pfr for the proposed expansion of polyurethane foam (puf ... · pfr for the proposed expansion of...

PFR for the proposed expansion of Polyurethane Foam (PUF) Plant by M/s. Duroflex

Private Limited – R & D Division.

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1.0 EXECUTIVE SUMMARY

S. No. Particulars Details

1. Name of the project Proposed expansion of Polyurethane Foam (PUF) manufacturing plant

2. Project Proponent M/s. Duroflex Private Limited – R & D Division, Komaranapalli, Denkanikottai Taluk, Hosur – 635 110.

3. Location of the project

S.F. No. 88, 89/1 & 89/2, Komaranapalli village, Denkanikottai Taluk, Krishnagiri District, Tamil Nadu.

4. Co-ordinates 12°41'39.33" - 12°41'44.65" N

77°44'8.66" - 77°44'10.74" E

5. Production Capacity Polyurethane Foam – 300 to 1500 TPM

Chipping & Bonding Foam – 60 to 200 TPM

6. Major Raw Materials Polyol, Toluene Di-isocyanate (TDI), Methylene Chloride, Catalyst & Glue

7. Land availability 4.55 ha (11.25 acres)

8. Man Power Requirement

100 to 400 Nos

9. Power Requirement 170 KVA to 310 KVA

10. Water Requirement 5.5 KLD to 21 KLD

11. Source of Water Private Water Tankers

12. Sewage generation 18 KLD

13. Effluent Generation Nil

14. Major Machineries Batch foaming machine, Ladder berg Continuous foaming machine, Chiller Unit, Testing units & cutting units

15. APC measures Activated Carbon Filter

16. Project Cost (Rs.) Rs. 1526 Lakhs

17. EMP Cost (Rs.) Rs. 50 Lakhs



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2.0 Introduction

M/s. Duroflex Private Limited – R & D Division is an existing plant manufactures

polyurethane Foam (PUF) and Chipping & Bonding Foam. Duroflex - R&D Division is

located at S.F. No. 88, 89/1 & 89/2, Komaranapalli village, Denkanikottai Taluk,

Krishnagiri District, Tamil Nadu.

2.1 Identification of Project

Due to the demand for their PU Foam, Duroflex has planned to increase the production

quantity of Polyurethane Foam & Bonding Foam at their existing plant with the

following quantities.

1. Polyurethane Foam – 300 to 1500 TPM.

2. Chipping & Bonding Foam – 60 to 200 TPM.

2.2 Identification of Project Proponent

In 1963, when founder of Duroflex, the late Mr. P. C. Mathew first began manufacturing

coir mattresses, it was a pioneering effort. In the 50 years that followed, much has

changed. People, policies, economies, markets, ergonomic theories, customer

preferences and many new technologies. But the spirit of new ventures has endured.

The pioneering effort 50 years ago has endeavoured to create India's leading

manufacturer of advanced sleep systems. Duroflex is now India's largest exporter of

sleep and comfort products. What began as a small manufacturing plant along the quiet

canal at Alleppey, Kerala, is today a leading enterprise with the most modern

manufacturing processes in Kerala, Tamil Nadu, Telangana and Maharashtra State.

2.3 Brief Description of Nature of the Project

The proposed expansion project will fall under Schedule 5(f) & Category ‘A’ as per EIA

Notification 2006. Moreover, as the project site located adjacent to the inter-state

boundary (within 5 km) between Tamil Nadu & Karnataka, the expansion activity

requires prior Environmental Clearance from MoEF&CC, New Delhi.



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2.4 Need for the Project

The Indian mattress sector has transformed over the years from dull, predictable

and slow growth market into an aggressive, dynamic and lucrative market place.

Technology advancement, innovative products and the consumers’ willingness

for a comfortable and durable mattress is driving the growth in the India

mattresses market.

Customers are upgrading from traditional mattresses to contemporary RC /

Spring / Foam / Sandwich mattresses is on the rise.

The Indian mattress industry is Rs. 8,000 to 10,000 Crore approx, of which 75%

is the unorganized sector and only 25% is organized. The potential for growth is

tremendous and the combined growth of the industry is estimated at 8% to 10%,

for the next few years.

25% organized mattress industry, 4.5% is the premium segment. The growth in

the premium segment is estimated at around 10% to 12%, substantially higher

than the overall growth.

A variety of material used for mattresses in the international market like spring,

memory foam, coir, water beds, air beds, gel mattresses and mattresses made

from animal hair.

The Polyurethane Foam is 100% synthetic and cheaper. Its value added variants

have the advantages of being more flexible, breathable, odourless, light weight,

durable, and can also be treated with an Anti-bacterial treatment. The Demand of

PU Foam is increased worldwide.

Due to the demand the proponent planned to increase the production.

2.5 Demand Supply Gap

There is a demand for mattresses in domestic as well as export market. To fulfill

requirement there will be enhancement as well as new plants are always welcomed.



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2.6 Import vs. Indigenous production

The PU Foam is not imported from foreign countries and it is produced 100%

indigenous.

2.7 Export Possibility

There is always demand for Indian mattresses in world market as India. The proposed

expansion project will contribute significant role in the above export market too.

2.8 Employment Generation (Direct and Indirect) due to the project. During the construction phase required manpower is 25 numbers and for Operation

phase the existing manpower is 100 numbers, after expansion the manpower will be

increased to 400 numbers of employees and most of the employees are hired locally

based on the qualifications.

3.0 Project Description

3.1 Type of project

The proposed project involves the capacity enhancement of production of PU Foam

from 300 TPM to 1500 TPM and Chipping & Bonding Foam from 60 TPM to 200 TPM

respectively. The proposed expansion project will fall under Schedule 5(f) and Category

‘A’ as per EIA Notification 2006. Moreover, as the project site located adjacent to the

inter-state boundary (within 5 km) between Tamil Nadu & Karnataka, the expansion

activity requires prior Environmental Clearance from MoEF&CC, New Delhi.

3.2 Location

The proposed expansion project site located at S.F. No. 88, 89/1 & 89/2, Komaranapalli

village, Denkanikottai Taluk, Krishnagiri District, Tamil Nadu. No alternative site is

considered, as it is an expansion of an existing plant producing PU Foam and Chipping &

Bonding Foam. Location map of project site and Satellite image of the plant site is shown

in Figure - 1 & 2.



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TABLE - 1: ENVIRONMENTAL SETTINGS OF PROJECT SITE

S. No. Particulars Details

1 Site Latitude 12°41'39.33"N -12°41'44.65"N

2 Site Longitude 77°44'8.66"E - 77°44'10.74"E

3 Site Elevation above MSL 951 m

4 Nearest highway NH 7– Bengaluru to Salem (9.6 km, NE)

SH17B - Anekal to Hosur Road (0.13 km, N)

5 Nearest railway station Anekal Road Railway Station - 4.1 km, NW

Hosur Railway Station - 9.7 km,

6 Nearest airport

TAAL Airport – 4.5 km, SE

Bengaluru International Airport – 29 km, NNW

7 Nearest town/ city Hosur – 10 km, NE

8 Topography Plain

9 Archaeologically important places

Nil in 10 km radius

10 National parks/ Wildlife Sanctuaries

Nil in 15 km radius

11 Reserved/ Protected Forests Tali Extension RF - 7.5 km, WSW

12 Seismicity Zone III as per IS : 1893 (Part-1): 2002

13 Defense Installations Nil in 10 km radius

14 Interstate Boundary Tamil Nadu – Karnataka – Adjacent



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FIGURE – 1 : LOCATION OF THE PROJECT SITE



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FIGURE - 2 : SATELLITE MAP IMAGES

Point Lat Long

1 12°41'44.65"N 77°44'10.74"E

2 12°41'42.25"N 77°44'14.75"E

3 12°41'35.37"N 77°44'11.65"E

4 12°41'31.68"N 77°44'13.10"E

5 12°41'31.90"N 77°44'9.55"E

6 12°41'39.33"N 77°44'8.66"E



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3.3 Alternate Sites

The proposed expansion project will take place within the existing facility owned &

operated by M/s. Duroflex Private Limited – R&D Division. This site has the following

advantages:

As the factory is currently in operation & all infrastructural facilities are already in

place.

It is the expansion of existing operation and space for new unit is also available

within the premises as a vacant land.

There is no adverse sitting factor such as reclassification of land use and pattern, R &

R as the facility is located within the existing Industrial land.

Hence, no alternative sites were considered.

3.4 Size and Magnitude of Operation

M/s. Duroflex Private Limited – R&D Division is currently manufacturing following

products at the production rates are detailed below,

1. Polyurethane Foam (PUF) – 300 TPM.

2. Chipping & Bonding Foam – 60 TPM.

Individual production capacities of the products of the existing and proposed expansion

have been detailed in Table 2.

TABLE – 2: LIST OF PRODUCTS WITH CAPACITIES

S. No. Name of the product Existing (TPM)

After Expansion (TPM)

1 PU Foam 300 1500

2 Chipping & Bonding Foam 60 200

Total 360 1700



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3.5 Project Description with process details

3.5.1 Polyurethane Foam

Flexible polyurethane foams are manufactured in two main groups, the Polyether foams

and the Polyester foams. The polyester type of foam was first developed (1952), and

represents today 3-5% of the flexible P.U. Foam. The Polyester foam is mainly produced

on relatively complicated and expensive high-pressure machinery working by high-

pressure piston pumps. Chemical handling is also more complicated with this kind of

foam, due to the very high viscosity.

In 1956-58 the first polyether Polyol was introduced on the market and replaced more

and more the polyester polyols. The polyether foam has the advantages of being

manufactured with “easier to run” low-pressure machines by the so-called one-shot

method. In this way the components do not need any kind of pre-mixing, but are

metered separately and mixed on the fly when foam-reaction is wanted.

The polyester foams are nowadays mainly utilized for special purposes like textile

lamination, carpet backing and technical packing materials.

The polyether foams with their much softer touch and greater elasticity are the number

one and almost the only type used in upholstery for the furniture industry. They

dominate the use in mattresses, cushions, etc. With the extensive range of polyether

polyols of today, a wide range of different foams can be made from the light and hard, to

the soft and heavy.

Important Parameters:

Temperature:

A correct temperature is of greatest importance to the foaming process. The

formulations given by the chemical suppliers are usually based on the chemicals having

a temperature of 22˚C (MC: 10-14˚C), which has to be the most favourable for the

reaction and thus giving the best foaming results.



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Foaming:

A correctly balanced formulation and stable processing variables are the key to a

successful production of flexible Polyurethane foam by the one-shot technique of

continuous block-production.

The stages from freshly mixed chemicals to cured foam are usually divided in three.

1. Cream time (approximately 10-12 seconds after mixing)

2. Rising time (75-140 seconds after mixing)

3. Curing time (at least 24 hours)

Foam Quality:

Good quality foam should normally possess the following properties:

Good resilience

Good air penetration

Open cells

No splits or cracks

No air-bubbles in the foam

If there should arise any failure in foam quality, it’s almost always related to the

chemicals or to the processing variables. It is seldom or never related to the mechanical

parts. E.g. too much silicon will give splits or cracks in the foam, so will also too little

Stannous Octoate, too high mixer-speed, too much air-injection or too high temperature.

Foam Density:

The densities of foams are normally between 14 kilos/m3 in all grades.

3.5.2 Manufacturing Process

3.5.2.1 Polyurethane Foam (PU Foam)

In the manufacturing process of Polyurethane Foam (PU Foam), the raw materials like

Polyol, TDI along with Catalysts, ABA, Pigment & water are loaded in the foaming mixer

machine. Then the mixture is passed through foaming tunnel where exothermic

reaction takes place to produce the PU Foam. Then the formed foam passed through

block cut off machines where side edges on both sides will cut. Then the foam is passed



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to curing area where the foam allowed for about 24 hours. Then they are shifted to

block storage area and send cutting section whenever required. In the cutting section

the cured foam is cut as per required farm and size. Then the foam is labelled and

packed for dispatch. In the cutting section trimmed waste generated during cutting

operations will be send to rebonded foam plant to reuse in manufacturing of Cutting &

Bonding Foam. Manufacturing flow diagram of Polyurethane Foam making is shown in

Figure – 3.

3.5.2.2 Cutting & Bonding Foam

The cutting slices, edges from the cutting section of PU foam plant is being sent to

rebonded foam section for reuse. In this section the waste foam is weighted and cut into

required size. Then it is mixed with binder in a bonded mixer to make the bonding foam.

Then the mixture is poured in to required mould to make required size and farm of

foam. After required curing the foam is cut into sheets using slizzing machine and tested

for required properties. Then they are despatched to the customers in required packing.

Manufacturing flow diagram of Cutting and Bonding Foam making is shown in Figure –

3.



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FIGURE -3 : POLYURETHANE FOAM PRODUCTION

Polyol + TDI Additives Catalysts &

ABA Pigment

Water

Continuous Foaming Mixer Machine

Foaming Tunnel Exothermic Reaction

Block Cut-Off Machine

Curing Yard (24 Hrs)

Block Storage

Cutting Section (Trimming & Slicing)

Labelling & Packing

Dispatch Department

Trimming waste to Rebonded Foam Plant

Chemical Mixture

Uncured Long Bun

Uncured Blocks

Cured Blocks

Cured Blocks

Sheets & Cushions

F.G



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FIGURE - 4 : CUTTING & BONDING FOAM PRODUCTION

Waste Foam

Cutting Waste foam

Bonded

Mixer

Block Curing & Storage

Use Slizzing Machine - Cut the Sheet

Check Foam Property - Hardness & Density

Despatch Section

Pour Required Mould

Binder



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3.6 Raw Material Requirement

The raw materials required for the production of Polyurethane Foam including its

quantity before and after expansion are tabulated in Table - 3.

TABLE – 3 : LIST OF RAW MATERIALS

S. No. Description Existing (Tons /Month)

Proposed (Ton /Month)

For PUF 1 Polyol 206 1070 2 TDI (Toluene Di-isocyanate) 97 530 3 Methylene Chloride 1.4 15 4 Water 3.6 20 5 Catalyst 2 15 For Chipping & Bonding Foam

6 Waste Foam – Captive 25 150 7 Waste Foam – Outside 29 20 8 Glue 6.5 30

3.6.1 STORAGE OF RAW MATERIALS

Existing and proposed tank details for storage of raw materials are given in Table - 4.

TABLE – 4 : STORAGE TANK DETAILS

S. No. Raw material Type of storage Capacity

in MT

1 Polyol Tanker/Drum 200

2 TDI (Toluene Di-isocyanate) Tanker/Drum 150

3 Methylene Chloride Drums 6

4 Calcium Carbonate HDPE Bags 40

5 Silicone Surfactant HDPE Bags 6

6 Stannous Octoate HDPE Bags 3

7 Amine Metal Cans 1



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FIGURE - 5: LAYOUT OF THE PLANT



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3.7 Resource optimization / recycling and reuse

In the proposed expansion project one the raw material is Waste Foam which is

generated from manufacturing of PU Foam. In this plant the above waste is reused to

make Chipping & Bonding foam.

3.8 Availability of Water with Source

The total water requirement after the proposed expansion will be increased from 5.5

KLD to 21 KLD. Out of it about 20 KLD is being used for domestic purposes and 1 KLD is

being for Process. The additional water requirement will be sourced from Private

tankers.

TABLE – 5 : WATER REQUIREMENT

S. No. Requirement Existing (KLD) Proposed (KLD)

1 Domestic 5 20 2 Process 0.5 1

Total 5.5 21

FIGURE – 6: WATER BALANCE (KLD)

Private Tankers

21

Domestic (20)

Process (1)

Sewage (18) Utilized in

Process

STP

Green belt development



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3.9 Quantity of waste generation (Liquid and Solid) & its management

In the process along with the products, different waste materials will also be generated.

These waste materials mainly include gaseous emissions and solid wastes from the

utilities. The various types of pollution from the foam unit are categorized under the

following types:

Air pollution

Water pollution

Solid waste generation

3.9.1 Air Emissions

The major air pollution source of the existing plant is Foaming Section and standby DG

set. The following air pollution control measures are provided to control the gaseous

emissions from the existing plant to meet the standards prescribed by TNPCB / CPCB.

TABLE – 6 : DETAILS OF AIR POLLUTION CONTROL MEASURES

S. No. Sources of Emission

Stack Height from ground level in m

APC Measures Provided

Existing

1 Foaming Section 7.7 Activated carbon filter & stack

2 DG Set - 180 KVA 7.8 Acoustic enclosures with stack

After Expansion

1 Foaming section 10 Activated carbon filter & stack

2 DG set - 250 KVA 7.7 Acoustic enclosures with stack

3 DG set - 125 KVA 5.0 Acoustic enclosures with stack

4 DG set - 82.5 KVA 5.0 Acoustic enclosures with stack

3.9.2 Liquid (Sewage)

The Sewage generation will increase from 4 KLD to 18 KLD after the expansion. The

existing sewage is being treated in the septic tank followed by dispersion trench

arrangement. Now it is proposed to provide a Sewage Treatment Plant of 20 KLD

capacity. The treated sewage will be utilized for green belt development within the

plant premises as the green belt area is enough to handle the sewage of 18 KLD. There is

no trade effluent generation from the existing plant and it is also not expected after the

proposed expansion.



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3.9.3 Solid waste

The quantities of generation and the disposal of other solid wastes in the plant are

presented in Table - 7.

TABLE – 7 : NON HAZARDOUS WASTE GENERATION

S. No. Nature of Solid

Waste

Quantity(TPM) Mode of Disposal Existing Proposed

1 Domestic Solid Waste 20 80 Composting

2 Cutting Foam 25 150 Reused as raw material for manufacturing of Chipping & Bonding Foam

TABLE – 8 : HAZARDOUS WASTE GENERATION

S. No. Category

No Name of the waste

Quantity (TPA) Disposal Method Existing Proposed

1 33.3 Discarded containers/ barrels contaminated with hazardous chemicals

40 150 Authorized recyclers

2 5.1 Used / Spent Oil 0.5 1.0 Authorized recyclers

3 5.2 Waste / residue containing oil

1.0 2.0 Common TSDF

4.0 SITE ANALYSIS

4.1 Connectivity

The site connected by a good road which leads to Anekal –Hosur Road (SH-17B). State

Highway - SH 17B is located just 0.18 km from the site in NNW direction and it has good

connectivity with other parts of the state as well as country. The site is well connected

with Hosur Railway station which is about 9.67 km and Anekal Railway station is 4.4 km

from the project site. The nearest airport is TAAL Airport is 4.5 km and Kempegowda

International Airport, Bengaluru is 29 km from the project site.



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FIGURE – 7 : CONNECTIVITY MAP OF PROJECT SITE 4.2 Land Form, Land use and Land ownership

Existing land use of the project site is “Industrial Use Zone”. The total plot area of the

existing facility is 4.55 ha (11.25 Acres). The topo map showing 10 km radius around

the project site is given in Figures - 8.

4.3 Topography

Topographically, the project site is of plain terrain. Map showing the topographical

features around the project site covering 10 km radius is already shown in Figure-8.



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FIGURE 8 : TOPO MAP (10 KM RADIUS)



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4.4 Existing Land Use Pattern

The existing and proposed land use breakup of the site is given in below Table - 9.

TABLE 9 : LAND USE BREAK-UP

Description Area (Ha) Percentage

Production facilities 1.76 38.7

Internal Roads 0.51 11.2

Green Belt 1.52 33.4

Remaining Open 0.76 16.7

Total 4.55 100

4.5 Existing Infrastructure The proposed project site is well connected with a network of panchayat, state high

ways and national high ways to the nearby markets of southern Indian states like Tamil

Nadu, Karnataka, Andhra, Telangana, Kerala and Maharashtra. The power requirement

can be catered through the existing network of TANGEDCO which are situated very

close to the site. The requirement of skilled and unskilled labour force can be fulfilled

due to the proximity of the industrially well developed cities like Hosur and Bengaluru.

4.6 Soil Classification

Soils have been classified into Black soil, mixed soil, red loamy soil, gravelly and sandy

soils. Red loamy and sandy soils are predominant in Hosur. Vast stretches of loam soils

and black soils occur in Krishnagiri district.

4.7 Climate

The climate of Krishnagiri district is comparatively more pleasant than that of the

surrounding districts due to general dryness of atmosphere and appreciable drop in

temperature in the monsoon season. The year may be divided into four season namely

dry season from January to March, summer season April and May, southwest monsoon

season from June to Sept. and northeast monsoon season from October to December.



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A. Temperature

During summer season (April to May) the maximum temperature is about 37°C and the

mean daily minimum temperature of about 25°C in the plains. There is a gradual

decrease of both day and night temperatures from June onwards till December, when

the mean daily maximum temperature is about 30°C and the mean daily min. is about

19°C in plains. The day temperature increases gradually from January onwards. The

lowest temperature is reached in January when the mean daily minimum is about 19°C.

However, in higher areas i.e., Hosur, Thally and Krishnagiri taluks day and night

temperatures are lower by about 2 to 3°C. In these areas weather is comparatively

pleasant round the year.

B. Rainfall

The district receives the rain under the influence of both southwest and northeast

monsoons. The normal annual rainfall over the district varies from about 750 to about

900 mm. It is the minimum around Hosur (767.7 mm) and Rayakottai (768.0 mm) in the

northern and central parts of the district. It gradually increases towards west and east

and is the maximum around Denkanikotai (910.7 mm) in the western part.

5.0 PLANNING BRIEF

5.1 Planning concept

The proposed expansion will be carried out within the existing project site. The total

area of the project is 4.55 ha and is used for industrial purposes. The necessary

infrastructure in terms of land, power, water and personnel are readily available. It is

only an expansion of the existing operation. There will be no significant adverse impact on

the environment due to the project; rather many beneficial impacts are estimated.

There is no adverse factor such as reclassification of land use and pattern, displacement

etc.

During the construction phase required manpower is 25 numbers and for Operation

phase the existing manpower is 100 numbers, after expansion the manpower will be

increased to 400 numbers of employees and most of the employees are hired locally

based on the qualifications.



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5.2 Population Projection

The proposed project will provide direct employment to about 400 persons. The

additional man power requirement is mostly fulfilled by the region of 10 – 15 km radius.

Hence no major population is expected to rise in the region.

5.3 Land use planning The total area of the existing plant is 4.55 ha. The land use break-up of the existing plant

and planning after expansion is tabulated below. The proposed expansion proposal

does not require any additional land area.

TABLE – 8: LAND USE BREAK-UP OF PROJECT SITE

S. No.

Description

Before Expansion After Expansion

Area (Ha) Percentage

(%) Area (Ha)

Percentage (%)

1 Production facilities 1.76 38.7 2.00 44.0

2 Internal Roads 0.51 11.2 0.51 11.2

3 Green Belt 1.52 33.4 1.52 33.4

4 Remaining Open 0.76 16.7 0.52 11.4

Total 4.55 100 4.55 100

5.4 Assessment of Infrastructure Demand

Adequate physical and social facilities are available in this area.

5.5 Amenities/Facilities

All infrastructure facilities such as education, health facilities and other social facilities

are adequate at district headquarter which site makes the region adequate in amenities.

6.0 PROPOSED INFRASTRUCTURE 6.1 Industrial Area – Processing Area

The land available and earmarked for the proposed project is categorized as industrial

land by the Local Planning Authority. The total land available is owned by project

promoter is 4.55 ha. The proposed activities will be carried out within the above area

itself which is sufficient for the planned activities.



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6.2 Residential area - non processing area

No residential classified area will be utilized for the proposed project. No housing or

non-processing area is proposed in this project.

6.3 Green Belt

An area of about 1.52 ha will be developed with green belt which constitutes about

33.4% of the total project area. Adequate no of trees, bushes, shrubs are already planted

in the existing green belt area based on the site conditions.

6.4 Social Infrastructure

The proposed expansion project will provide employment to about 400 persons

directly. So about 400 families get benefited due to the project and economic condition

of the family improved due to the proposed expansion project. Adequate capacity of

social infrastructure like road, water supply, etc. is available in the region to manage the

current proposal.

6.5 Connectivity

The site connected by a good road which leads to Anekal –Hosur Road (SH-17B). State

Highway - SH 17B is located just 0.18 km from the site in NNW direction and it has good

connectivity with other parts of the state as well as country. The site is well connected

with Hosur Railway station which is about 9.67 km and Anekal Railway station is 4.4 km

from the project site. The nearest airport is TAAL Airport is 4.5 km and Kempegowda

International Airport, Bengaluru is 29 km from the project site.

6.6 Drinking Water management

The quantity of drinking water required during construction & operational phase will

be supplied by the local private water tankers.

6.7 Sewerage System

In the existing unit the sewage generated from the domestic activities, toilets and

canteen are treated in the septic tank followed by dispersion trench arrangement. After

the expansion it is proposed to provide a Sewage Treatment Plant of 20 KLD capacity

and the treated sewage will be used for green belt development.



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6.8 Industrial Waste Management

The solid waste management details are already mentioned in Section 3.9.3.

6.9 Power Requirement & Supply /Source

The TANGEDGO is the power supply source for the plant. The existing power

requirement of the plant is 170 KVA and after expansion the power requirement will be

increased to 310 kVA. The infrastructure to connect the power supply from the

TANGEDCO grid is already in place near the project site. Hence the project proposal sees

no hitches / delay in getting the required power supply from the Grid. To meet the

emergency power requirement during the grid failure a DG set having capacity of 180

KVA is available. After expansion 3 more DG sets having capacity of 250 KVA, 125 KVA

and 82.5 KVA will be provided. HSD is the only fuel used in the plant which is for DG

sets. The requirement of the diesel will vary with TANGEDCO power failure and its

maximum requirement will be about 220 lit/day.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

As the project land owned by the project proponent and not additional land is required

for the proposed expansion project no R & R Plan is required to prepare.

8.0 PROJECT SCHEDULE & COST ESTIMATES

The proposed expansion project will be implemented immediately after obtaining EC

from MoEFCC and CTE from TNPCB. The implementation period of the expansion

project is six months from date of implementation to achieve the significant production

with new equipment. The total cost of proposed expansion project is estimated as Rs.

1526 Lakhs. The funding will be sourced by own funding of promoters as well as loans

from Banks.

9.0 ANALYSIS OF PROPOSAL – FINAL RECOMMENDATIONS

9.1 Financial and Social Benefits with Special Emphasis on the Benefits to the

Local People including Tribal Population

The basic requirement of the community needs will be strengthened by extending

health care, educational facilities to the community, providing infrastructural support

for drinking water to the villages, building strengthening of existing roads in the area.



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M/s. Duroflex Private Limited will initiate the above amenities either by providing or by

improving the facilities in the area, which will help in uplifting the living standards of

local communities. The construction of new roads in the project area will enhance the

transportation facilities. With improved transportation facilities there is always a scope

for development. The communication facilities will improve after the plant operations

begin. Medical facilities will be augmented in dispensaries of the plant area. These

medical facilities would also be available to local people in the surrounding in case of

emergencies.

The project implementation will result in improvement in the social infrastructure in

following manner

Generation of employment and improved standard of living;

Establishment of small and medium scale engineering ancillaries,

Increased revenue to the state by way of royalty, taxes and duties;

There shall be significant change in the socio-economic scenario of the area.

The proposed expansion of foam industry shall enhance the prospects of direct and

in direct employment during construction and in operation phases. Recruitment for

the unskilled and semiskilled workers for the proposed project will be from the

nearby villages.

The development of the basic amenities viz. roads, transportation, electricity,

drinking water, proper sanitation, etc. will be developed as far as possible.

Overall this project will change living standards of the people and improve the socio-

economic conditions of the area.

The impact of the plant on the economic aspects can be clearly observed. The activity of

project will provide employment to persons of different skills and trades. The local

population will have preference to get an employment. The employment potential will

ameliorate economic conditions of these families directly and provide employment to

many other families indirectly who are involved in business and service oriented

activities. The employment of local people in primary and secondary sectors of project

shall upgrade the prosperity of the region. These will in-turn improves the socio-

economic conditions of the area.



`

27

The total manpower required for the proposed during the operation phase is about 100

to 400 persons which would be mainly sourced from local community in and around

existing plant and few technical persons will be employed from outside area. In addition

to the above, direct employment shall be provided to the contractual labour and indirect

employment opportunities will also arise after project completion.

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