GHANI RASHEED AND CO.

Aneeq Ahmed S
A Study on the export strategies of
Ghani Rasheed And Co.
1.Leather Industry in India
The Indian leather industry represents around 12.93 percent of the world's leather generation
of conceals/skins. The nation positions second regarding footwear and leather garment
production on the planet and records for 9 percent of the world's footwear generation. India's
leather industry has developed radically, changing from an insignificant crude material
provider to an esteem included item exporter.

Exports

In 2016-17, total exports from Leather and Leather Manufactures recorded fare esteem worth
INR 371.75 billion including Raw Hides and Skins, Finished Leather, Leather Goods,
Leather Garments, Footwear of Leather, Leather Footwear Component and Saddlery and
Harness.

Amid April 2016-January 2017, the significant markets for Indian leather products were US
(15.69 %), Germany (11.82 %), UK (10.85%), Italy (6.61 %), Spain (5.27 %), France (5.02
%), Hong Kong (4.71 %), UAE (3.69 f%), China (3.16 %), Netherlands (3.01%), Belgium
(1.78 %) and Australia (1.44 %).

Board for Leather Exports

The Council for Leather Exports (CLE) is a self-sufficient non-benefit association, which is
depended with export promotion activities and the improvement of the Indian leather
industry. Around 3,172 organizations manufacturing/exporting leather are individuals from
the Council.

The Leather Industry holds an extremely conspicuous place in the Indian economy and is one
of the most seasoned assembling enterprises in India. It gives work to around 2.5 million
individuals in the nation and has a yearly turnover of roughly INR 349.73 million.

India is a standout amongst other countries on the planet for putting resources into the leather
business since it is bounteous with crude materials as tremendous populace of cattle. India
represents 21% of the world's dairy cattle and buffalo and 11% of the world's goat and sheep
populace.

Aside from the simple accessibility of crude materials, speculators can appreciate simple and
rich supply of talented labor, world-class innovation, able and good ecological models, and
the committed help of united businesses.

Leather is a sturdy and adaptable material made through the tanning of putrescible creature
rawhide and skin, basically steers stow away.

A few driving universal calfskin merchandise fabricating brand names, for example, Hugo
Boss, Tommy Hilfiger, Versace, Guess, and DKNY, have put resources into India and are
occupied with sourcing cowhide products from India.

Leather Industry in India is a blend of both the sorted out and the sloppy areas. Around 75%
of the calfskin yield in India is created by the little, bungalow and craftsman divisions
(chaotic). Leather making dates back to pre-memorable age. Be that as it may,
the cutting edge technique for leather production was acquainted with India by the English
and the French in 1857.

Generally, the leather business in India produces hides and skins. Be that as it may, there are
likewise the optional leather ventures, for example, leather shoes, leather garments and other
leather goods for example, women's packs, gloves, travel cases, wallets, belts and work areas.

Throughout the years the leather business in India has experienced radical change from being
a simple exporter of crude materials in the mid 60's and 70's to now turning into an exporter
of completed, esteem included leather products.

The fundamental purpose for the change is the few approach activities taken by the
legislature of India. Indian leather industry has achieved a conspicuous place in the Indian
export and has turned into the best 7 businesses that acquire outside trade for the nation. After
the advancement of Indian economy in 1991, the leather business has thrived reliably in a
few different ways and has contributed vigorously to the Indian exchequer.

The legislature of India in its Foreign Trade Policy for 2000– 2009 has recognized the leather
industry as a centre segment in perspective of its massive potential for export development
and activating work age prospects.

Venture openings in the leather industry lie in various portions identified with the business,
which incorporate tanning and completing of leather, assembling of leather garments,
assembling of leather footwear and footwear parts, and assembling of leather goods, for
example, tackle and saddlery among a large group of different chances.

However, the footwear business specifically holds more noteworthy potential for interests in
India. India delivers roughly 700 million sets of leather footwear consistently and represents
a 18% offer of the aggregate Indian leather export. After footwear fabricating, leather goods
and products, for example, wallets, travel products, belts, and totes offer incredible degrees of
profitability.

Taking a gander at the expanding positive insights and the outside direct venture, MBA
graduates can make an invasion into the showcasing area of the Indian leather industry in the
footwear and clothes segment, which is blasting step by step.

The structure of the leather industry is spread in various fragments, to be specific, tanning
and finishing, footwear and footwear parts, leather garments, leather merchandise including
saddlery and outfit, and so on.

Indian Leather Goods Industry: Items created by this area incorporate, in addition to packs,
purses, hand gloves and modern gloves, wallets, backpacks, folios, brief cases, travel product,
belts, sports merchandise, upholstery and saddlery products. With items running from planner
accumulations to personal leather accessories, this segment has an offer of 20.53 % in the
leather industry, while keeping up a normal development rate of 11% recorded over the most
recent five years.
Indian Saddlery Industry: India is one of the biggest makers of saddlery and harness products
on the planet. The saddlery business was built up in the nineteenth century fundamentally to
take into account the necessities of military and police. From that point on activities were
taken to build up, the industry and today there are more than 150 units in the composed
division, out of which around 105 are 100% export oriented units. Kanpur, in the province of
Uttar Pradesh, is a noteworthy creation community for saddlery merchandise in India
representing over 95% of the total exports of saddlery things from India. The significant
shippers of Indian saddlery are Germany, USA, UK, France, Scandinavia, Netherlands,
Japan, Australia and New Zealand.

Indian Leather Garments Industry: The Leather Garment Industry involves a position of
unmistakable quality in the Indian leather sector. The item grouping of leather garments
contains coats, long coats, midriff coats, shirts, gasp/short, kids pieces of clothing, motorbike
coats, apron and industrial leather garments. The major export destination of leather garments
from India is Germany.

Tanning is the way toward changing over putrescible skin into non-putrescible leather,
generally with tannin, an acidic substance exacerbate that counteracts disintegration and
frequently grants shading. With tanning and finishing capacity with respect to preparing 1192
million bits of hides and skins per annum spread over various parts of the nation, the vast
majority of which is sorted out along present day lives, the ability of India to maintain a
significantly bigger industry with its crude material asset is apparent.

Keeping in mind the end goal to increase the local crude material accessibility, the
Government of India has permitted obligation free import of hide and skins from anyplace on
the planet. It is a fascination for any outside producer who plans to move his generation base
from a surprising expense area to ease base.

There are more than 2,000 tanneries in India. Huge numbers of them are scattered in little
scale and cabin division all finished India particularly West Bengal, Tamil Nadu,
Maharashtra and Uttar Pradesh. It is no big surprise that India is one of the best exporters of
leather alongside France and the UK.

The significant generation communities for leather and leather goods are situated at Chennai,
Ambur, Ranipet, Vaniyambadi, Trichy, Dindigul in Tamil Nadu, Kolkata in West Bengal,
Kanpur in Uttar Pradesh, Jalandhar in Punjab, Bangalore in Karnataka and Hyderabad in
Andhra Pradesh.

There exists an extensive crude material base in the Indian leather industry. This is because
of populace of 194 million dairy cattle, 70 million buffaloes and 95 million goats. As per the
most recent evaluation, India positions first among the significant animals holding nations on
the planet. In regard of 48 million sheeps, it asserts the 6th position. These four species give
the essential crude material to the leather industry. The yearly accessibility of 166 million bits
of hides and skins is the primary quality of the business.

India is the world's second biggest maker of footwear; its generation assessed more than 700
million sets for every annum. At about INR 21.05 billion every year, footwear represents 18
percent share of total exports of leather exports.
Different kinds of shoes created and traded from India incorporate dress shoes, casuals,
slippers, sports shoes, horacchis, shoes, ballet dancers, and booties. The vast majority of the
advanced footwear producers in India are as of now providing to well build up brands in
Europe and USA.

For the most part there are three sorts of leather which is sold in three structures: Full-grain
leather, Corrected-grain leather and Suede.

There are various procedures whereby the skin of a creature can be framed into a supple,
solid material normally called Leather like Vegetable-tanned leather, Chrome-

tanned leather, Aldehyde-tanned leather, Synthetic-tanned leather, Alum-tanned leather and

Raw.

Today the offer of the esteem included completed items in the aggregate fares from leather
sector are 80% as against 20% of every 1970s. Despite the fact that a large portion of the
leather and leather products from the business in India are traded, the leather shoe makers or
exporters in India for example, will import soles, insoles, shoe keeps going, counters, toe
puffs, polishers and stiffeners. The estimation of such transported in things can make up to
10% to 20% of the total value of the leather goods.

India being one of the top exporters of leather is facing few challenges in the Leather
Industry:

 Historically, the slaughter of cattle in India is banned in respect of the government

legislation due to the animal's sacred status. Leather producers wait for the cattle to
die from natural causes such as old age, starvation or diseases. Unfortunately, cattle
with diseases cannot produce high quality leather.
 Cattle died from natural causes must be quickly processed to prevent decay and hide
deterioration. This makes it challenging for leather producers because the dead cattle
must be processed wherever the carcass is found instead of doing it within a leather
production facility.
 For vegetable dyed leather, the supply of chrome salts used in leather production is
limited in supply to the leather producers. When producers tried to switch to a
chemical dye, PCP (Pentachlorophenol), it was eventually banned in India due to the
chemical being a carcinogen.
 Apart from this effluent management, non-tariff barriers, quality specifications and
cost of compliance to various standards hinder the export growth of the Indian leather
industry.

However, going by the future forecast of the Indian leather industry gives ample
scope to the sector to progress. With its rich resource base of raw hides, skins and
human capital the industry has the capability to increase its share in global leather
trade. The global leather industry is in the process of shifting its manufacturing base
from

developed to developing nations. This provides an opportunity for increased flow of foreign
direct investment (FDI) into India.
Production and Exports of leather products :

It is normal that the future viewpoint of the leather production and exports to be extremely
encouraging. The future production and export outlook have been anticipated on the
suspicion that the offer of the footwear utilization in private last utilization consumption
would achieve 1.5% in next ten years. India's share in the worldwide leather market is
likewise anticipated that would increment by around 5%in 2027. Inside these two
contemplations, a development of 12% in the private last utilization use of footwear, can be
anticipated, giving the flexibility of consumption to GDP at 1.3. The export sector is relied
upon to development at 15% for every annum in rupee terms. The projection is at 2011‐12
costs. In view of these, the future standpoint for production and export is demonstrated
underneath. The export projection at the item level has additionally been worked out
accepting differential rates of development for finished leather, footwear and other leather
goods.

The results are presented in the following table:

An Introduction – GHANI RASHEED & Co.

Few ventures are as exciting as those pursued in an environment of continuous improvement

and constant customer feedback. Those who aspire to the challenge of such opportunities and
equip themselves accordingly are rewarded with rare success. One such story began in 1960,
when one man dared to dream of taking Indian leather to the centre stage of the world leather
industry.Mr. S. Abdul Rasheed established his first tannery in 1966, with a leased tannery in
Ranipet.A remarkably short five years later, the company had emerged as the largest exporter
of vegetable tanned leather to China, Europe and Far eastern countries.

A team with a Commitment to Excel:

Today GHANI RASHEED & Co is one of the leading leather manufacturing group of
companies across the globe and is ably led by its
Managing Partner - Mr. S.Shafeeq Ahmed,
Partner – Mr. S .Khaleequr Rahman,
Mr.S.Rasheequr Rahman
Highly Qualified Engineers, technicians and administrative managers work towards one goal
united Quality. Several leathers developed by GHANI RASHEED & CO are the obvious
choice of trend setting brands across the world. To keep pace with the ever changing needs of
the industry, the company constantly sources global expertise. Talented management teams
setting ambitious goals, creative talents inspired by our customers , dynamic employees
delivering our success on the ground. Essentially, it is a commitment that has translated
exceptionally into the success story that GHANI RASHEED & CO is today.

ABOUT:

The GHANI RASHEED & CO group established in the year 1966 is one of the private sector
enterprises specialising in leather manufacturing. Our group started with making finished
leather and has had exponential growth. It is located Ranipet.

This Tannery is a well equipped tannery with state-of-the-art machinery procured from the
best manufacturers. The product lines processed in here are Buffcalf, Cowcalf with
processing facilities from beam house upto crusting. Equipped with a state-of-the-art effluent
treatment plant (ETP) and chrome recovery plant (CRP) the tannery focuses on the
importance of environmental protection.

Equipped with world class post tanning and finishing operations to cater to the requirements
of top brands in the industry. A Research and development (R&D) division of the tannery plays
a key role in continuously developing and catering to the ever changing trends of the fashion
and leather industries.

This tannery produces high quality finished leathers which are exported to UK, Germany,
Japan, China, Italy, Europe and Far eastern countries.

The company does not employ child labor in its operations. The principles and philosophies
that govern the operations and business of GHANI RASHEED & CO are based not only on
laws and regulations, but are also found on legality and respect for the individual, a strong
commitment to common sense, fairness, diversity, and ethical business practices and policies.

Achievements over the years:

o Ghani Rasheed & Co, also received entrepreneurship award from the Tamil Nadu
Government.

o Ghani Rasheed & Co, also held a big share in building an effluent treatment plant in
Chennai and Ranipet which helped the whole industry and the Government to keep
the pollution caused by the industry to the most minimal level possible.

Products and Services: Finished Leather:

The company specialises in production of finished leather from cow and buff and offers them
in any colour that is being used to make leather products.

Servicing the complete leather needs of select clients, we have built enduring associations
with major global brands such as Marks & Spencer, Coach, Lloyd‘s, Zara, Clarks and many
others. Providing specialised leather solutions, our forte is consistent quality and
individualised service, honed to suit specific clients and end products.
The company also started doing small scale business transactions with domestic companies
like Metro & Metro and Tata for their requirements.
We are an industry leader in environmentally conscious leather production, from both Indian
and global perspectives. Through the activities of our extensive in-house R&D and the use of
emerging technologies, we have created and incorporated eco-friendly processes into our
leather manufacturing processed.
Our performance leather division offers fully integrated leather and component
manufacturing capabilities to our customers. Utilising the latest technology, our tannery
produces a range of world-class upholstery leathers designed to meet the rigorous standards
required in today’s furniture and automotive industries

ENVIRONMENTAL MANAGEMENT:

GHANI RASHEED & CO is totally committed towards environmental pollution control. We

are among the companies in this industry to have fulfilled all its statutory environmental
protection norms set by the statutory council. We have a clear vision for the upgradation of
the technology being used and many more research activities are still on the rise in this
sector.

Our fashion and lifestyle leather tannery supplies a wide range of finished leathers to some of
the world’s leading manufacturers of footwear, apparel, handbags and accessories.

VISION :

We believe that we are catering the best quality finished leather and we are constantly
focusing on innovation. We will engage in sustainable practices and anticipate the needs of
our customers globally with a focus on environmental stewardship, activities to benefit
society. We believe that we need to own and control the primary technologies behind the
products that we make.

MISSION: -

To become the premier manufacturing organization in the leather industry, gaining market
competitiveness and diversifying into value added leather with clean, well maintained and
friendly environment and to become the No.1 in the Finished Leather Segment category in
India.
1. PROCESS OF MAKING LEATHER

India represents 12.93% of world's leather production of hides/skins. India is the second
biggest maker of footwear and leather garments on the planet. The leather manufacturing
process is a progression of six stages that starts with planning of crude material and closures
with definite review and shipment.

The leather fabricating process is separated in to three major sub-forms: Pre-Tanning stages,
tanning, and Post Tanning. Every single genuine leather will experience these sub-forms.
Additionally sub-process, surface covering, can be included into the leather process sequence
,but not all cowhides get surface treatment. Since numerous kinds of leather exist, it is hard to
make a rundown of activities that all leathers must experience.

Its Initially Divided into Three Stages they are

First Stages - Pre-Tanning.

Second Stages - Tanning.

Final Stages - Post Tanning.

FIRST STAGE. PRE-TANNING.

The Pre-Tanning stages are the point at which the hides/skin is set up for tanning. During the
preliminary stages a considerable lot of the undesirable raw skin segments are removed.
Many choices for pre-treatment of the skin exist. Not the greater part of the choices perhaps
performed. Preliminary stages may incorporate:

1. PRESERVATION
   The normal filaments of leather will breakdown with the entry of time.

Acidic leather are especially powerless against red rot, which causes powdering of the
surface and an adjustment in consistency. Harm from redrot is bothered by high
temperatures and relative dampness and is irreversible

  Exposure to significant lots of low relative humidity (below40%) can cause leather
to wind up desiccated, irreversibly changing the stringy structure of the cowhide.
  Various treatments are accessible, for example, conditioners, but these are not
prescribed by conservators since they impregnate the structure of the leather ancient
rarity with dynamic chemicals, are sticky, and pull in stains.

2. SOAKING

 Water for motivations behind washing or rehydration is reintroduced.

3. LIMING

In Liming for material or leather processing, the covers up are absorbed a soluble base
arrangement by a drum/oar or pit-based activity where four principle goals are met. The
destinations are:

Removal of entomb fibrillar proteins. Removal of Keratin proteins.

Collagen swelling because of the soluble pH. Collagen fiber package part

Liming activities of cows covers up typically most recent 18 hours and are by and large
connected with the soluble period of shaft house operations. Unwanted proteins and "opening
up "is accomplished.

4. UNHAIRING-The majority of hair is removed.

  In the tanning business the unhairing stage concerns the expulsion of animal hair
from the skin by compound consuming of the hair root, or by concoction corruption
of the hair shaft. The sort of hair expulsion relies upon the sort and length of the hair
itself. Two principle groupings of hair expulsion exist: painting and drum/paddle/pit
unhairing. Sheepskins or creatures with long hair(e.g.wool)— utilize the artistic
creation technique to expel the hair from the follicle. Animals with shorter
hair(e.g.cattlehides)can have their hair evacuated in a procedure vessel.

 Historically, scalding and searing were different strategies used to expel hair from
hides. These techniques are as yet utilized today to some extent, in hides not bound to be
utilized for cowhide

  The synthetic concoctions utilized for unhairing are numerous. Traditionally, alkali
is, for example, lime (calcium hydroxide) or pop ash (sodium carbonate) were
utilized. These medicines were lengthy, and the hair maintenance was typically high.
This implied a manual scratching of the hair from the follicle was required. It is
currently realized that lime (analkali with a low solubility) and feeble salts cause an
inoculation (to the activity of chemicals) of the keratin.
   To increment the speed of unhairing and to bring down hair degrees of consistency,
honing specialists are added. The most normal is sodium sulphide. Sodium sulphide,
at pH esteems more noteworthy than 11.5,

break the disulphide connect of cystine (found in keratin) and result in the crumple of the hair
or releasing of the hair bringing about depilation. Over the top honing specialist result in hair
pulping. Controlled presentation of honing agent, or other alkali, to the hair will result in
hair-spare unhairing (during which the hair can be expelled flawless from the procedure
vessel).

5. FLESHING

 Subcutaneous material is expelled.

6. Part

 The hides/skin is cut into at least two level layers.

7. RELIMING

• The hides/skin is additionally treated to accomplish more "opening up" or more protein
evacuation.

8. DELIMING

• Liming and unhairing synthetic compounds are expelled from the pelt.

9.BATING

• Proteolytic proteins are acquainted with the skin to evacuate assist proteins and to help with
softening of the pelt.

10.DEGREASING

• Natural fats/oils are stripped or as much as is conceivable from the hide/skin. 11.
PICKLING

• Lowering of the pH incentive to the acidic district. Must be done within the sight of salts.
Pickling is typically done to help with the infiltration of certain tanning agents
,e.g.,chromium (and other metals),aldehydic and some polymeric tanning operators.
SECOND STAGE Tanning:

Tanning is the procedure that changes over the protein of the rawhide or skin in to a steady
material which won't fester and is appropriate for a wide assortment of end applications. The
key distinction amongst rawhides and treated leathers is that rawhides dry out to form a hard-
firm material that can fester when re-wetted(wetted back),while tanned material dries out to
an adaptable shape that does not be come put free when wetted back .A extensive number of
various tanning techniques and materials can be used; the decision is at last reliant on the end
use of the cowhide. The most generally utilized tanning materials chromium, which leaves
the leather, once tanned, a light blue colour(due to the chromium),this item is ordinarily
called "wet blue". The acridity of covers up once they have completed the process of pickling
will normally be between pH of 2.8-3.2. Now the stows away are stacked in a drum and
inundated in a buoy containing the tanning liquor. The covers up are permitted to soak (while
the drum gradually pivots about its axle) and the tanning alcohol gradually enters through the
full substance of the cover up. Customary checks will be made to see the infiltration by
cutting the cross area of a cover up and watching the level of entrance. Once an even level of
entrance is observed, the pH of the buoy is gradually brought up in a procedure called
basification. This basification process settles the tanning material to the cowhide, and the
additionally tanning material fixed, the higher the aqueous soundness and expanded
shrinkage temperature obstruction of the calfskin. The pH of the cowhide when chrome
tanned would commonly complete somewhere close to 3.8to4,

Preparatory steps prior to tanning. Curing

Getting ready conceals starts by restoring them with salt. Relieving is utilized to avoid
festering of the protein substance(collagen)from bacterial development amid the time slack
that may happen from acquiring the stow away to when it is prepared. Relieving expels
overabundance water from the cover up sand skins utilizing a distinction in osmotic pressure.
The dampness substance covers up and skins gets extraordinarily reduced. In wet-salting, the
stows away are intensely salted, then squeezed into packs for around 30days. In saline
solution restoring the stow away are disturbed in a salt

water shower for around 16 hours. Generally speaking, curing significantly lessens the
possibility of deterioration by microscopic organisms. Relieving should likewise be possible
by saving the covers up and skins at a low temperature.

In a procedure known as soaking, the stows away are then absorbed clean water to evacuate
the salt and increment the dampness with the goal that the cover up or skin can be
additionally treated

Liming process of hides and skins

After soaking, the stows away and skins are taken for liming: treatment with drain of lime (a
basic agent) that may include the expansion of, sharpening agents"(disulphide decreasing
agents) like sodium sulphide, cyanides, amines etc. The objectives of this task are basically
to:

Remove the hairs, nails and different keratinous matter.

Remove a portion of the bury fibrillar solvent proteins like mucins.

Swell up and split up the strands to the coveted degree.

Remove the characteristic oil and fats to some degree.

Bring the collagen in the stow away to an appropriate condition for attractive tanning

The debilitating of hair is subject to the breakdown of the disulphide connection of the amino
acid called cystine, which is the normal for the keratin class of protein that offers quality to
hair and wools(keratin normally makes up 90% of the dry weight of hair).The hydrogen
particles provided by the honing specialist debilitate the cystine- cysteine sub-atomic link,
and the covalent disulphide bond joins are ruptured, which debilitates the keratin. To some
extent, sharpening additionally adds to unhairing, as it keeps an eye on breakdown the hair
proteins.

The isoelectric purpose of the collagen in the hide (this is a tissue reinforcing protein
disconnected to keratin) is additionally moved to around 4.7 because of liming, which is an
acidic sort of tannage.

Unhairing operators utilized amid liming are: Sodium sulphide, sodium hydroxide, sodium
hydrosulphite, calcium hydrosulphide, dimethylamine, and sodiumsulphydrate.

The lion's share of hair is then evacuated mechanically, initially with a machine and
afterward by handusing a dull knife ,a process known as scudding. Depending on the end
utilization of the leather, hides perhaps treated with proteins to relax them in a procedure
called “bating”. But before bating, the pH of the collagen is conveyed down to a lower levels
so compounds may follow up on it. This procedure is known as "de-liming."

Once bating is complete, the covers up and skins are treated with a blend of normal (table)salt
and sulfuric acid, in case a mineral tanning is to be finished. This is done to cut down the pH
of collagen to a low level in order to encourage the infiltration of mineral tanning operator
into the substance. This procedure is known as "pickling". The basic salt (sodium chloride)
penetrates the conceal twice as quick as the corrosive and checks the evil impact of sudden
drop of pH.

TYPES OF TANNING:

1. CHROME TANNING.

It is designed in 1858, chrome tanning is tanned utilizing chromium sulphate and different
salts of chromium. It is suppler and more at risk than vegetable-tanned cowhide and does not
stain or lose shape as definitely in water as vegetable-tanned. It is otherwise called wet-blue
for its shading got from the chromium. More esoteric colours are conceivable utilizing
chrome tanning.
2. VEGETABLE TANNING

Vegetable tanning utilizes tannin (this is the starting point of the name of the process). The
tannins (a class of polyphenol astringent substance) happen normally in the bark and leaves
of numerous plants. Tannins tie to the collagen proteins in the cover up and coat them making
them become less water-soluble, and more impervious to bacterial attack. The process
additionally makes the stow away turn out to be more flexible.

The essential barks handled in Bark Mills and utilized in present day times are
chestnut,oak,redoul,tanoak,hemlock,quebracho,mangrove,wattle(acacia;seecatechu), and
myrobalan. Covers up are extended on outlines and inundated for a little while in vats of
expanding groupings of tannin. Vegetable treated leather is adaptable and is utilized for gear
and furniture.

3. ALUMINIUM TANNING

Tawing is a technique that utilizes aluminium salts, generally in conjunction with different
items, for example, egg yolk, flour, and different salts. The cowhide progresses toward
becoming tawed by absorbing a warm potash alum and salts solution, between 20°C and
30°C.The process expands the calfskin's pliability, stretch ability, softness, and quality.
Adding egg yolk and flour to the standard splashing arrangement additionally upgrades its
fine taking care of characteristics. Then the cowhide is airdried("crusted") for a few weeks,
which enables it to stabilize. Tawing is customarily utilized on pig skins and goat skins to
make the whitest colours. It remains in a wet condition, tawed calfskin will experience the ill
effects of decay. Technically, tawing isn't tanning.
Production and Exports of leather products :

It is normal that the future viewpoint of the leather production and exports to be extremely
encouraging. The future production and export outlook have been anticipated on the
suspicion that the offer of the footwear utilization in private last utilization consumption
would achieve 1.5% in next ten years. India's share in the worldwide leather market is
likewise anticipated that would increment by around 5%in 2027. Inside these two
contemplations, a development of 12% in the private last utilization use of footwear, can be
anticipated, giving the flexibility of consumption to GDP at 1.3. The export sector is relied
upon to development at 15% for every annum in rupee terms. The projection is at 2011‐12
costs. In view of these, the future standpoint for production and export is demonstrated
underneath. The export projection at the item level has additionally been worked out
accepting differential rates of development for finished leather, footwear and other leather
goods.

The results are presented in the following table:

Commodity Composition of Exports (INR millions)

2011‐12 2012‐13
Product 2013‐14 2014‐15 2015‐16 2016‐17 2021‐22 2026‐27

Finished Leather 89176 102595 135681 272853

67450 77603 118002 548830
156200 179630
Footwear 206610 237566 273208 314175 631900 127042

Leather Garments
46931 143633
35500 40825 53960 62125 71426 288899

Leather Goods 89176 102595 135681 272853

67415 77603 118002 548830

Saddlery& Harness 8875 10224 11715 13419 17821 35420

15549 72207
510206 674784 2729808
Total 335475 385814 443679 586744 1357165

The Government of India had distinguished the Leather Sector as a Focus Sector in its
Foreign Trade Policy 2004-09 in perspective of its tremendous potential for send out
development prospects and work age. In like manner, the Government is additionally
executing different Special Focus Initiatives under the Foreign Trade Policy for the
development of leather sector. With the usage of different modern formative projects and also
trade special exercises; and keeping in see the past execution, and industry's inalienable
qualities of gifted labour, inventive innovation, expanding industry consistence to worldwide
natural measures, and devoted 328 help of the unified enterprises, the Indian leather industry
plans to enlarge the generation, consequently improve send out, and resultantly make extra
business open doors for in general one million individuals.

Against the above setting Kerala has better prospects for leather and subordinate enterprises
to do both assembling and exchanging exercises on a sensibly substantial scale. Despite the
fact that full tanning process can't be embraced in the state because of natural issues, all
different business rehearses will be done effectively. Leather industry can contribute towards
the monetary improvement of the State in the routes examined previously.

Leather Value Chain Analysis:

The value chain analysis is a portrayal of the interrelated chain of exercises that are required
to be embraced to convey the finished leather product to the doorsteps of the clients. The net
revenue that an association gains relies upon how viably the value chain has been overseen.
The leather industry uses the results of butcher houses and changes the crude material into
different sorts of leather and fabricated finished results. The leather production consumption
chain has three handling stages, each requiring diverse mixes of materials, information
sources, work and capital. The main stage is the recuperation of crude materials that has
coordinate connections with Animal production activities. Hides and skins are recouped from
dairy, draught animals from butcher houses. The second stage is leather tanning and
finishing, which includes capital escalated activities. The third stage is the creation of leather
goods, which is a work escalated movement. These three preparing stages are connected to
key business segments of the chain, for example, the advertising of moderate data sources,
segments 311 and finished results, trade and utilization. The different contributions to the
chain without which the chain can't work intensely are qualified work, outline and
workmanship focuses, segments creation, access to synthetic compounds, specialized and
regulatory help foundations, innovative work, preparing and an arrangement of satisfactory
approaches.
2.3 MAJOR PRODUCTION CENTRES IN INDIA

Major production centres in India are

Tamil Nadu

Tamil Nadu has a dominant presence in the leather and leather-based industries. The tanning
Industry in India has a total installed capacity of 225 million pieces of hide and skins of
which Tamil Nadu alone contributes to an inspiring 70%. Leather industry occupies a pride
of place in the industrial map of Tamil Nadu. The major production centres in Tamil Nadu
are Chennai, Ambur, Ranipet, Vaniyambadi, Trichy and Dindigul.

West Bengal

West Bengal is one of the country's top states for export of finished leather goods. Bata India
Limited is India's largest manufacturer and marketer of footwear products. It has 5 plants
near Kolkata. Main plant is located in Bhatnagar near Kolkata. Bata India secures its leather
supply from two tanneries in Mokamehghat (Bihar) and Bhatnagar (West Bengal). The
number of manufacturing industries engaged in leather products is 538 in West Bengal.

Uttar Pradesh

U.P. is one of the most important states in India holding sizeable population of livestock.
Claiming a share of 22% U.P. ranks Ist in case of Buffalo and IInd in case of Cattle having a
share of 12% Thus, U.P. has a very strong raw material base and all types of main raw
material for leather industry are available. Major production centres and Number of leather
and leather products industries in U.P. are to the tune of approx. 11500 of which Kanpur and
Agra are the two famous production centres in the world .Kanpur is a prominent centre for
leather processing. About 200 tanneries are located in Kanpur. Kanpur tanneries specialize in
processing hides into heavy leather (Sole, harness and Industrial leather). This is the only
Centre in India where saddlery products are manufactured. Agra has been the biggest centre
for shoe-manufacturing in the country.

2.4 Government Regulation and Support to Leather Industry:

The Government of India had identified the Leather Sector as a focus sector in view of its
immense potential for export growth prospects and employment generation. Accordingly, the
Government is also implementing various Special Focus Initiatives under the Foreign Trade
Policy for the growth of leather sector. With the implementation of various industrial
developmental programmes as well as export promotional activities, and keeping in view the
past performance, and industry’s inherent strengths of skilled manpower, innovative
technology, increasing industry compliance to international environmental standards, and
dedicated support of the allied industries, the Indian leather industry aims to augment the
production, thereby enhancing export, and resultantly creating additional employment
opportunities for one million people.
Government of India has announced various key policy initiatives to make the leather
industry more competitive.

They are:

•De-authorizing of incorporated tanneries that convert raw hides and skins into finished
leather.

•Several leather goods have been de-held from the small scale sector.

•Free import of raw hides and skins, semi-completed and finished leather.

•Concessional obligation on imported apparatus and synthetics.

•Free export of raw hides and skins, semi-completed and finished leather and leather
products.

•Policies to encourage modernization/ upgradation, for example, "Integrated Leather

Development Program".

•Setting up of leather parks by Council for Leather Exports (five leather parks out of that two
in Chennai - one for footwear and the other for segments, one each in Nellore, Agra and
Kolkata).

•Establishment of „design centres‟ at individual manufacturing units, to encourage change in

outline capacities under the joint endeavours of Council for Leather Exports (CLE) and the
National Institute of Fashion Technology (NIFT).

•Research and improvement abilities by The Central Leather Research Institute (CLRI)
which is the world's biggest leather Research Institute. Condition of-craftsmanship offices in
CLRI are to help advancement in leather processing, inventive planning of leather products
and improvement of novel ecological innovations for leather sector.

•The support is extended to well-equipped training institutions to encourage training

programmes to be given jointly along with reputed foreign enterprises and experts.

•No industrial license is required to manufacture most of the items of leather industry.
However, the location of industrial projects will be subjected to Central or State
environmental laws and regulations including local zoning and land use laws and regulations.

Institutional Support to Leather Industry:

Abundant support has been provided by the institutions and associations to promote leather
industry to a special place in the international market.
The main objectives of the institute are:

  To train personnel in Footwear Technology as per the requirements of the trade

and industry.
  To train Footwear Designers.
  To provide training and research facility to trainers and technologists in the
 Footwear and allied industry with a view to upgrade their skills.

  To train personnel in maintenance of Footwear Machinery.

  To design and develop moulds and dyes for the Footwear Industry.
  To introduce modern technology in footwear design.
  To assist and promote technology upgradation in Footwear Industry.
  To develop products and design with a view to secure advantages in export

production.

  To undertake testing and assessment of Footwear and its materials.



To promote acquisition of international standards in the industry.

To foster appropriate linkages between Central Footwear Training Institute and Industry for
utilization of existing capacity and their upgradation and to undertake consultancy services
for development of Footwear Industry.

To establish linkages with educational, research and development institutions in India and
abroad, and to collaborate with them in training, research and development.
To organize data bases and information dissemination on Footwear Technology, Export
marketing etc., and to establish suitable Library and Resource Centre for trainees and
industry.

 Central Leather Research Institute (CLRI):

Being the world's biggest Leather Research Institute it was established on 24thApril, 1948.
CLRI made an activity with foresight to connect innovation framework with both institute
and industry. CLRI, today, is a central centre in Indian leather sector which has coordinate
parts in education, research, training, testing, outlining, estimating, arranging, social
strengthening and driving in science and technology identifying with leather. Condition of-
workmanship offices in CLRI bolster advancement in leather processing, innovative planning
of leather products viz., leather garments, leather goods, footwear and improvement of novel
natural advances for leather sector

 Council for Leather Exports (CLE):

The Council for Leather Exports was set up in July 1984. Being a non- benefit organization
enlisted under the Indian Companies Act, 1956, the Council works under the Ministry of
Commerce, Government of India. The Council is depended with export promotion activities
and large improvement of the Indian leather industry. It is the single biggest and Apex
exchange advancement association of the solid and rapidly developing Indian leather and
leather product industry. The Council's activities also include advancing Foreign Direct
Investments and Joint Ventures in the Indian leather industry. CLE fills as a bridge between
Indian leather exporters and purchasers all over the world. CLE is committed towards the
general advancement of Indian leather sector and achieving higher export to improve India's
offer in worldwide leather trade. It is the notified Export Promotion association for whole
leather and leather products industry.

 Indian Leather Development Programme (ILDP): Department of Industrial Policy and

Promotion (DIPP) has implemented an Indian Leather Development Programme (ILDP) for
the overall industrial growth of leather sector. The thrust of the ILDP scheme is on
technology upgradation and modernization of production units, expansion of production
capacities, creation of institutional facilities in the country, training Human Resources for the
leather sector, support to rural artisans for design and product development, to create market
linkages, environment management in the tanning sector etc. The Government through its
various policy measures is endeavouring to facilitate the leather industry in augmenting
production capacity on modern lines.

 Indian Shoe Federation (ISF):

Started in 1992, the Indian Shoe Federation has come a long way and many driving producers
and exporters of footwear and footwear components from India are its individuals.
Notwithstanding pushing its individuals to constantly upgrade the innovation, utilization of
best materials and aptitude, keep up strict quality control and fine tuning of client
introduction, the ISF co-ordinates with the Government in overcoming procedural and
strategy bottlenecks for a smooth direct of the business. Its pro-dynamic activities have
helped the business hugely and have conveyed it to the position of prominence that it
appreciates today. The ISF is conferred in advancing the development of the Indian Footwear
Industry universally through adoption of modern, transparent and superior industry practices.

 Indian Institute of Leather Fair (IILF): IILF displays the entire range of products relating
to leather industry from raw material to finished products (excepting shoes) and auxiliary
products such as finished leather; shoe components - uppers, soles, heels, counters, lasts;
machinery and equipment, process technology, software, chemicals and publications. The
business visitors will surely be attracted to exhibits displayed by more than 150 companies,
including over 50 from foreign countries. The brand IILF is well established and recognized
by the trade and industry not only in India but in overseas market also. A large number of
companies participate in the show regularly. IILF has played a catalytic role in showcasing
innovative products, technologies and services and contributed to the economic growth of the
country. Apart from mirroring the advances made by the Indian leather industry, IILF also
provides a ready and reliable window to the status of the global market and its changing
demands to enable the industry to review its marketing strategies and makes it more effective
and result-oriented. It is hoped that the foreign participants take note of the highly conducive
climate in India for investment on a big scale and the returns that these can offer.

Other Contributing Institutions/Associations are:

  International Council of tanners (ICT) (UK), to advance the interests of the

leather industry universally
  International Council for Hides Skins and Leather Traders Associations
(ICHSLTA), to advance, create and secure the worldwide exchange crude hides, skins
and cowhides.
  International Union of Leather Technicians and Chemists (IULTCS), to establish
and to keep up customary contact and viable co-task between Member Societies.
  A UNDP-assisted National Leather Development Programme (NLDP), to
upgrade preparing frameworks for planning and making of footwear, articles of
clothing and leather merchandise.
  The All India Skin and Hide Tanners and Merchants Association, Chennai
(AISHTMA), to advance the enthusiasm of tanning industry, leather exchange and
other allied exchanges and ventures.
   Indian Finished Leather Manufacturers and Exporters Association (IFLMEA), it
deals with issues confronting the leather industry by embraced review of availability
of crude materials, present infrastructure and the innovation in the manufacture of
sophisticated and top notch completed leather.

National Leather Technology Mission (NLTM), to promote leather industry internationally.

National Environmental Engineering Research Institute (NEERI), to overcome the problems

faced by them in day-to-day operation and maintenance of the plants.
People for Ethical Treatment of Animals (PETA), for ethical treatment of animals.

The United Nations Industrial Development Organization (UNIDO).

Future Outlook of Leather Industry:

Establishment of Mega Leather Clusters under ILDP Scheme

The Indian leather industry is working on low overall revenues by virtue of savage rivalry in
the worldwide market. Considering the generally safe taking limit of the current business
visionaries, it might be hard to draw in interests in extensive amounts except if the
administration likewise takes part in the production of framework bigly. The idea of Mega
Leather Clusters looks to address the imperative of substantial foundation with incorporated
creation chains in the nation.

The real target of creating Mega Leather Cluster is to make a world-class framework and to
coordinate the generation chain in a way that takes into account the business needs of the
leather industry to oblige the residential market and fares. In a word, these super groups will
help the business people to set up world-class units with present day foundation, most recent
innovation, and satisfactory training and Human Resource Development (HRD) inputs. The
advancement of Mega Leather Clusters would help in making extra work openings,
especially for the weaker areas of society. The Mega Leather Clusters may have creation
units of all sections specifically footwear, footwear parts, leather products (counting gloves),
leather garments and saddlery and harness items.

The plan targets advancement of Greenfield Mega Leather Clusters with every single
required office for the working of a group, for example, Core foundation - street, water,
power, lighting, and sewage lines, parking spot and so on., Social framework - distribution
centre, exchange focus, show focus, outline studio, inn with residence,

crude material bank, authoritative building, wellbeing focus and so forth., Production
foundation prepared to utilize manufacturing plant sheds with connect to office for
apparatus/gear, HRD - Training focuses, Recruitment focus, Library, Crèche and Canteen,
Labour Restroom and so on., Research and 102 Development offices - Product Design and
Development Support Centre, Testing Laboratory, Quality Benchmark Centre, Material and
Technology Research and so on., and send out administrations related framework.

Each Mega Leather Cluster will be executed by a SPV (Special Purpose Vehicle), which will
be a corporate body enlisted under the Companies Act 1956 shaped by partners, especially a
gathering of willing business visionaries (least being seven lawfully autonomous
organizations) that are occupied with leather tanning, manufacturing of leather merchandise
and segments and different exercises related with the leather industry and who plan to set up
creation units in the proposed Mega Leather Cluster. The SPV would define, accomplish
budgetary conclusion, execute and deal with the framework.

Proposition are being set up by the SPVs for setting up six Mega Leather Clusters in different
parts of the nation.

Three clusters in Uttar Pradesh (Ramaipur, Sandila and Agra) One cluster in Haryana
(Mewat)

One cluster in Andhra Pradesh (Tada Mandal) One cluster in Tamil Nadu (Perambalur)

Establishment of Leather Tanning Complex in Andhra Pradesh under ILDP Scheme:

A Leather Tanning Complex is coming up at Nellore locale, Andhra Pradesh. The SPV is
making fundamental move to set up the Leather Tanning Complex in Nellore locale, Andhra
Pradesh.

Upgradation / Installation of Infrastructure for Environment Protection in the Leather Sector

under ILDP Scheme:

This sub-plot gives money related help to the CETPs to meet the recommended
contamination control release standards, by method for foundation of framework viz.,
foundation of CETPs, establishment of Reverse Osmosis framework and reject taking care of
and so forth. Comprehensively, the plan would cover foundation/extension/upgradation of
CETPs, 103 creating Secure Land Fills, change of waste into some bye-items and some other
procedures for risky waste administration.

Setting up of Leather Parks: under ILDP Scheme

The sub scheme of leather parks under ILDP was proposed during XI Plan for addressing the
infrastructure constraints faced by leather industry in the country. The scheme would be
assisting the industry in addressing the infrastructure needs of the entire sector in a holistic
manner. This would enable the industry in improving its global competitiveness, apart from
meeting the regulatory and trade related compliances. The scheme will cover the entire value
chain of leather industry i.e., tannery, finished leather products, footwear components etc.
The strategy is to aggregate the demand of the industry in the form of clusters and to develop
need-based infrastructure for them through exclusive leather parks/complexes.

The basic concept of a complex is to develop a particular industrial sector demanding a

special and common infrastructure in one select location and to organize the planned growth
of a group of industries. Complex is like a well- planned and constructed city. Development
of leather industry in complexes has started gaining importance in European, Asian and Latin
American Countries. Realizing that infrastructure is the key to a globally competitive leather
industry, the Department has laid emphasis on setting up of infrastructure for the growth of
the leather sector in the XI Plan Period. It proposes to establish at least six to seven parks
during the XI Five Year Plan period with the total outlay of Rs.300 Crore. Establishment of
such parks will enable the provision of infrastructure in a more cost-effective manner, will
help in addressing the environmental concerns more effectively, will ensure greater
sustainability of the efforts finally resulting in positive impact on the competitiveness of
Indian leather industry.

Human Resource Development Sub-Scheme of LDP:

HRD sub-plan would target potential work drive in the provincial regions and would lay
weight on expertise advancement and specialized improvement. The primary target of this
plan is to overhaul the aptitudes of the current workforce which would prompt the 104
change underway and in addition quality, redesigning the abilities of the coaches/specialists
of specialized organization/NGOs associated with the undertaking and open them to the
accepted procedures to spread and support an innovation culture in the Indian leather sector.

The normal result of the intercession of HRD sub-plan will upgrade the aptitudes of the
administrators to create actually better items for the shoppers and will help build up Indian
Brands. Granting market-construct abilities in light of shop floor tasks to the adolescent
through a request driven Skill-Development Program and making them employable in the
leather industry and setting the effective learners in leather units are other expected results.

Leather Technology, Innovation and Environmental Issues: Sub-Scheme of LDP:

Leather Industry and tanning action specifically, everywhere throughout the world is
connected to environmental concerns. The natural issues are gradually making strides and
broad measures are to be set up for ventures to adapt to the stringent standards. Tanneries
have found a way to address the issue of waste water treatment. Tanneries are associated with
wastewater treatment systems, which could render the wastewater manageable to release.
Zero wastewater release is likewise influenced obligatory in a few states and the tanneries to
have introduced satisfactory luxuries set up to achieve zero waste water release. Be that as it
may, the ecological issues keep on exerting huge power of down pulling; this is one issue that
is straightforwardly associated with the maintainability of the business.

Assistance could be provided for the following four categories of environment related
projects:

Technology Bench Marking and Environmental Management for Leather Sector:

The goal of the plan is to upgrade the manageability of Indian Leather Units by giving
budgetary and specialized help to evaluating the procedure innovation received at present and
re-building them keeping in mind the end goal to add economic and environment benefits.

  Common Effluent Treatment Plants (CETPs):

This part would give money related help to Leather Cluster to meet the endorsed
contamination control release 105 standards. This would cover
foundation/extension/upgradation of CETPs, creating Secure Land Fills and some
 other strategies for dangerous waste administration. Different moves made to decrease
the ecological issues by tanneries are Chrome Recovery, Zero Liquid Discharge
Technology through RO and Bio Processing.
  Solid Waste Management:
The point of this plan is to include the business in the usage of strong waste from
tanneries for the creation of significant items that could be used locally.
  Environment Related Workshops:
This plan goes for sorting out the workshops to instruct and prepare the leather
experts and tannery representatives on housekeeping, concoction stockpiling and
dealing with, security and wellbeing and improving profitability and quality.

2.5 India Exports of Leather & Products

Exports of Leather & Products in India diminished to 27.43 INR Billion in February
from 29.09 INR Billion in January of 2017. Exports of Leather & Products in India
arrived at the mid-point of 11.90 INR Billion from 1991 until 2017, reaching an
unequalled high of 36.46 INR Billion in August of 2014 and a record low of 1.81 INR
Billion in June of 1991.
Tannery Effluent Treatment Plants, India

In Chennai and Tamil Nadu/India, which was the basis for demonstration of UNIDO regional
projects, circumstances at the time of project (mid 90's) commencement were such that the
tanning Industry was under considerable pressure vis-à-vis effluent treatment. As a result
several tanneries or clusters had already undertaken investments in primary or secondary
effluent treatment. Rather than create a possible redundant model plant, the project strategy
was oriented towards demonstration of four full scale model effluent treatment plants
representing different aspects of tannery effluent treatment plant in terms of influent, treatment
process and size. Thus, the Ranitec CETP with treatment capacity of 4,000 m3/d receiving
effluent from 76 tanneries processing from raw to finished and using amongst others an
anaerobic treatment system (lagoon) was upgraded to serve as a model for similar treatment
plants in the region. The Vishtec CETP with a capacity of 3,400 m3/d of effluent using two
stage aerobic treatment system was upgraded (mainly process control) to be a second model
site. The President Kid Leather Company ETP, 120 m3/d receiving effluent from semi-finished
to finished tanning processes from an isolated was upgraded as a model site (automatic dosing,
laboratory). The MHT Company ETP, capacity 100 m3/d, receiving effluent from a traditional
isolated vegetable tannery, a low cost anaerobic treatment system, was upgraded and serves as
a model for similar units.

Detailed reports describing assisted tannery effluent treatment plants:

i) Common Effluent Treatment Plant, Amburtec, Ambur, India

ii) Common Effluent Treatment Plant, Kolkota, Leather Complex Kolkota, India

iii) Effluent Treatment Plant, Meera Hussain Tannery, Melvsiharam, India

iv) Common Effluent Treatment Plant, Pallavaram, Chennai, India

v) Common Effluent Treatment Plant, Ranitec, Ranipet, India

vi) Common Effluent Treatment Plant, SIDCO, Ranipet, India

vii) Common Effluent Treatment Plant, VISHTEC, Melvisharam, India

About RANITEC, Ranipet

Ranipet, a town about 120 kms from chennai has a large concentration of tanneries processing
hides and skins from raw of finish. Born out of the urgent need to control pollution,several
centralized treatment facilities were planned. The Ranipet Common Effluent Treatment Plant
(RANITEC) at V.C.Mottur is one of such successful facilities catering to the needs of 82
tanneries.

The effluent from the tanneries spread over an area of 4-5 sq.km is collected and transported
to the treatement plant through a system of pumping stations, pressure and gravity mains. The
total length of the pipe work is about 12 km.

The entire permeate from the Reverse Osmosis and Condensate from the Evaporator are being
mixed and recycled to the tanneries through the closed pipe lines for resue in their processes
of tanning. The total length of the pipeline for the Recovered Water Distribution is about 25
km and pumped through three Over Head Tanks located in different arears of the cluster.
Unique Features of the CETP of RANITEC, Ranipet

The plant is designed to handle about 4500 Cum/day of effluent, making it one of the largest
Common Effluent Treatment Plant (CETP) for tannery wastewater in the country. Since its
establishment in the year 1995, the CETP has been constantly upgraded with either partial
assistance or matching grant from the Government of India and Tamil Nadu.

Some of the unique features of this treatment facility are:

o India's first CETP to achieve the highest International Standard for Quality - the ISO
Standard. RANITEC CETP achieved ISO 9001 Certificate on 15th November 1999 and
is currently ISO 9001: 2008 Certified Company by DNV, The Netherlands.
o World first RANITEC CETP in leather sector to achieve the highest International
Standard for Environmental Management System - the ISO Standard. The CETP has
achieved ISO 14001 Certification on 29thJanuary 2014, certified by DET NORSKE
VERITAS (DNV), The Netherlands.
o The formation of Waste Minimization Circles with support of Central Leather Research
Institute (CLRI) has created awareness among the CETP member tanners and resulted in
reducing the usage of water consumption in the processes of tanning to 28 litres/Kg in
compliance to the Corporate Responsibility for Environmental Protection (CREP).
o Implementation of Zero Liquid Discharge (ZLD) System of the CETP by a Special
Purpose Vehicle formed in the name and style "Chennai Environmental Management
Company of Tanners" (CEMCOT) under the chairmanship of Mr.M.Mohamed Hashim
Sahib and vice-chairmanship of Mr. A.Sahasranaman, I.A.S., (Rtd).
o Installation of ZLD System at a cost of Rs.460 million under the Up-gradation and
Installation of Infrastructure for Environmental Protection in the Tanning Industry of the
Department of Industrial Policy & Promotion (DIPP), Ministry of Commerce and
Industry under the ILDP scheme of 11th Five Year Plan.
o The ZLD System of RANITEC CETP consists of the following:

o CETP Upgradtion: Replacement of the collection and conveyance lines, new mixing
system and odour control system in receiving sump, new mechanical screen, pre-
settler, new aeration tank with new blowers and diffusers, additional mechanical
sludge dewatering, softening to remove hardness and improvement in monitoring.
o RO System: Pre-treatment filtration, organic scavenger, ultra-filtration, two stage reverse
osmosis and automated control system for the same.
o Multiple Effect Evaporation of RO Reject: Seven effect evaporation with thermal
vapour re-compression system and pusher centrifuge for separation of salts.
o Salt Disposal Yard: Special disposal unit to store generated salt for two years at full
capacity.
o Recovered Water Conveyance System: Over Head Tanks and piping system with
metering for conveying the recovered water back to individual tanneries.

o Connection of CETP flow meters to the CARE AIR CENTER of Tamilnadu Pollution
Control Board (TNPCB) for online monitoring.
o Operation of the plant in the CETP with computerized management system.
o India's First Tannery CETP to have installed Electromagnetic flow meters in all
operating member tanneries and implemented flow based maintenance charges since
1999. This also complies with the Charter for Corporate Responsibility for
Environmental Protection (CCREP), 2003
o This plant was co-sponsored by the United Nations Industrial Development Organization
(UNIDO) until 2001 and considered a model CETP for the South East Asian region,
under an agreement signed by RANITEC and then UNIDO's Regional program office in
Chennai.
o Construction of a Secure Land Fill System (SLF) with a capacity of 1,00,000 ton at a
cost of Rs.81.81 million under the ASIDE scheme with the technical assistance from
Central Leather Research Institute (CLRI).

Establishment of a Leather Testing Laboratory

The RANITEC Technical Team has offered its supervision in the establishment of a state-of-
the-art 'SITDA Testing Lab' at Ranipet Leather Cluster at a cost of Rs.100 million with 75%
grant under the Central ASIDE Scheme of the DIPP, GoI, with CLRI as Technical Agency,
CLE as Implementing Agency and ILIFO as Management Consultant.

The Lab has been established with an aim to meet the growing needs of the testing of leather
and leather products. The Lab has all modern equipments for performance testing sthrough
physical testing and mandatory requirements on restricted substances. The Lab is also equipped
to meet the testing needs of buyer-specific private standards.

Pre-Treatment System

Before discharge of effluent to the sewer system, each tannery carries out the following
activities.
I. All trade effluent undergoes Screening and Sedimentation in a Pre-Treatment Unit (PTU)
before discharge into the CETP sewer line

This PTU consists of the following:

o Oil and Grease Trap: The floating matters like fat and proteins presence in the effluent
are removed.
o Bar Screen Chamber: Major particles in the effluent are removed by the PVC/ SS type
rigid, non corrosive, fixed bar screens with 5mm spacing provided.
o Raw effluent Collection Tank: The screened effluent is collected in this tank before
being pumped into the Overhead Sedimentation Tanks.
o Pre-Settlers: Two settlers of overhead type are provided for sedimentation of coarse
solids in the effluent. These settlers have valves at the bottom for withdrawal of sludge
to the Sludge Drying Beds/Filter Press.
o Final Collection Tank: The overflow from these Sedimentation Tanks is collected in
this tank before being pumped to the CETP Sewer Network through a Flow Metering
System.
o Sludge Drying Beds: Sludge from the sedimentation tanks is discharged into the drying
beds with filter media for solar drying. The dried sludge is transported to the Secure
Landfill (SLF) of the CETP.
o Filter Press: Wherever Filter Press is installed, the sludge from the sedimentation tanks
is fed to the same for quick drying of sludge with less moisture content for disposing to
the SLF.
o Flow Metering System: A skid mounted unit comprising of an Electromagnetic Flow
Meter with flow Indicator and Totalizer with a pump is installed in each tannery. The
effluent from the Collection Tank is pumped through the flow meter to the CETP Sewer
Network. The quantity of effluent discharged is recorded in the flow meter. The flow
metering system is housed in a sealed close room with opening to switch ON/OFF of the
pump. The room key is in the custody of the CETP.

Chrome Recovery Units

Tanneries doing Chrome Tanning Process have installed Chrome Recovery Units in their
premises. These tanneries segregate the chrome liquor and collect in a tank for precipitation of
the chrome by adding magnesium oxide solution. The precipitated chrome slurry is added with
sulfuric acid to regenerate chrome and filled in carboys. Thus the chrome is recovered and
mixed with fresh basic chromium sulphate for re-use in the tanning process.

Process Description

This PTU consists of the following:

Oil and Grease Trap: The floating matters like fat and proteins presence in the effluent are
removed.

Bar Screen Chamber: Major particles in the effluent are removed by the PVC/SS type rigid,
non-corrosive, fixed bar screens with 5mm spacing provided.

Raw effluent Collection Tank: The screened effluent is collected in this tank before being
pumped into the Overhead Sedimentation Tanks. Pre-Settlers: Two settlers of overhead type
are provided for sedimentation of coarse solids in the effluent. These settlers have valves at the
bottom for withdrawal of sludge to the Sludge Drying Beds/Filter Press.
Final Collection Tank: The overflow from these Sedimentation Tanks is collected in this tank
before being pumped to the CETP Sewer Network through a Flow Metering System.

Sludge Drying Beds: Sludge from the sedimentation tanks is discharged into the drying beds
with filter media for solar drying. The dried sludge is transported to the Secure Landfill (SLF)
of the CETP. Filter Press: Wherever Filter Press is installed, the sludge from the sedimentation
tanks is fed to the same for quick drying of sludge with less moisture content for disposing in
to the SLF.

Flow Metering System: A skid mounted unit comprising of an Electromagnetic Flow Meter
with flow Indicator and Totalizer with a pump is installed in each tannery. The effluent from
the Collection Tank is pumped through the flow meter to the CETP Sewer Network. The
quantity of effluent discharged is recorded in the flow meter. The flow metering system is
housed in a sealed close room with opening to switch ON/OFF of the pump. The room key is
in the custody of the CETP.

Chrome effluent stream is segregated at source to process in chrome recovery and reuse.
Tanneries doing Chrome Tanning Process have installed Chrome Recovery Units in their
premises. These tanneries segregate the chrome liquor and collect in a tank for precipitation of
the chrome by adding magnesium oxide solution. The precipitated chrome slurry is added with
sulfuric acid to regenerate chrome and filled in carboys. The chrome is recovered and mixed
with fresh basic chromium sulphate for re-use in the tanning process.

The CETP has installed Zero Liquid Discharge (ZLD) System with partial assistance from
Govt. of India and Govt. of Tamilnadu under the Up-gradation and Installation of Infrastructure
for Environmental Protection in the tanning industry of the Department of Industrial Policy &
Promotion (DIPP), Ministry of Commerce and Industry (MoC&I) under the ILDP scheme at a
cost of Rs.460 million of 11th Five Year Plan.

The ZLD project was implemented by Chennai Environmental Management Company of

Tanners (CEMCOT) as SPV. Under this scheme new equipment like Extended Diffused
Aeration System, Reactivated Clarifier, Reverse Osmosis Plant, Multiple Effect Evaporator
with Boiler, Lab and Administrative Building, Salt Storage Yard, Replacement of Raw Effluent
Conveyance System and Recovered Water Conveyance System.

The effluent from different tanneries flow through a Mechanized Rake Bar Screen to the
Receiving Sump, wherein 1No of Submersible mixers is installed for complete mixing before
it is transferred to the pre-settler units for removal of easily settleable coarse solids. The
overflow from this unit is passed through a rotary fine screen (which screens solids < 3 mm)
before discharge into the Equalization Tank with 2 Nos of Aspirators and 3 Nos of Blowers for
the coarse bubble mechanism are installed for homogenous mixing of the effluent.The effluent
from the Equalization Tank is chemically treated with lime and alum in the flash mixer and
polyelectrolyte is added in the flocculation to facilitate coagulation and flocculation of solids
which is sedimented in the Primary Clarifier and conveyed to the Filter Press for dewatering
the sludge. A pH of 8.0 to 8.2 is maintained in the Primary Clarifier to precipitate the
chromium(Cr3+)present in the effluent as chromium hydroxide.

The above-mentioned primary treatment removes 65-70% and 40-45% of incoming suspended
solids and BOD as well as precipitating most of the chromium. The overflow from the Clarifier
is further treated in the Pre-aeration tank for removal of Hydrogen Sulphide using Liquid
Oxygen with Mix flow system before entering in to an Extended Aeration Type Activated
sludge process in Aeration tank I is with Diffused Aeration System and Aeration Tank -2 is
with Original Hydrodynamic Reaction (OHR) a Japanese technology. Three blowers of 7000
m3/hr capacity of each have been installed to maintain a D.O between 1.5 to 2.0 mg/lit. The
outflows from the Clarifiers have a BOD of around 30 mg/l. To further improve the effluent
characteristics and colour, the effluent is passed through Pressure Sand Filters after the addition
of Alum and polyelectrolyte in the flash mixer and flocculation in the flocculator.

The treated effluent reaching the RO system is first subjected to softening through lime-soda
process in a reactivated clarifier. The softened effluent is further filtered in the dual media
filters and disc filters imported from Israel and very fine filtration is obtained in an
ultrafiltration system employing hollow fibre UF membranes. The ultra-filtered effluent is then
polished in organic scavenger before it is desalinated in two stages Reverse Osmosis unit. The
entire UF and RO skids are made in USA and is automatic, controlled through SCADA. The
UF-RO skid is imported from Singapore.

The reject from the RO are again subjected to third stage High Pressure RO to recover
additional permeate and thereby reduce the volume of reject fed to the seven stage Multiple
Effect Evaporator with four stages of falling film and three stages of forced circulation
evaporation towers (calandrias). The fuel used for producing steam is firewood and biomass
briquette. The salt-laden solid residue is separated out in a pusher centrifuge.

The permeate from RO system and the condensate from evaporator are combined and
distributed back to the tanneries for use in manufacturing process through a recovered water
conveyance system with three Over Head Tanks at different locations in the cluster and supply
lines with electronic water meters.

The Sludge from the Primary, Secondary clarifiers and Reactivated clarifier are dewatered in
five number of chamber filter presses. The back-washing effluent from Sand filters is
discharged back to the Receiving Sump and Back washing from Dual media filters, OS and
RO are recycled back to the Secondary Effluent Collection Tank. The dried sludge is then
disposed of to the Secure Land Fill (SLF) system .

The salt-laden solid residue is stored in bags and a huge salt storage yard has been constructed
for the purpose.

Efforts to re-use the salt in preservation of hide / skins and purification system is underway.
The CETP meets the Zero Liquid Discharge standards of Tamil Nadu Pollution Control Board
(TNPCB), and the Electro Magnetic Flow Meters connected to the CARE AIR Centre of
TNPCB at Chennai for real time online monitoring.

Statistical Profile of Tanning Industry in Ranipet*

Estimated
Estimated Annual Annual
No.of.workers
SI.No Type of Product No.of Uniits Turnover Million Export
Employed
Rs. turnover
Million Rs.
1 Raw to Finish 23 2,526 4,370 3,465
2 Raw to Semi-Finish 22 3,165 2,383 -
3 Semi Finish to Finish 37 4,868 1,322 1,380
Manufacture of Full Shoes
4 18 10,368 4,557 2,734
and Shoe Upper
Total 100 20,928 10,249 7,579
* The Data excluedes Units in SIPCOT Industrial Estate and Melvisharam
Ghani Rasheed Effluent Treatment
Process of Effluent Treatment:
1. Primary treatment

Basic steps:

Screening (bar, self-cleaning)

Pumping/lifting

Fine screening Equalization and sulphide oxidation

Chemical treatment (coagulation, flocculation)

Settling

Sludge dewatering

1. Screening

Quite often a grease-and-sand trap is also included, usually before fine screening and
pumping. Primary and secondary sludge are handled/dewatered together; however, since
some ETPs have only primary treatment and the main part of sludge is generated during that
stage, sludge dewatering is covered here.

2. Pumping

It is not possible to transfer effluents throughout the ETP by gravity only; at least one, often
more pumping/lifting stations are needed, the first typically located before the rotary screen.
Depending on specific requirements (capacity/flow), different types of pumps are used. For
medium-scale ETPs, submersible pumps are generally used for this purpose, for large-volume
ones, screw (Archimedes) pumps are preferred. Introduction to treatment of tannery effluents
15 Figure 11. Schematic view of an Archimedes-type lifting pump Figure 10. Submersible
pump The scheme of submersible pump positioning (usually with a stand-by pump) is shown
below:

3 Fine screening Equalization and sulphide oxidation

Fine screening should drastically reduce the amount of fine suspended solids. The figures
below show rotary-drum screens with outer and inner flow.

Equalization – homogenization – sulphide oxidation

The main aims here are:

• Homogenization of the effluent (quantity and quality); and

• Sulphide elimination, mostly by catalytic oxidation.

It is very important to keep all particulate matters in suspension, i.e., to avoid settling of
solids. This is achieved by using mixing-cum-aeration devices such as diffused-air systems
(preferred), Venturi ejectors, and fixed or floating aerators (lately avoided due to lower
efficiency and the problem of aerosols). In practice, to play it safe, the volume of the
equalization tank corresponds to the total daily effluent discharge.

Approximately 1 kg of O2 is needed to oxidize 1 kg of S2- to thiosulphate, whereas the

oxygen transfer efficiency is about 1.5 kg O2/kWh (simplified approximation: 1 kg S2- = 1
kg O2 = 1kWh). Again, in practice, attention is focused on the energy required to keep the
solids in suspension (some 50 W/m3), which is then sufficient for sulphide oxidation; the
amount of catalyst, MnSO4 · 4 H2O, industrial purity, is about 20 g per cubic meter of tank
capacity. Whichever the mixing/aeration system chosen, it is necessary to be possible to
remove the mixing device without stopping the treatment process. The inlet and the outlet of
the equalization tank should be as far away from each other as possible to allow proper
mixing (and no short-circuiting).
4. Chemical treatment (coagulation, flocculation)

Chemicals are added in order to improve and accelerate the settling of suspended solids,
especially of fine and colloidal matter. In wastewater treatment operations, the processes of
coagulation and flocculation are employed to separate suspended solids from water. These
terms are often used interchangeably, or the single term – be it “coagulation” or
“flocculation” – is used to describe both; sometimes “flocculation” is understood as the
second stage of “coagulation”. In fact, they are two distinct processes usually carried out in
sequence as a combination of physical and chemical procedures. Finely dispersed solids
(colloids) suspended in wastewater are stabilized by negative electric charges on their
surfaces, causing them to repel each other. Since this prevents these charged particles from
colliding to form larger masses, called flocs, they do not settle. Coagulation is the
destabilization of colloids by neutralizing the forces that keep them apart. Cationic coagulants
provide positive electric charges to reduce the negative charge (zeta potential) of the colloids.
As a result, the particles collide to form larger particles (flocs). Rapid mixing is required to
disperse the coagulant throughout the liquid. Care must be taken not to overdose the
coagulants as this can cause a complete charge reversal and thus re-stabilize the colloid
complex

5. Settling – primary sedimentation

The main objective at this stage is the removal of suspended solids; however, various
constituents such as fats, waxes, mineral oils, floating non-fatty materials, etc. (“grease”), not
already removed in the grit-andoil chamber (usually positioned between screening and
equalization), are also separated here. Primary settling tanks (clarifiers) are either circular
(more commonly used) or rectangular with continuous grease (scum) removal at the top and
sludge removal at the bottom. The key design parameters are: • detention time – usually 1 to
2 hours (vertical clarifiers of the Dortmund type); • surface hydraulic loading, expressed in
m3/m2 of tank surface per hour or m/h, typically 1 to 2 m3/m2 per hour; • surface solids rate,
expressed in kg/m2 and indicating the quantity of SS crossing the surface area of the tank
over a certain time span (hour, day). The surface solids rate is most frequently used in the
design of sludge thickeners but, due to the quantity (4-6 g/l) and flocculent nature of tannery
effluent solids, it is useful in controlling the primary sedimentation as well. Circular tanks are
generally preferred as recirculation is easier. A mechanical device (scraper) is necessary in
larger settling tanks
6. Sludge dewatering

The sludge drawn from the bottom of the tank is in the form of slurry with a dry-solid (DS)
content of only 2-4%. For its evacuation, special pumps – usually of the Mohno type – are
used. For further handling and disposal of sludge, it is necessary to reduce drastically the
water content. This is usually achieved by: (i) thickening in sludge thickeners (very much like
circular clarifiers); (ii) mechanical dewatering in filter presses, belt-filter presses or decanters
(centrifuges); (iii) natural drying in sludge-drying beds. In addition to power and chemical
requirements, the key parameter for equipment selection is the achievable dry matter content
in the dewatered sludge.
2. Biological (secondary) treatment

The main objective at this stage is to further reduce the amount of organic (expressed as BOD
and COD)3 and other substances still present in the effluent after the primary treatment and
thereby satisfy the standards/limits for discharge into surface waters (rivers, lakes). The
biological treatment duplicates processes that take place in nature, but under controlled
conditions and, especially, at a highly accelerated pace; however, the efficiency of this
treatment largely depends on the biodegradability of the polluting substrate, i.e., its inherent
capacity to decompose by biological processes. The remaining suspended and colloidal solids
are removed by flocculation and adsorption. While biological treatment may be aerobic,
facultative or anaerobic (or some combination thereof), in practice, almost only aerobic
systems are used; exceptionally, in countries with a hot climate and where a lot of land is
available, facultative (preferably aerated/facultative) lagoons are also used. Due to the
inherent characteristics of tannery effluents, primarily their sulphide/sulphate content, in
practice, anaerobic treatment is used only in sludge digestion. Among many variations of the
aerobic process, the most widely used method is (complete-mix) activated sludge treatment
with extended aeration; despite some very interesting features, membrane bioreactors
(MBRs) have not made significant inroads in the tanning sector.

Generally, the biological stage is the most complex part of the overall effluent treatment
process, with highest investment and operational costs, its day-to-day running requiring
considerable skills and experience

1. Main operational parameter

The main operational parameters – expressions important to understanding the process –

are:

• Total influent volume, Q: volume of treated effluent (m3/day)

• Tank volume, V: aeration tank volume (m3)

• Organic loading, F: total BOD5 applied (kg/day) F = (f x Q)/1,000 where f is the BOD5 of
the influent (mg/l)

• Mixed liquor suspended solids, M: M = (MLSS x V)/1000 where MLSS is the

concentration of SS in mixed liquor in the aeration tank (mg/l)

• Loading factor, F/M: BOD5 kg per day per kg of mixed liquor suspended solids (MLSS) in
the aeration tank (mg/l)

• Hydraulic retention time, T: T = (V/Q) x 24 where V is aeration tank volume (m3)

2. Aeration devices

Water (effluent) aeration is important business that employs a wide range of equipment. In
addition to cost, reliability, etc., the key criterion is the amount of air (oxygen) transfer per
kW installed. Here is one – rather arbitrary – classification:

a. Surface aerators Radial flow, low speed, 20-60 rpm Axial flow, high speed, 300-1200 rpm
Brush rotor (oxidation ditch)

b. Submerged turbines

c. Diffusers Bubblers – porous and non-porous diffusers Tubular Jets (developed from
Venturi ejectors)
3. Anaerobic biological treatment

As mentioned earlier, despite its high performance, comparatively lower costs and wide use
in other industries, anaerobic treatment has failed to make inroads in the tanning industry.
The main reason is that tannery effluent treatment leads to the development of a highly
toxic, corrosive and flammable gas, hydrogen sulphide (H2S); difficulties and risks in dealing
with this gas prevail over other, positive features of anaerobic treatment

4. Secondary sedimentators

Their design is very similar to those of primary sedimentators, but the operational
conditions are different. Also, the (excess – wastage) sludge evacuated at the tank bottom is
normally bulkier and more difficult to dewater. Surface hydraulic loading – or surface
overflow rate (SOR) – is the vertical velocity of the influent in the secondary sedimentation
tank (m3/m2 of tank surface per hour, m/h). SOR of approximately 0.5 m3/m2 per hour is
generally used for secondary sedimentation of tannery effluents, i.e., less than for primary
clarifiers. Surface solid rate (SSR) is the quantity per hour of MLSS (kg) crossing the surface
area of the secondary sedimentation tank (kg/m2 of tank surface per hour) (see primary
sedimentation). SSR values between 2.0 and 3.0 kg/m2 per hour are generally used for
secondary sedimentation of tannery effluents. The overflow from the secondary clarifiers
represents the fully treated effluent usually fit for discharge into a final recipient. In order to
satisfy the legal limits for nitrogen (ammonia and TKN), very often nitrification and
denitrification stages need to be introduced into the biological system. Nitrification requires
extensive aeration as well as a low F : M ratio (< 0,1) to facilitate conversion of nitrogen
containing organic matter into nitrate and nitrite salts. During the denitrification stage,
which for operational reasons can take place either at the very beginning or at the end of
the biological treatment, these salts are converted under anoxic conditions into neutral
nitrogen gas (N2) and water

3. Advanced (tertiary) treatment

In certain cases, despite extensive physical-chemical and biological treatment in a

well designed ETP, the quality of the final effluent does not meet the promulgated discharge
limits. The usual culprit is the recalcitrant COD, i.e., compounds that the micro-organisms
present in the floc are unable to decompose. In such cases, it is necessary to resort to
additional, usually more sophisticated and rather expensive treatments such as
mineralization of organic compounds by oxidation with H2O2 in the presence of ferrous
sulphate (Fenton process and its derivatives). Ozonation is sometimes included not so much
to kill potentially harmful micro-organisms but to destroy part of the residual COD.
4. Sludge handling

Mechanical sludge dewatering

The main purpose of sludge dewatering is not only to reduce the volume and weight of
material to be transported but also to attain the dry matter content required for disposal at
landfills. The equipment used for this purpose – recessed-plate filters, belt presses and
decanter centrifuges – was already described earlier. Here is a short comparative overview
of the main characteristics and efficiencies of the various systems as well as changes in DS
content throughout the treatment process.

Utilization and disposal

In comparison with sanitary sludges, tannery sludge has greater inorganic matter content,
greater heavy metal content, especially chromium and greater sulfur compound content.
However, the main stumbling block is the chromium content, with legislation and practice
varying a lot from country to country. A number of solutions for utilization and/or safe
disposal of tannery sludge have been proposed, practiced, tested, and applied at pilot and
industrial scale: landfill, land application, composting, anaerobic digestion, thermal
treatment, vitrification, pyrolisys, brick making, etc., none of them proving satisfactory
enough. There is certainly no universal solution for sludge utilization/application. Each ETP
produces sludge of specific characteristics and different regions and countries have quite
different regulations regarding sludge utilization. Therefore, prior to any ETP construction, a
detailed assessment of options should be prepared and the most suitable application
proposed. In any case, handling, storage and transport of sludge and solid wastes from PTPs
and ETPs should also be safe and not contaminate the surroundings; thus, for example, the
collection points should be protected against bad weather (rain, for example).
5. The issue of bad odour

Odours associated with wastewater are difficult to quantify because they are caused by a
wide variety of compounds and they are a nuisance that is more qualitative than
quantitative – sensitive persons easily detect very low concentrations of odoriferous
substances in the air (sulphides/other sulphur compounds, ammonia, amines, etc.). Local
geographic and climatic conditions such as wind direction, land shape, air humidity, ground
and air temperature, etc. play an important role. Along the treatment line, the main sources
of bad smell are:

• Equalization and sulphide oxidation;

• Sludge thickening;

• Biological aeration;

• In-plant storage of dewatered sludge;

• (temporary) sludge disposal site.

Yet, the main source of bad smell remains the stripping of hydrogen sulphide; it is not the
concentration of sulphide per se, but the lowering of pH: the not disassociated H2S is
present only at pH below 10. Thus, it is crucial to control pH and, if needed, alkalis like NaOH
or lime are added to achieve pH > 9.5-10. More extensive, uninterrupted aeration may help,
but sometimes rigorous (and expensive) methods such as adding hydrogen peroxide or pure
oxygen are necessary. Nowadays, in some places, nearly the entire ETP is covered and the
air is purified.

6. Monitoring, costs, OSH, management

The extent of monitoring activities largely depends on local legal requirements and ETP size
and it includes a wide range of parameters: effluent volume(s), peak loads, pollution loads,
chemical dosing, dissolved oxygen (DO), sludge volume index (SVI), etc. The costs of
Treatment vary a lot, depending on the local costs of:
• Power;
• Chemicals;
• financing;
• Labour;
• sludge utilization and disposal options, etc.
In developing countries, the largest component is power, while sludge handling and disposal
costs are comparatively low. If the reverse osmosis (RO) stage for desalination is installed,
the cost of energy escalates further. In industrialized countries, the largest cost component
is dewatering and safe disposal of solids (sludge).

While working out the costs of an ETP at an individual tannery is quite straightforward,
different methods are applied to compute the distribution of CETP operation costs among
individual tanneries. The key parameters used are typically the following:
• water consumption, m3/day;
• production capacity, tonnes of wet-salted hides/day;
• actual pollution load in terms of COD, suspended solids, sulphides and Cr;
• production output, m2/day of wet blue, crust or finished leather.

In developing countries, cost calculation methods for CETPs are usually very simple, being
based solely on effluent volume and type of tanning, whereas in Italy, for example, these
methods are very sophisticated and are based on many factors measured on-/off-line or
estimated.

When it comes to occupational safety and health at work (OSH) in (C)ETPs, the main focus is
on hydrogen sulphide gas. As mentioned earlier, hydrogen sulphide is an extremely toxic
and irritating gas. It has a strong odour of rotten eggs but, paradoxically, it is perceived only
at lower concentrations. This explains the numerous accidents despite its known toxicity

New toxicological data have led authorities in some countries to start reducing the
recommended chronicexposure limits to hydrogen sulphide – the 8-hour time-weighted
average of the threshold limit value (TLVTWA8) for H2S came down from 10 ppm to 1 ppm,
and the short-term exposure limit (TLV-STEL) from 15 ppm to 5 ppm; as a result, even
confirming compliance with the new standards will be a challenge. Instruments used to
detect and monitor H2S exposure can be either fixed or portable, whereas personal
detectors are worn by employees and typically sound an alarm at levels between 10 ppm
and 15 ppm. Due to this nearly permanent life threatening hazard, H2S meters are always
positioned at critical points and/or carried by staff. Also, certain activities such as entering
pits can be carried out only in the presence of skilled supervisors (the worker performing
such an operation must also wear a safety harness). Otherwise, general and specific
measures concerning equipment and chemicals also apply to ETPs. Nowadays it is taken for
granted that in a well managed tannery there is a person of appropriate competence and at
an appropriate level of seniority who deals exclusively with increasingly complex
environmental issues, especially those related to effluent treatment; in some countries, this
is a legal requirement.