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200,000KLPAPAINTPLANT

AtVijayanagar,Dist.Ballari,

Karnataka

ProjectReport


TechnoProjectsManagementLtd.
Mumbai

August2016
JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka

Project Report

CONTENTS

Chapter No. Title Page Nos.


From To
01 Introduction 1-1 1-1
02 Market Analysis 2-1 2-5
03 Process Description 3-1 3-12
04 Raw Material Requirement 4-1 4-3
05 Proposed Site 5-1 5-3
06 Services, Utilities & Manpower Requirement 6-1 6-5
07 Environmental Management 7-1 7-6
08 Project Implementation 8-1 8-1
09 Costs And Financial Analysis 9-1 9-1

LIST OF DRAWINGS

Sl. No. Description Drawing No.


1. Location Map JSW/VW/PR/001
2. Regional Map JSW/VW/PR/002
3. Road Linkage JSW/VW/PR/003
4. Process-Cum-Material Flow Sheet JSW/VW/PR/004
5. General Layout JSW/VW/PR/005
6. Implementation Schedule JSW/VW/PR/006

This document is the property of JSW Paints Private Limited and contains
confidential information and proprietary intellectual property. This is not to
be copied or used for other projects unless expressly permitted by JSW
Paints Private Limited.
JSW Paints Private Limited
200,000 KLPA Paint Plant Karnataka

Project Report

01 INTRODUCTION

The JSW Group has emerged as a dynamic US$ 11 billion


conglomerate. The Group is a multi-location, multi-product
business with interest spanning across Mining, Carbon Steel,
Cement, Energy and Infrastructure. Growth with a social
conscience is a paradigm the Group lives by. Its strength lies in
its individual companies, with each one committed to consolidate
its core strength and excelling in its field of specialization.

JSW Steel is Indias leading integrated steel producer with a


combined capacity of 18.0 Mt/yr at Vijayanagar(Karnataka), Dolvi
(Maharashtra) & Salem (Tamil Nadu). JSW Energy operates 4,531
MW (Thermal - 3140 MW & Hydel - 1,391 MW) of power
generation capacity and JSW Cement has an installed capacity of
6.8 Mtpa.

As a part of its product diversification strategy, JSW proposes to


setup 200,000 KLPA water based Decorative Paint Plant at
Vijayanagar. It is proposed to setup 100,000 KLPA decorative
paint plant in phase 1 and then scaling upto 200,000 KLPA
decorative paints with 40,000 tonnes of emulsions in phase 2 in
the next 4 to 5 years. The total capital investment is about Rs.
600 crores. The proposed investment will further boost the
socio-economic profile of the region and will open up additional
employment opportunities for the local people in the region.

This Project Report is based on proven production technology,


market demand, site suitability with respect to environmental
norms, available infrastructure and economic viability of the
project.

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200,000 KLPA Paint Plant Karnataka

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02 MARKET ANALYSIS

02.01 Introduction

The paint industry in India is driven by consumption and growth


in both Decorative and Protective Segment.
The factors for growth of the market includes growth in real estate
construction, automotive industry, industrial sector and disposable
income and increased Government expenditure on
infrastructure. India is an emerging economy with a rising GDP
and the market is optimistic about its impact on the paint industry.
For new constructions, paint has become an integral component of
the development stage. The per capita consumption of paint in
India is about 2.6 kg against 10-13 kg globally. The low per capita
consumption of paints in India provides enough opportunity for
further growth in this sector.
The paints and coatings industry can be categorized into three
markets:
Decorative/ Architectural
Protective/Industrial
Special purpose coatings

Decorative coating is the largest segment followed by


protective/industrial coatings and special purpose coatings. The
protective/industrial coatings segment was driven by rise in
industrial production and automotive OEM sector.
Rapid urbanization and availability of easy housing loans have
become the prime drivers of growth in the decorative paint
segment, which comprises about 80% of the Indian Paint industry.

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02.02 Global Paints Scenario

Due to the huge demand in the construction industry, the global


paints and coatings market is still growing. In 2014, sales of global
paints reached 43.38 million tons, with total sales of about $ 132.3
billion. The architectural coatings sales was 21.69 million tons,
accounting for 50% of sales of $63.5 billion; industrial coating was
12.58 million tons, accounting for 29% of total sales of $33.07
billion. The remaining 21% accounts for other paint sectors.

02.03 Paints Scenario in Asia Pacific Region

Asia Pacific is still the largest consumer of paints and coatings,


followed by Europe, North America and Latin America. In 2013,
sales of the Asia-Pacific region accounted for 47% (the largest in
global painting sales). In Asia-Pacific region, sales of China was
the largest and accounted for 61.1% of the Asia-Pacific coatings
market while India accounted for 13%.

02.04 Domestic Paint Scenario

The current Indian Market size is 4 million tonnes per year i.e.
about Rs 40,000 crores.
The Indian paints market was ~Rs 35.5K Cr. in FY14 and will
grow at ~12% to about Rs. 56,500 crores by 2018, driven by
favourable demand drivers as shown in fig 02.01.

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Fig. 02.01

Following are the key growth drivers:


Growth in real estate construction sector @ 12% CAGR
Growth in automotive industry accompanied by rising
disposable incomes @ 10% CAGR
Low paint usage per capita as compared to developed
economies-3 kg compared to international of 10-13 kg

The decorative and industrial markets are generally in the ratio of


80:20.

The detailed market segmentation is shown in Fig. 02.02.

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Fig. 02.02
Detailed Market Segmentation

IndianPaintIndustry

DecorativeSegment IndustrialSegment
(80%) (20%)

Consumer
PremiumRange MediumRange Distemper Automotive CoilCoating&
DurablesMarine
(Highend (EnamelPaints) Range Sector General
PaintsOther
Acrylic & (LowEndPaints) Industries
OEMs
Emulsion) Emulsions

The Indian paint market is dominated by Top 4 players who


comprise ~80% of the market with a strong distribution expertise
and wide product portfolio as shown in fig. 02.03.
Fig. 02.03

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02.05 Target Market

The water based paints are the target market to start with and
then it is proposed to expand the operations.
Looking at the Indian markets, it is proposed to produce water
based emulsion paints and enamels.
Since the market is substantial and well developed in the South
and West of India, it is proposed to set up the first plant in the
Southern part of India.

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03.00 PROCESS DESCRIPTION

03.01 General

JSW propose to install a 200,000 klpa Paint Plant at Vijayanagar,


Ballari, Karnataka, in phases. The emulsions of 40,000 tpa shall be
used as raw material for Paint production within the plant itself.

Paint manufacturing is a process which aims at converting a wide


range of raw materials into a range of finished goods that meet
the sophisticated needs of customers. Making up the final
suspension or emulsion from predetermined ingredients is by itself
a simple operation, but the establishment of formulation ratios,
exact recipes and the choice of appropriate pigments, binders,
additives etc is a expertise of this business.

03.02 Major Constituents of Paint

Water based Decorative Paints are manufactured from four major


constituents; Pigments (5-15%), Emulsion (30-35%), Water (25 -
35%), Additives (3-5%) and Extenders (5-10%).

03.03 Types of Paint

03.03.01 Based on market utilization


(i) Water-based paints (80% of market), as the name
implies, are emulsions of paint ingredients dissolved mostly in
water as the major solvent. As a consequence, there is no
escape of organic and hence ecologically harmful fumes into
the atmosphere. The trend in western world is towards water-
based paints for environmental reasons and the same is being
targeted in Indian markets.

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200,000 KLPA Paint Plant Karnataka

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(ii) Solvent-based paints (20% of market) use of organic


solvents such as mineral turpentine (MTO) aromatics, ketones
etc for dissolving the different types of binders such as Alkyds,
vinylics, polyurethanes etc to give tough and high gloss
finishes.

03.03.02 Based on End-use

Paints tend to be classified into two broad groups in the market as


per their end use applications. These are:

(i) Decorative Paints which are mostly household paints used


for indoor and exterior wall, wood & metal finishing purposes.
They are based on various types of binders, essentially
synthetic polymers such as styrene acrylics, pure acrylics,
versatate blends, acetates and alkyds. These binders give
good film coverage in various types of paints including high
gloss and enamels.

(ii) Industrial Paints are pigmented liquids or powders that are


used to protect and/or beautify substrates. Industrial paints
are used in the aerospace, architectural and construction,
automotive, electrical and electronics industries. They are
also used in marine, medical, military, optical, pharmaceutical,
semiconductor, and textile applications. In India, the major
industrial paints are used for automotives and a good amount
of them are used for coil coatings.

03.04 Paint manufacturing Process

The key operation in paint making is the dispersion of fine


pigment particles into a liquid polymer binding medium, using

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high speed mixers or dissolvers which wet the pigments. A typical


process flowsheet for the paint plant has been shown in Drg. No.
JSW/VW/PR/004 and general layout of the paint plant has been
shown in Drg. No. JSW/VW/PR/005.

Making paint consists of following carefully, a series of systematic


procedures which have been described below :
1. Raw material testing and storage.
2. Weighing and transfer of appropriate raw materials into the
mill.
3. Dispersion / Grinding operation
4. Stabilizing the dispersion.
5. The dispersion is pumped into the blending / mixing tank.
6. Incorporation of other additives by mixing to a uniform state.
7. Tinting is carried out at this stage if required.
8. Samples are taken for colour evaluation and analysis of other
rheological properties of film.
9. Final check for viscosity, density etc is carried out. Eventual
addition of additives/water, and or driers if necessary to meet
viscosity and drying specifications.
10. Material is strained and filtered for filling into cans.
11. Product is gravimetrically or volumetrically filled into cans and
labelled.
12. Storage in warehouse & dispatch to customers.

The main general process steps in paint manufacturing


are as below:
a. Dispersion stage
b. Scaling up stage/sieving (Blending/Mixing to required specifications)
c. Quality Control stage

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d. Packaging and Shipping.

a) Dispersion Stage
This stage is the most essential and in fact determines the
paint quality. It should also be pointed out that pigment is
the most expensive paint component and is usually
introduced into a finished product system in the physical
state of dispersion.
A great deal of attention should be accorded to the
processing of dispersions in order to achieve maximum
pigment utilization, that is optimum hiding power (opacity)
and colour.

Dispersion is composed primarily of a combination of


pigment, binder and water. In addition to these three main
components, dispersion contains a fourth ingredient called
additives.

This dispersion process can be separated with three distinct


phases. In practice, these stages overlap and occur
simultaneously rather than strictly consecutively during the
dispersion process. These three phases are:

1. Wetting
2. Particle separation
3. Stabilization

Wetting involves replacement of the pigment air and


pigment moisture interface with the pigment resin
interface. Wetting can be accomplished by mixing which

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permits intimate physical contact between the exposed


pigments surface and the liquid media.

The particle separation phase involves the reduction of the


pigment particle size during the dispersion process.

Although the primary pigment particle size is either equal to


or more commonly below that size required to be achieved
during dispersion, therefore, the phase of dispersion process
is to accomplish reduction of agglomerate and aggregate
sizes. Ideally, this phase which can be called deagglomeration
or deaggregation separates the agglomerates and aggregates
completely into primary pigment particle during this stage.

The third phase of dispersion process is stabilization and it


involves the development and maintenance of a homogenous
distribution of pigment particles in the liquid media.
Subsequent to deagglomeration, particles could dump
together and form floe, floccules or flocculates. Thus, this is
the process of stabilization.

However, the dispersed raw materials (pigments, binder,


water and additives) are charged into the processing
equipment or better called dispersers and allowed to disperse
for a minimum of 45 minutes. For high viscosity range
required, 42% by wt of the total binder needed are employed
at this stage with 100% by wt of the total pigment needed
and 35% by wt of solvent.
A satisfactory dispersion is confirmed by the quality control
department after test.

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200,000 KLPA Paint Plant Karnataka

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b) Sieving and Scaling Up Stage (Blending / Mixing to


required specifications)
Sieving involves the filtration of unused agglomerates thereby
allowing only the passage of pure paint.
The purpose of scaling up is to bring the paint to the required
standard, quality and workable viscosity. This is achieved by
adding the remaining resin, solvent/water and then the paint
additives and driers respectively into the paint slurry system.
The paint is then transferred to a storage tank inside the
production area.

c) Quality Control Stage


Quality control is an important parameter in paint production.
This is done in various stages of the process starting from
dispersion till final shipment.
This stage provides the desired end point. But before this, the
paint content from the dispersion section will be transferred
to the mixing machine through a tube. The mixing machine
or low-speed mill is fed by means of a pipe from the
dispersion container. Then, the binder and more bodying
elements are added. These agents will make up for
adjustments in volume and quality of paint, where
eventually if mix is too thick, it will be made less viscous by
adding a thinning agent.

In the quality control stage, along with the quality or


property, the degree of dispersion must be measured and
ascertained.

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To measure degree of dispersion, either a fineness or tint


strength as a quality control test can be used. Fineness
method is the one extensively used by many paint factories.

d) Packaging and Shipping


From the storage tank, the paint is then packed and
subsequently shipped. All paint packaging materials must
form an effective barrier to skinning (oxidation drying of paint
at the wrong place and at the wrong time) moisture, dirt and
other micro-organism which might act on the paint. Hence,
paint products are packed in cans made of tins or they may
be packed in plastics made of P.V.C or polyethylene.

The common container sizes used in the paint industry range


from 200 litre drums to 20, 10, 4, and 1 litre, and then sub-
litre sizes of 500, 250 and 100 mls. The 20 and 10 litre sizes
are referred to as "drums" or "pails", and from 4 litres down
as "tins or "cans". Plastic containers are also used,
particularly for latex paints. Metallic containers need to have
their interiors coated.

03.05 Labelling of Paints

Successful marketing of paints depends to some extent on


presentation. Cans used for holding paints can thus be
lithographed with multiprint colours, or pasted with printed paper
material.

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03.06 Waterborne Paints


Process Route Description
Dispersion
Measured quantities of raw materials pigments, extenders,
water and small additives are added as per the batch card (recipe
sheet), into the dispersion equipment (high speed disperser), to
manufacture slurry.
The disperser is run for specified time, as required by the recipe.
The finish and particle size distribution of the slurry is checked.
The slurry is transferred to mixing tanks. The mixing tanks are
intermittently agitated.

Mixing
Other raw materials like balance emulsion resin, water, and other
additives are also measured and added into the mixers, as per the
recipe.
The mixer is run for specified time as required by the recipe to
prepare the paint. The density, viscosity, strength are checked in
laboratory.

Filling
If the paint meets all quality parameters in the mixer, the paint is
filled into the containers of different pack sizes 1litre, 4litre,
10litre and 20litre.

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Typical Block Diagram of Waterborne Paints Process

03.07 Emulsion Manufacturing Process


Copolymer Emulsion (for water based products)
Production process consists of following steps:
Pre Emulsion Stage: De-ionised water, surfactants and
Monomers are mixed at Room temperature in Pre Emulsion
Vessel. Initiators and chain terminators solutions prepared in De
mineralized water are 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. The temperature is raised to 50 deg C and 3% of
Pre Emulsion from Pre Emulsion tank is charged. The heating is

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started and after attaining 78 deg C the sample is taken out and
checked for wetting. If wetting is good, Pre Emulsion addition is
continued for four hours by means of metering pump.

Digestion Stage: After Pre Emulsion addition, the catalyst is


added and digested for one hour at 80 deg C to remove Free
Monomers if any.

Additive Stage: After digestion, the batch is cooled to 40 deg C


and Additives such as defoamers and Preservatives/Terminators
are added. This is followed by pH adjustment using Neutralizers.
After Neutralization the batch is filtered using 80 mesh Filter cloth
and transferred to Emulsion Storage Tank.
Typical Process Flow Chart for Water based Emulsion

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03.08 Tentative Product Mix


The product mix considered for the proposed paint plant:

S.N. Type Unit Ph-I Ph-II Total


A. Paints
1. Exterior Paints KL 52,000 52,000 104,000
2. Interior Paint KL 43,000 43,000 86,000
3. Enamels & Varnishes KL 5,000 5,000 10,000
B. Copolymer Emulsions Tons 40,000 40,000
(for water based paints) -

03.09 A typical equipment list for the plant is given in table 03.01
Table - 3.01

Sr. No. Equipments

1. Raw Material Handling and Storage System


2. Emulsion, Resin and Monomer Storage Tanks
3. Electric Hoist
4. Weighbridge
5. Dispersing Equipment
6. Milling Equipment
7. Mixing Equipment
8. Batching Screw
9. Pneumatic Diaphragm Pumps
10. Centrifugal Pumps
11. Water ring vacuum pump
12. Automation system
13. Thermic fluid heater system
14. Air compressors / Instrument Air system
15. Bag Filters & Dust collectors
16. Scraper type self cleaning filter

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17. Automatic Filling Machine and packing system


18. Cooling Tower/ Chilling unit
19. Soft Water Plant / DM Water plant
20. Electricals & Controls
21. Fire fighting & Safety Equipments
22. Lab Equipments
23. Pollution Control System

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04 RAW MATERIAL REQUIREMENT

04.01 General

The main raw material for the proposed plant would be pigment,
emulsion, additives, extenders, monomer & water. The plant
would produce water based paints to cater to the market
requirements.

04.02 Requirement of Raw Material

The raw material requirement for the paint may vary based on the
final grades/product mix of paints.
The product mix considered for the proposed decorative paint
plant is as below:

S.N. Type Unit Ph-I Ph-II Total


A. Paints
1. Exterior Paints KL 52,000 52,000 104,000
2. Interior Paint KL 43,000 43,000 86,000
3. Enamels & Varnishes KL 5,000 5,000 10,000
B. Copolymer Emulsions Tons 40,000 40,000
(for water based paints) -

Based on the above product mix, the requirement of the


major items is as below

Ph-I Ph-II
Sr. No. Item Quantity (Tons)
1. Pigments 10,200 10,200
2. Emulsions 21,200 21,200
3. Extenders 51,500 51,500
4. Additives 4,500 4,500
5. Water 45,400 65,400
6. Monomers - 20,000
7. Additives - 800

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Apart from the major raw material, there are many other
materials required for paint manufacturing in small quantities.
The list of major material, state and packing details are as below-

Sr. No. Material State Storage Means

1 Pigment Powder, liquid, Bags, carboy


paste
2 Extenders Powder Bags
3 Additives Powder & Liquid Bag, Barrels &
Carboy
4 Emulsions Liquid Barrel,
Carboy,
Storage Tank
5 Biocides Powder & Liquid Bag, Barrels &
Carboy
6 Driers Liquid Barrels
7 Liquor Ammonia Liquid Carboy
8 Chemicals Powder Bags
9 Water Liquid Storage Tank
10 Emulsion Liquid Tankers, Storage
Tank
11 Monomer Liquid Tankers, Storage
Tank
12 De-ionised water Liquid Storage Tank

04.02.01 Pigments

Pigments form a large proportion of stored items because of the


variety of colours and types needed to make a comprehensive
range of modern surface coatings. Titanium dioxide is the major
base for white paints, and majority of paints are white.

To obtain non-white paints, other pigments are used. Mineral-


based inorganic, pigments such as iron oxide, ground to a
micronised opacity are added, giving stability to the total mixture.
Greater variation in colours can be obtained by using organic dyes
such as toluidene red dye, etc.

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04.02.02 Binders

Binders are often synthetic adhesive polymers such as acrylics,


styrenic acrylics, polyurethanes etc., and are the essential
elements in holding together the different ingredients of an
emulsion to form a film.

04.02.04 Additives

A wide variety of products are grouped under the name additives.


They include anti-UV agents to stop paints deteriorating with light,
biocides to keep away moss and insects etc.

04.02.05 Chemicals

Stabilizing agents such as silicone surfactants and thickeners are


added to alter viscosity, and stabilize the emulsions resulting from
paint manufacture.

04.02.06 Extenders

Extenders can be anything from lime, chalk, Sulphates to


carbonates, depending on the type of paint.

It is proposed to purchase all the Raw Material from external


sources initially. Subsequently, it is proposed to set up a
copolymer emulsion production plant to be used for water based
paints in-house to meet the internal requirement.

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05 PROPOSED SITE

05.01 Site Location

The Paint Plant of 200,000 KLPA capacity is proposed to be set up


within the existing steel plant of JSW Steel Ltd. This is located in
HK-2 economic zone and this will add up to the overall
development of the area. The existing integrated steel plant is
situated near Tornagallu village of Bellary district in the state of
Karnataka. The site is at a distance of 29 km from Bellary, 33km
from Hospet and about 340 km from Bangalore by Road. The
location map and the regional map of the proposed site have been
shown in the drawing no. JSW/VW/PR/001 and drawing no.
JSW/VW/PR/002 respectively.
The indicative coordinates of the proposed site are given below:
Latitudes : 15 11 02 N to 15 11 00 N

Longitudes : 76 42 09 E to 76 42 19 E

05.02 Area Requirement

05.02.01 General

The area requirement for the proposed plant has been estimated
based on the following factors:

Area requirements of individual technological and service


facilities

Smooth and uninterrupted flow of incoming and outgoing


materials for different technological facilities.

Logistics in location of technological units as well as services


facilities.

Safety requirements and statutory provisions.

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Adequate green belt all around the plant.

05.02.02 Estimated area

67 acres of land have been earmarked for the proposed plant


within the existing steel plant at Vijayanagar.

05.03 Proposed Site

The area of about 67 acres will be subleased by JSW Steel Limited


to JSW Paints Private Limited after obtaining the required
approvals from Govt. of Karnataka. The layout of plant was
prepared keeping in mind the area requirement for infrastructure,
material handling facilities, different shops / units as required and
also area for plant ancillaries and for future expansion within the
acquired land within the demarcated area. JSW Steel Limited Plant
is on the West and South side of the plant and JSW Cement is
located on the west side of the plant.

05.04 Logistics

05.04.01 Road

The National Highway NH 63 passes on the north side of the


plant.
The Road linkage of the proposed site is shown in
Drg.No. JSW/VW/PR/003.

05.04.02 Railways

The nearest railway station Toranagallu is about 5 km from the


plant site and is located in the south on the South Western
Railway Hubli - Bellary main line. Bellary Railway Station is located

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at about 38 km from the site and Hospet Junction at about 32 km


from the plant site.
The Rail linkage of the proposed site is shown in
Drg.No. JSW/VW/PR/004.

05.04.03 Port Connectivity

Chennai Port is situated on the Coromandel Coast in Tiruvallur


District of Tamil Nadu, about 537 km on the eastern side of the
Plant site. The Mormugao Port is about 408 km on the western
side of the Plant site. Also, Krishnapatnam Port is about 517 km
on the eastern side of the plant site. Imported raw materials could
be handled through these ports.

05.04.04 Air Connectivity

The nearest Bangalore airport is 340 km away from site connected


through major road. There is a small airport at Vijayanagar also.

05.05 Water

The water requirement for the proposed plant will be about 530
KLD for 200,000 KLPA paint plant and will be sourced from the
existing network of the steel plant.

05.06 Power

The estimated power requirement of the plant will be about 5.5


MW for the proposed plant. The total power requirement is
proposed to be fulfilled by the nearby Substation of the existing
network of the steel plant.

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06 SERVICES, UTILITIES & MANPOWER REQUIREMENT

06.01 General

Besides raw materials, other major requirements of the plant are


water & power.

06.02 Water System

Make-up water for the proposed plant is about 530 KLD which will
be drawn from the existing network of the steel plant after
obtaining necessary approvals.
Water is required for cooling needs, process needs, fire fighting,
drinking needs, etc. of the plant.

06.03 Electrical Services

The total estimated power requirement of the proposed plant is


about 5.5 MW and will be met from the nearby Sub-station.

The plant envisages the electric power supply & distribution for a
Decorative Paint Plant along with auxiliary drives, composite grid
earthing, illumination system for in plant and outdoor area, road
lighting.

The consumption of major utilities is as per the table below.

S.N. Item Total


1. Power 5.5 MW
2. Water 530 KLD

06.04 Cooling Water Pump House

A cooling water pump house shall be considered. The industrial


water pump, emergency pump, hot & cold water pump, Fire

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fighting pumps, necessary electrics and instrumentation will be


installed inside this pump house.

06.05 Fire Fighting

A covered fire water sump has been considered for storing water
for fire fighting. Make up water will be added to fire water sump
by gravity from makeup water storage tank. This water will be for
external as well as internal hydrants. A ring main is considered for
the plant.

06.06 Plant Automation

It has been envisaged that Level-1 and Level-2 automation


systems will come along with the various equipment/facilities to
provide process and equipment level control including supervisory
automation functions. In addition, higher-level computer system
will be provided to cater to the needs for Production Planning &
Control (PPC) as well as Management Information System (MIS)
for the whole plant.

06.07 Communication System

Telephone system will be provided for communication inside as


well as outside the plant. Telephone system shall comprise one
Electronics Private Automation Branch Exchange (EPABX) of
required line capacity and associated cable network along with
Press-to-talk system, CCTV, VHF wireless system as required.

06.08 Repair and Maintenance Facilities

In order to ensure continuous operation of various plant and


equipment the works will be provided with adequate repair and

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maintenance facilities which will help to maintain the various


equipment in smooth running condition.

06.09 Warehouse

A central warehouse will be provided to keep paint constituents


and consumables and another ware house will be provided as
product storage. For this purpose, a structural building has been
envisaged. A Part of the building will be raised for easy manual
loading and unloading of the materials from trucks. Forklifts will
be used for movement of materials inside the stores building.

It is proposed to install an automated storage and retrieval


system (ASRS ) system. An ASRS consists of a variety of
computer-controlled systems for automatically placing and
retrieving loads from defined storage locations. Automated
storage and retrieval systems are typically used in applications
where there is a very high volume of loads being moved into and
out of storage.

06.10 R & D Facility

It is proposed to set up a R&D facility in the proposed plant. This


will help us to make new developments in paint products. A major
R&D facility is proposed to simulate and test various aspects of
both decorative and industrial coatings performance/formulation.

06.11 Laboratory

To meet the analytical and testing needs of the proposed paint


product, laboratories as mentioned below will be provided in the
plant. The following are the major equipment for the proposed
project.

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Sl. No. Description


1 Colour Computer & Matching Cabinet
2 Brooke Field Viscometer
3 Burst Strength Tester
4 Glossometer (Sheen)
5 Hand Pull Strength Tester
6 Sheen Heggmen Guage ( 0 To 8)
7 Ford Cup
8 Bar Coat Applicator(150 Micron)
9 Bar Coat Applicator(500 Micron)
10 Descicator
11 Digital Ph Meter
12 Hot Air Ovens
13 Mini H.S.D
14 Muffle Furnace
15 Penetrometer
16 Reflectance Meter
17 Scratch Hardness Tester
18 Spectrophotometer
19 Stormer Viscometer (Sheen)
20 Stop Watch
21 Various Seives
22 Thermometer (Mercury)
23 Water Bath
24 Vacuum Pump
25 W.P.L Cup ( 100 Cc )
26 IR Chamber

06.12 Ancillary Facilities

Necessary ancillary facilities such as administrative building,


canteen, parking area, first-aid station and fire-station etc. shall
be provided.

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200,000 KLPA Paint Plant Karnataka

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06.13 Drainage and Sewerage System


Open type drain has been envisaged for the plant storm water
drainage. The storm water drain will be led to a rain water
harvesting tank. This water will be reutilized. The overflow from
this tank in monsoon season will be suitably connected to a
natural nallah, running nearby.

Sanitary faecal sewage will be collected from the ablution blocks


through pipeline and the same will be connected to a sewage
treatment plant. The effluent from the sewage treatment plant will
be utilized for the development and maintenance of greenery.

06.14 Roads

Adequate plant road system will be provided considering the types


of vehicles and traffic volume. Adequate vehicle parking facilities
and road weighbridges will be provided.

06.15 Manpower Requirement

The proposed plant will not only require management and


executive manpower but also, skilled, semi-skilled, unskilled and
clerical manpower. However, a number of jobs like major repair
and maintenance, cleaning, transportation and loading/unloading
of bulk materials, etc. will be done by engaging outside agencies.

The total direct manpower required for the proposed plant will be
about 600 (200 at site & 400 for marketing, warehousing,
logistics, accounts, taxations etc. at multiple locations).

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07 ENVIRONMENTAL MANAGEMENT

This chapter briefly outlines the nature and sources of pollution


and also suggests broad environmental protection measures to be
adopted for limiting pollution within permissible levels.

07.01 Nature of Pollution

The major wastes that the paint industry produces are empty
paper cartons, gunny bags, dust from air pollution control
equipment, off-specification paint, spills and sludge from
treatment plants. The disposal methods for the wastes are given
in subsequent sections.

07.02 Pollution Prevention and Control Measures

In consideration of the above stated pollution potential of the


paint plant, suitable mitigation schemes are envisaged in order to
control environmental pollution within the permissible norms and
keep the environment fairly clean.

Industrial waste management


During paint manufacturing process, various effluent streams will
be generated at various sources due to carry out manufacturing
activities. Effluent streams will be generated from paint
manufacturing process during activities such as cleaning of
mixers, equipment cleaning, calibration of vessels, cleaning of line
flushings barrels and containers etc. In addition to above, the
utility waste water streams viz. cooling tower blow down,
backwash of soft water plant will also be generated. There will not
be any effluent generated during reaction. The liquid effluent will
be treated in Effluent treatment plant.

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200,000 KLPA Paint Plant Karnataka

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Other industrial wastes like process waste/ residue/ paint sludge


will be stored in designated place in factory premises and
disposed off through authorized TSDF as a land filling. In case the
contents of the packages are hazardous, their disposal will be
done carefully through TSDF or through authorized recycler.

Solid waste management


There are two types of solid wastes generated process wastes
and non process wastes, which may or may not be hazardous in
nature. There is no solid waste generation during manufacturing
process itself. The waste water from manufacturing process,
washings, etc. will get treated in the effluent treatment plant and
that will give rise to sludge. The other type of solid wastes
generated will include the dust collected from dust collectors,
empty barrels (metal and plastic), bags, sweepings and other
biodegradable waste from canteen. Solid waste of organic nature
such as canteen wastes, STP sludge, sweepings etc will be
composted or vermin composted for use as manure in the
greenbelt and lawns. Other non hazardous waste like empty
container, bags, paper/cardboard, metal , wooden waste etc will
be sold to external agency.
The hazardous waste will be disposed off through TSDF as a land
filling.

07.03 Effluent Treatment Plant

Effluent Source : Effluent from process plants

Effluent Volume : the approx. quantity of the effluent : 12 KLD

The expected characteristics for process effluent from


water based paint manufacturing process is as below

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200,000 KLPA Paint Plant Karnataka

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Water Based Paints Unit Value


TSS (mg/l) - 100
COD (mg/l) mg/l 1300
BOD (mg/l) (3days @27*C) mg/l 300
Oil and Grease (mg/l) mg/l <8
pH value mg/l 6

The treated effluent characteristics is as below

Parameters Unit Value


pH - 7.0 to 8.0
Suspended Solids mg/l <30
COD mg/l <30
BOD mg/l <10
Oil and Grease mg/l <8

07.04 Sewage Treatment Plant :

Sewage source : Sewage from factory

Sewage generation : 6 KLD

The sewage will be suitably treated to meet the statutory


requirements.

End use of treated sewage Gardening

07.05 Rain Water Harvesting :

The recharge structures will be constructed as per the site


requirement. Necessary connecting drains shall be provided for
the runoff to be diverted to the recharge structures from roof top/
sheds; paved area and green belt separately to recharge
structures. Necessary provision of storm water drains and settling
chambers shall be made to ensure that the rainfall runoff
generated from the plot area is suitably diverted to the proposed

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recharge structures. Necessary provision of bye-pass and sluice


arrangements shall be made to ensure that the contaminated
water is being avoided to be diverted to these recharge
structures. The designs & the work will be undertaken by the
specialized agencies so that the objective of the rain water
harvesting is implemented in true spirit & due benefits are
accrued. Besides this, the following points will be also being taken
care of after commissioning of the plant:

All the storm water drains/ catchment area will be cleaned


prior to monsoon. Necessary repair/maintenance will be
carried out wherever required.
Before the onset of the monsoon all the catchment area
considered for recharge will be cleaned. The recharge
structures will be kept in operation during the monsoon
season only so as to avoid any contamination.
A mesh will be provided on the mouth of the inlet to discard
the debris entering into the recharge trenches. A sluice/
shutter will be provided to ensure that no water other than
rainwater is diverted to the recharge structures.
After the first rain the de-silting pit will be cleaned and
subsequently this will be repeated on the onset of next
monsoon.
Prior to monsoon season the top most layers in the pit will be
scrapped and replaced with the fresh & cleaned one, if
necessary.

07.06 Solid and Hazardous Waste Management :

The details regarding hazardous waste generation for the project


is provided in table below

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S. N. Waste Stream Proposed Mode of


(MT/Annum) Disposal
A Hazardous Wastes
1 Cotton Waste 6 Authorised TSDF
site
2 ETP & Process Sludge 125 Authorised TSDF
site
B Solid Wastes
1 Empty Metallic drums 4 Authorised
Recyclers
2 Empty Paper Bags 38 Authorised
Recyclers
3 Card Board Boxes and 90 Authorised
Paper from Boxes Recyclers
4 Wooden Waste 220 Authorised
Recyclers
5 Empty Plastic Drums 120 Authorised
Recyclers
6 Bags 190 Authorised
Recyclers
7 Waste Oil & Grease 6 Authorised
Recyclers

Method of Disposal of Hazardous Waste

The hazardous waste will be sent for disposal into hazardous waste
landfill site authorized by the State Government.

Mitigation Measures to be adopted

Hazardous waste will be sent to an authorized TSDF site


All hazardous wastes shall be securely stored, under a shed
for eventual transportation to the authorized TSDF
The solid domestic waste shall be stored within the
premises temporarily and then sent to common solid waste
disposal facility.

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07.07 Design Targets

The proposed pollution control measures would be designed on


the basis of the mandate set by MoEF.

Routine environmental monitoring of stack emission, ambient air


quality, work zone air quality, noise level and waste water
receiving area and surface water stream will have to be carried
out. The monitored data would be recorded and necessary
corrective measures implemented to ensure that design targets
are maintained and avoid any non-compliance of Statutory
Regulations. The guidelines & environment protection rules laid
down by MoEF shall be adhered to for the plant facilities.

07.08 Plant safety

Plant safety measures would form an integral part of the


environment protection plan of the proposed plant. Workers
safety would be of highest degree of concern so as to avoid any
form of personal injury or untoward accident. In-build safety
features of the plant and machinery would be made adequate in
order to avoid hazardous events causing damage to the life and
property.

07.09 Greenbelt

About 33 % of green belt would be created for gardening and tree


plantations. This would prevent the fugitive dust emissions.
Unpaved areas, if any, within the plant boundary would be
provided with grass cover.
This would not only act as lung space but would also improve the
plant aesthetics.

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08 PROJECT IMPLEMENTATION

08.01 General

Implementation of the 200,000 klpa Decorative Paint Plant in


phases is a challenging task and calls for meticulous planning,
scheduling and monitoring to realize the project goals in budgeted
time frame. A highly experienced team is available with JSW to
implement the project.

08.02 Schedule

The implementation schedule for installation of the proposed Plant


is indicated in the form of bar chart in the drawing no.
JSW/VW/PR/006. The overall schedule shows that from the date
of start of the project, the phase-1 of the plant will be
commissioned in 18 months. The schedule of 18 months has been
proposed, considering the existing practices and delivery schedule
of similar plants.

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09 BLOCK CAPITAL COST

The estimated block capital cost outlay for the paint plant of
200,000 KLPA capacity is estimated as Rs. 600 crores.

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200,000 KLPA PAINT PLANT AT VIJAYANAGAR, KARNATAKA
PROJECT IMPLEMENTATION SCHEDULE

SL. ACTIVITIES DURATION OF DURATION IN MONTHS


NO. ACTIVITY 2 4 6 8 10 12 14 16 18

1 Project Approval 0 Month

2 Basic Engineering 3 Months

3 Detailed Engineering 12 Months

4 Tendering, Scrutiny and order placement 8 Months

5 Planning & construction of Infrastructure facilities 14 Months

6 Civil works 15 Months

7 Fabrication & Erection of Structures 12 Months

8 Delivery of Equipment 10 Months

9 Erection of Equipment 11 Months

10 Testing & Commissioning of Plant 2 Months

11 Production to commence -

Drg No: JSW/VW/PR/006