wetting is good continue Pre Emulsion addition for Four hours by means of metering pump. Digestion Stage: After Pre Emulsion addition add chaser catalyst and digest for one hour at 80 deg C to remove Free Monomers if any Additive Stage: After digestion, cool the batch to 40 deg C and add Additives such as defoamers and Preservatives. This is followed by pH adjustment using Neutralizers. After Neutralization the batch is filtered using 80 mesh Filter cloth and transfer to Emulsion Storage Tank. Figure 3-6: Process Flow Chart – Water Based Emulsion KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 17
PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
3.6 Raw material required along with estimated quantity, likely source,
marketing area of final products, mode of transport of raw material and
finished product.
The major raw materials required for manufacture of Paint include the following:
Additives
Biocides
Driers
Emulsions
Extenders
Pigments
Solvents
Miscellaneous (Water & Others)
The project shall provide all necessary aspects in design, to support safe and environment friendly
handling of all hazardous chemicals.
Table 3-2: Raw Material Storage Details
S. Storage Size of storage Consumption
Chemical State
No. means means (MT/Month)
Product: Water based paint
Bag, barrel & Bag: 25 kg
1. Additives Powder & liquid Carboy Barrel: 200 liters 310
Carboy: 25 Liters.
Bag, barrel & Bag: 25 kg
2 Biocides Powder & liquid Carboy Barrel: 200 liters 162
Carboy: 25 Liters.
3 Driers Liquid Barrel 200 Liters 3
Barrel, Barrel: 200 Liters
Carboy, Carboy: 25 Liters
4 Emulsion Liquid 2850
Storage Tank Storage Tank: 30
KL
5 Extenders Powder Bag 25 Kg 4073
Bag , Carboy Bag:25 Kg
6 Pigments Solid, Liquid, Paste 383
Carboy: 25 Kg
7 Liquor ammonia Liquid Carboy Carboy: 25 Liter 27
8 Chemicals Powder, Solid Bag 25 Kg 112
9 TiO2 Powder Bag 25 Kg 725
10 Water Liquid Storage Tank 60 KL 5650
Product: Powder coating paint
11 Additive Solid Bag 25 kg 22
12 Catalyst Solid Bag 25 kg 0.5
13 Extender Solid Bag 25 kg 444
14 Hardener Solid Bag 25 kg 7
15 Metallic Pigment Solid Bag 25 kg 0.2
16 Pigment Solid Bag 25 kg 99
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 18PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
S. Storage Size of storage Consumption
Chemical State
No. means means (MT/Month)
17 Resin Liquid, Solid Barrel, Bag 200 Liter, 25 Kg 650
18 Wax Solid Bag 25 kg 3
Product : Emulsion
19 Additives Powder Bag 20 kg 4.7
Bag- 25 kg
Bag, Carboy, Carboy: 25 liter
20 Chemicals Powder, Liquid 140
Barrel Barrel: 200 liter.
Styrene :60 KL
21 Monomer Liquid Storage Tank Other Monomers– 1386.5
100 kl
22 Liquor ammonia Liquid Carboy 25 liters 24.5
23 De-ionized water Liquid Storage tank 60 KL 1471.5
24 Biocides Liquid Carboy 25 liters 3.75
Table 3-3: Material Balance
Input/MT of Product
S. No.
Raw Materials Quantity (MT/MT)
Product: Water Based Paint
1 Additives 0.0218
2 Biocides 0.0113
3 Driers 0.0002
4 Emulsion 0.2006
5 Extenders 0.2868
6 Pigments 0.0270
7 Liquor Ammonia 0.0018
8 Chemicals 0.0078
9 TiO2 0.0509
10 Water 0.3978
Total 1.006
Product: Powder coating paint
1. Additive 0.0180
2 Catalyst 0.0004
3 Extender 0.3698
4 Hardener 0.0056
5 Metallic Pigment 0.0002
6 Pigment 0.0826
7 Resin 0.5416
8 Wax 0.0023
Total 1.0205
Product: Emulsion
1 Additives 0.0015
2 Biocides 0.0013
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 19PFR FOR EXPANSION OF INTEGRATED
M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN
LIMITED GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
Input/MT of Product
S. No.
Raw Materials Quantity (MT/MT)
3 Monomer 0.4621
4 Chemicals 0.0466
5 Liquor Ammonia 0.0082
6 De-ionized water 0.4904
Total 1.0101
Output/MT of Product
S. No. Liquid Air Recovery/ Solid Remark
Product
Effluent Emission Product Waste
1. Effluent after
separation of
solid is sent to
Water based paints ETP
( with traces of 2. Dust collected
1 0.0035 0.0005 1 0.002
biocide/fungicide in dust collector
as preservative) is recycled.
3. Solid waste is
sent to TSDF
1. Powder fines
are collected and
Powder coating
2 0 0.0110 1 0.0095 recycled
paints
2. Solid waste is
sent to TSDF
1. Effluent sent to
ETP for treatment
3 Emulsion 0.0037 0 1 0.0064 2. Solid waste
sent to TSDF for
disposal
0.0072 0.0115 3 0.0179
Total
3.0366
3.6.1 Transportation details of Raw Materials
There shall be movement of approximately 46 trucks per day (of 9 T) for the finished goods and
almost equal number of raw materials. The total movement is approximately 10530 MT/Month or
413 MT/day. The loading /unloading shall mostly be done at the RM Godown and warehouse
which is surrounded by loading and unloading bays of for the trucks. Additionally, a truck parking
area has been provided adjacent to the warehouse. The third place where trucks shall be moving
in would be the RDC (Regional distribution center), which has its own separate entry and
segregated from the main plant. Beside above, the internal movement of raw material or finished
goods shall be done through Forklift.
3.7 Resource Optimization/recycling and reuse envisaged in the project, if
any, should be briefly outlined
The following hierarchy is followed for waste management with an ultimate aim of “Zero Waste”.
1. Resource Conservation
2. Elimination of Waste Streams
3. Minimizing Waste
4. Reuse of Wastes
5. Recycle of Wastes
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 20PFR FOR EXPANSION OF INTEGRATED
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6. Treatment and Disposal for making wastes harmless
Wash water generated from cleaning of equipment will be re-used back into the process/product.
3.8 Availability of water its source, energy/power requirement and source
should be given
3.8.1 Water consumption
Water supply: Bore well / Tube well from PSIEC
Table 3-4: Existing and proposed Water Consumption
Existing Proposed
water water Total water
S. No. Area of Consumption
requirement requirement Requirement
KLD KLD
1 RO Plant 157 187 339
i Paint Manufacturing (Product water) 50 98 148
ii Boiler 15 12 27
iii DM plant 40 21 61
Emulsion Manufacturing
(a) 39 20 59
(Product water)
2 Cooling tower 217 0 217
3 Washings 48 20 48
4 Gardening 45 0 15
Others
5 15 20 47
(Fire-fighting, etc.)
6 Domestic 27 0 45
Total water consumption 504 227 711
Recycled water from recycling RO & MEE
134 75 165
condensate
Fresh Water consumption 370 152 546
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Table 3-5: Existing and Proposed Waste Water Generation Details
Existing Proposed Total waste
Waste water Waste Water water
S. No. Area of Consumption
generation Generation, Generation,
KLD KLD KLD
1 RO 47 56 103
i Paint Manufacturing (Product water) 0 0 0
ii Boiler 1 1 2
iii DM plant 1 1 2
Emulsion Manufacturing
a) 0 0 0
(Product water)
2 Cooling Tower 39 0 39
3 Washing 47 18 65
4 Gardening 0 0 0
Others
5 0 0 0
(Fire-fighting, etc.)
6 Domestic 25 16 41
Total 160 92 252
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 22PFR FOR EXPANSION OF INTEGRATED PAINT MANUFACTURING M/S. KANSAI NEROLAC PAINTS LIMITED FACILITY IN GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION Figure 3-7: Existing Water Balance Diagram KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 23
PFR FOR EXPANSION OF INTEGRATED PAINT MANUFACTURING
M/S. KANSAI NEROLAC PAINTS LIMITED FACILITY IN GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
Figure 3-8: Proposed Water Balance Diagram
Water Balance_KNPL_Panjab
Raw water from
PSIEC
75 152
227
187 0 20 0 20
RO Reject Evap. + Drift losses
RO Plant Washing/ Others Domestic
Cleaning
131
0 Cooling 16
98 21 12 Condensate Tower
23 11
STP Sludge use
Paint DM Plant Boiler for manure
Manufacturing 22 16
20
Losses Treated Sewage for
Emulsion
Consumed in Manufacturing Gardening
Product
56
Consumed in 1 1 0 18
Product
20
ETP
20
76
51 RO Permeate 80 % RO/UF All Values are in KLD
25 Raw Water
24 MEE 0.9 Effluent
MEE Condensate Loses
0.1
Evapo. Losses Recycled Water
Salts for
dispsoal
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 24PFR FOR EXPANSION OF INTEGRATED
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3.8.2 Power Requirement and Source
Punjab State Power Corporation Ltd (PSPCL) will supply power. The peak power demand will be
4200 KVA. The DG set (2 nos. x 2000KVA, 1no x 500 KVA) will be installed and will be used in
case of power failure. The details are given in above Table 3-6
3.8.3 Fuel
The fuel consumption data is given in Table 3-6.
Table 3-6: Fuel consumption
Existing Remarks
Sr. Stack Proposed Stack Type of Fuel
Capacity
No. Attached to Capacity Nos. Fuel used consumption
300 kg/hr Capacity
1 Boiler 450 kg/hr 1 HSD 27 kg/hr
increased
900 kg/hr Capacity
2 Boiler 1000 kg/hr 1 HSD 50 kg/hr
increased
3 DG set 2000KVA 2000 KVA 2 HSD 344 kg/hr No change
4 DG set 0 500 KVA 1 HSD 76 kg/hr New added
Note: DG Sets will be used only during Power failure.
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M/S. KANSAI NEROLAC PAINTS LIMITED FACILITY IN GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
3.9 Quantity of waste to be generated (liquid and solid) and scheme for their management /disposal
Table 3-7: Existing Hazardous Waste Generation and disposal Details
S. Hazardous Existing Quantity Proposed Quantity Total Quantity per
Type of Waste Source Method of Collection
No. Waste Category per Year per year year
1 ETP sludge 34.3 50 Tons 45 Tons 95 Tons ETP TSDF
1 DG set, Compressor, gear PPCB approved
2 Used/spent oil 5.1 5 Tons 6 Tons
box authorized recycler
Oil/grease scheming 1 PPCB approved
3 34.4 2 Tons 3 Tons ETP
residue authorized recycler
Process 64 Paint Manufacturing
4 21.1 36 Tons 100 Tons TSDF
waste/residue/sludge process
Contaminated cotton 5 Paint manufacturing
5 21.2 10 Tons 15 Tons TSDF
waste/liner process
Paint manufacturing
6 Filler residue 21.2 15 Tons 15 30 Tons process TSDF
Discarded
Paint manufacturing
7 containers/Bags, barrel 33.3 97920 nos 10000 nos 197920 Nos PPCB approved party
process
liners
8 MEE Salt 34.3 34 Tons 17 Tons 51 Tons ETP TSDF
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3.10 Details of Stack
Table 3-8: Details of Flue Gas Stack
Existing Remarks
Sr. Stack Proposed Stack Type of Fuel
Capacity
No. Attached to Capacity Nos. Fuel used consumption
300 kg/hr Capacity
1 Boiler 450 kg/hr 1 HSD 27 kg/hr
increased
900 kg/hr Capacity
2 Boiler 1000 kg/hr 1 HSD 50 kg/hr
increased
3 DG set 2000KVA 2000 KVA 2 HSD 344 kg/hr No change
4 DG set 0 500 KVA 1 HSD 76 kg/hr New added
Note: DG Sets will be used only during Power failure.
Table 3-9: Details of Process Vents
Nos. of Stack Pollutants Air Pollution Control
Stack/Vent Attached to
Stacks/Vents Height in m Emitted Measures Attached
Condenser vent in Emulsion VOC
3 - Close loop operation
Plant (Negligible)
Dust collector attached to
1 13.6 dust Pulse jet bag filter
Silo for powder charging
Dust collector attached to
ACM/DCM line Powder 8 13.6 dust Pulse jet bag filters
coating
Proposed Nil Nil Nil
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LIMITED GOINDWAL SAHIB, PUNJAB SITE ANALYSIS
4 SITE ANALYSIS
4.1 Connectivity
By Road
Amritsar Kapurthala road via Tarn Taran – Goindwal Sahib is main approach road to site. Passing
just 500 mtr from project site at Goindwal Sahib. Another important roads in the region are NH 15
and NH01. NH 15 connecting Amritsar with Rajasthan and Gujarat. It is passing at Tarn Taran at
an aerial distance of ~17.0 km towards W direction from project site. NH 01 passing at Beas
station an aerial distance of ~23 km towards NE direction from project site. It connects Amritsar
with Kolkata. It is historical route also known as Grant Trunk Road.
By Rail
Site is also approachable by railway. Goindwal Sahib is nearest railway station at an aerial distance
of about 2.2 km towards W direction from project site. This railway line connecting Amritsar with
Beas via Tarn Taran and Goindwal Sahib. District HQ Tarn Taran is other nearest railway station,
at an aerial distance of about 21.0 km towards NW direction from projects site. Amritsar Railway
station is a major and important railway station in the region located at an aerial distance of ~39
km towards NW direction from project site. Amritsar is well connected with various parts of the
country.
By Air
Nearest International as well as domestic airport is Raja Sansi Airport located at Amritsar, at an
aerial distance of about 48 km towards NW direction from project site. Amritsar is well connected
with daily multiple flights.
4.2 Land Form, Land Use and Land ownership
The total plot area of the proposed unit will be 1, 42,179 m2. Land use of the proposed site is
industrial which is given by PSIEC under “investment Punjab” to Kansai Nerolac Paints Limited
(KNPL) for their proposed paint manufacturing unit.
4.3 Existing land use pattern
Site lies in Notified Industrial area
No Forest land is involved in the subject Project
No clearance under Forest, CRZ and agriculture and Non- agriculture and water bodies are
required.
Land allotment letter from Investment Punjab vide letter no.: PSIEC/ Estate/ 1214 dated
28/08/2015 and PSIEC/ Estate/ 1201 dated 25/08/2015.
Table 4-1: Distance of Project site from Water Bodies
Water body Location Distance in km Direction
Beas river Near Khakh Village ~2 Km East
Sobraon Branch (UPPER Near Fatehabad ~4.69 Km NW direction
BARI DOAB CANAL)
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 28PFR FOR EXPANSION OF INTEGRATED
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LIMITED GOINDWAL SAHIB, PUNJAB SITE ANALYSIS
4.1 Existing Infrastructure
4.1.1 Land
The Plant facilities are spread over 1,42,179 m2 Land which is completely fortified and protected
on all four sides by boundary walls.
4.1.2 Buildings
Total built up area is divided into various sections like Production Blocks, Engineering,
Warehouses, Administration, Canteen, Toilets etc. There is adequate space & provision for
operations.
4.1.3 Plant Machinery & Utilities
The Plant Facilities have been designed and set up with the objective to carry out almost all
chemical reactions and processes. Details of plant and machinery and utility equipment used for
the production are as below:
Table 4-2: list of Equipment and Machinery
List of Equipment’s & Machinery Amritsar Project
Sl No EQUIPMENTS CAPACITY QUANTITY
A For Paint Manufacturing
Conti-TDS8 ( grinding
400 Kg /min 1 No
Machine)
Intermediate Slurry tanks 40 KL 8 Nos
Finished Goods tank 40 KL 6 Nos
Storage tanks 40 KL 5 Nos
Storage Tanks 10 KL 3 Nos
Storage Tank 30 KL 2 Nos
Storage Tank 100 KL 2 Nos
Storage Tank 60 KL 2 Nos
Storage Tank 150 KL 2 Nos
Storage Tanks 40 KL 1 No
Storage Tank 20 KL 5 Nos
Filling Machines
Retail Pack Fully Auto Filling
7.7 KL /hr 1 No
Machine (Cadetronics)
Bulk Pack Fully Auto Filling
24 KL / hr 2 Nos
Machine (Cadetronics)
Powder Handling System
Silo 250 m3 6 Nos
Charge Hopper 65 m 3
4 Nos
BSM 6 – 8Ton /hr 3 Nos
Big bag unloading Station 6 – 8 Ton / hr 1 No
Pigging System
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List of Equipment’s & Machinery Amritsar Project
Sl No EQUIPMENTS CAPACITY QUANTITY
For Emulsion Pigging 1 No
For additives, biocide 3 Nos
For FG 3 Nos
C Material Handling Equipments
BOPT 1 Ton 2 Nos
Electric Forklift Trucks 1.5 Ton 7 Nos
Electrical Stacker 1.5 Ton 5 Nos
Very Narrow Aisle Truck 1.5 Ton 5 Nos
Robot 6 picks per min 2 Nos
FG Conveying System 89 Pallets per hour 1 No.
D DG Sets 2000 KVA 2 Nos
500 KVA 1 No
E Boiler 1 Ton 1 No
Boiler 450 kg 1 No
F Chilling Plant 30 TR 1 Nos
G Air Compressor 1500 cfm 1 No
750 cfm 2 Nos
4.2 Soil classification
Saline and alkaline soils occur in the district. Soils with salt content exceeding 0.2% are considered
to be high salt soils and this concentration is injurious for plant growth. Soils whose pH values
exceed 9.0 have been classified as high alkali soils. The alkalinity render the soil impervious. The
alkali soils present in the area has low fertility as compared to normal soils. The Soils of the district
are categorized as tropical arid brown (weakly SOLONIZED), and arid brown soil (SOLONIZED).
These soils are deficient in NPK.
(Source: District Tarn Taran, website: http://tarntaran.gov.in/history.html#sl)
4.3 Climatic data from secondary sources
The State of Punjab has been classified into five agro-climatic zones on the basis of homogeneity,
rainfall pattern, distribution, soil texture, cropping patterns etc. the project site falls under Central
plain zone (Source: website: http://punjabrevenue.nic.in/for%20website/agro-
climatic%20zone.htm )
Information presented in subsequent paragraphs is from the most recently published Long Term
Climatological Tables (period 1981-2010) for the nearest IMD observatory. Kapurthala (42074) is
the nearest IMD Observatory from project site but due to non avaibility of sufficient data we are
using data of other observatory in the region i.e. at Raja Sansi airport, Amritsar (42071) by the
Indian Meteorological Department (IMD). A copy of the long-term climatological data is enclosed
as Annexure 2.
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4.3.1 Temperature
June is the hottest month with mean daily maximum temperature 44.1 OC, The extreme
highest temperature 47.8 OC was recorded on 9th June’1995.
January is generally the coldest month, with a mean daily minimum temperature 3.4 OC. The
extreme lowest temperature -2.6 OC was recorded on 8th February’ 1974.
During the post-monsoon months of October November and December, daily mean maximum
temperature remains between 21.1 – 32.0 OC and mean minimum temperature remains
between 4.1 – 15.4 OC.
In winters, i.e. January and February, mean daily maximum temperatures remain between
18.4 – 21.7 OC and mean daily minimum temperature remains between 3.4 – 6.3 OC.
4.3.2 Wind
In winter season average wind speed range is between 1.7 – 2.4 Kmph.
In summer season average wind speed range is between 2.8 – 3.4 Kmph.
In Monsoon season average wind speed range is between 1.9 – 3.6 Kmph.
In Postmonsoon season average wind speed range is between 1.4 – 1.8 Kmph.
Annual average wind speed is 2.4 Kmph.
Low wind speed is observed in the region. Long- term wind direction data is presented in Table
4-3 clearly indicates that the predominant wind direction is mostly from East and North West
during daytime whereas at evenings it is mostly from West and North West. Annually during
morning hours calm condition (No wind) observed for 61 % of the days and in evening hours it is
37 % of the days.
Table 4-3: Predominant Wind Direction
Predominant Wind
Month First Second Third
Morning Evening Morning Evening Morning Evening
January NW W W NW NE,E SW
February NW W W NW N,W SW
March NW W W NW N N,NE,E
April NW NW NE,E W N N
May E NW SE W NW SW
June E W SE SE,SW NE,NW S
July E E,SE SE NE NE S,W
August E E SE SE,W,NW NE S
September E NW SE W NE N,NE,SW
October E NW NW W N.NE N
November E,NW W N,NE,W NW SE,SW N,E
December NW W W NW E N,E,SW
Annual E W NW NW SE E,SE,SW
4.3.3 Rainfall
The total rainfall in year is observed to be 703.4 mm. Distribution of rainfall by season is 64.8 mm
in winter (January, February), 86.5mm in summer (March, April, May), 516.1 mm in monsoons
(June, July, August, September) and 36.0 mm in post-monsoon (October, November ,December).
KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 31PFR FOR EXPANSION OF INTEGRATED M/S. KANSAI NEROLAC PAINTS PAINT MANUFACTURING FACILITY IN LIMITED GOINDWAL SAHIB, PUNJAB SITE ANALYSIS 4.3.4 Cloud Cover The area remains cloudy between June to September and December to March. Season wise cloud cover ranges are 3.5 – 4.1 Oktas during winter, 2.2 – 3.5 Oktas during summer, 2.2 – 4.6 Oktas during monsoon and 0.8 – 3.1 Oktas during Post monsoon. 4.3.5 Humidity Most humid conditions are found in the winter, followed by monsoons, Post Monsoon and summer in that order. Humidity range for winter season between 55 – 90 %, summer season between 28 – 79 %, monsoon season between 39 – 84% and in Post monsoon it is between 50 – 89%. Generally mornings are more humid 77% than evenings with 52 % humidity. 4.4 Social infrastructure available Provision of additional social infrastructure such as schools, health centers, drinking water facilities, etc. is not envisaged. However, these facilities are adequately available in the Region. Where feasible and required, such infrastructure will be augmented. KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2018 32
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LIMITED GOINDWAL SAHIB, PUNJAB PLANNING BRIEF
5 PLANNING BRIEF
5.1 Planning Concept
The proposed expansion is for KNPL in State: Punjab; District: Tarn Taran; Tehsil: Khadur Sahib;
Village: Goindwal Sahib; Plot no.: A-1 (Zone -1). The project site is located in Phase-II, Goindwal
industrial complex which is developed in the year 1993-94 by Punjab Small industry and export
corporation (PSIEC).
5.2 Population Projection
Man power requirement for manufacturing facility is approx. 145 nos. (Permanent and contract
basis). Most of the employment will be generated from local people from nearby villages
depending upon the availability of skilled and semi-skilled people. So there may not be any
permanent migration of people. Hence, there should be no population projection.
5.3 Land use Planning (breakup along with greenbelt etc.)
The proposed Landuse at project site will be as given in Table 5-1.
Table 5-1: Proposed landuse at project site
S. No. Title Area, m2 % of total Area
1 Processing Area 7,750 5.45%
2 Storage Area
a Hazardous Chemicals 2056 1.45%
b Other Non-hazardous chemicals 13,568 9.54%
c Hazardous Waste 455 0.32%
d Water Storage 450 0.32%
e Fuel Storage 100 0.07%
3 Effluent Treatment Plant 1,655 1.16%
4 Boiler 375 0.26%
5 Cooling tower 400 0.28%
6 DG Sets 7,100 4.99%
7 Roads 16495 11.60%
8 Administrative Building 4,585 3.22%
9 Open Space 13996 9.84%
10 Greenbelt Area 46920 33.00%
11 Area for proposed Expansion 26,274 18.48%
Total 142179 100%
5.4 Assessment of Infrastructure Demand (Physical and Social)
The project is capacity expansion of existing facility by introducing automation. There will not be
any construction activity at the site. However, first-aid box with all necessary facilities will be
maintained at site office. Medical facilities, primary health centers are available in nearby villages
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for advance medical facilities. Communication services like post office, telephone, mobiles are
available in nearby villages.
5.5 Amenities/Facilities
5.5.1 Greenbelt Development
Adequate land will be available for open spaces and other non-building purposes. 33% area of
total plot area will be reserved for greenbelt development in the proposed facility. Suitable plant
species of local varieties will be planted with adequate spacing and density for their fast growth
and survival shall be ensured by taking due care.
5.5.2 Fire-fighting system
The firefighting systems have been categorised into the following types:
a) Fire Fighting systems – consisting of hydrant system, sprinkler system, foam system
and water spray system.
b) Portable Fire Extinguishers
c) Fire extinguishing system.
d) Fire Detection and Alarm System
The hydrant system which will be provided throughout the plant may be operated to control and
extinguish fires in incipient or advanced stages. Automatic sprinkler systems have been provided
at locations with potential fire risks to detect and control spread of fire.
The portable fire extinguishers which shall be located all over the premises can be used for
extinguishing small fires.
Sufficient number of fire hydrant valves and riser valves will be arranged to fulfill fire extinguishing
need of the plant. The hydrant points are in synchronization with the number of floors. Water
spray system and foam system is required for the monomer storage tanks. Apart from this, fire
extinguishers will be kept at various locations inside plant and those will be hydrostatically tested
and refilled at intervals as specified by statutory body.
e) ABC type – for class A,B.C type fire ( 4 kg , 6 kg)
f) DCP type – for class B& C type fire ( cap:6 kg, 10 kg)
g) Mechanical foam type – for Class B type fire ( 9 lts,)
h) Mechanical foam trolley – for Class B type (50 lit)
i) Carbon di oxide – for Class C ( cap: 4.5 kg, 6.5 kg)
j) Water mist ( cap: 10 kg) for spray booth
k) Cleaning agent – for server, UPS
l) Fire bucket (sand) – ( cap 9 lits)
Table 5-2: The premises/ areas where various fire protection systems will be provided are
listed below:
Sr.
Firefighting system Area coverage
No
1 Fire Hydrant network Cover all area, Outside building and riser to emergency exit of the each
building, Storage yard, scrap yard etc
2 Fire Extinguishers Inside buildings, storage yard, transformer area, utilities, ETP etc.
3 Water spray Packaging godown, Monomer Solvent storage,
4 Water cum foam monitor Fixed monitor from two side of monomer storage tank yard
5 Fire alarm, MCP & with Addressable fire alarm system covering all building. Manual call points to
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Sr.
Firefighting system Area coverage
No
hooter, siren and repeater be provided in each entry & exit point, scrap yard, storage tank yard,
panel ETP, utility etc
6 Detection system ( smoke, Smoke detectors for office building
heat & multi detector)
Sufficient amount of firefighting water will always be stored in storage tank for firefighting works.
In case of power failure, diesel driven fire engine pump has arranged to generate the power for
emergency lighting and to run water pump.
5.5.3 Storm water management plan
Storm water drains will be provided and Storm water from the entire plot will be collected through
network of storm drains. Most of storm water from plot area will be collected in the rainwater
harvesting structures/recharge wells provided for better utilization of available rainwater. The
excess storm water will be discharged through the storm water drainage facility provided in the
industrial complex.
5.5.4 Rainwater harvesting system
The roof top rain water will be collected in the recharge through channel & storm water drain.
Recharge wells of 100 to 300 mm. diameter will be constructed for recharging the deeper aquifers
and water will pass through filter media to avoid choking of recharge wells. The ground charging
will improve the water level in the vicinity.
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