m/s siddaganga cements pvt. ltd. pre-feasibility reportpfr)file.pdf · m/s siddaganga cements pvt....

M/s SIDDAGANGA CEMENTS PVT. LTD. Pre-Feasibility Report

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CHAPTER 1: EXECUTIVE SUMMARY

M/s. Siddaganga Cements Pvt Ltd is situated at Sy.No. 61 Sadarahalli Village,

Chikkanayakana halli Taluk, Karnataka State. It is a progressive company engaged in the

Manufacturing of cement and is professionally managed by people who have vast

experience in the field of cement. The company is promoted by technically qualified and

professionally experienced technocrats who crave for innovation and value addition. We

recognize that our ability to excel in our core competences depends on the skill,

knowledge, creativity and hard work of our employees. A high standard of ethics,

integrity and responsibility towards our customers remains our top priority. The

company’s competitiveness is displayed not only in cost-effectiveness and fast time

frames but also in dependability, quality and respect for intellectual property rights and

strict procedural norms ensuring clients and associates absolute confidentiality.

Manufacturing with effective quality management is of paramount importance to our

success. Our manufacturing sites are regularly evaluated internally and inspected by

regulatory authorities to ensure that finished product have the identity, strength, quality

and purity they are required to have. Our line of products is vast and varied. With a

strong emphasis on innovative and efficient process development our products conform

to the highest standards of quality that we have set for ourselves. Apart from our core

competence in standard unit operations, process innovation and development to achieve

higher yields, we see ourselves as our customers long term and faithful partners,

motivated by the understanding that the customers success is our success.

With the assistance of qualified professionals including those who have already worked

in the renowned cement companies in India as well as abroad, they are able to provide

quality cement. The company in a short span of time has expanded its operations to offer

total turnkey solutions to the various Indian cement industries. large installation capacity,

cost effective supply and customized packaging, they have secured a remarkable position

in this domain in short time.


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M/s Siddaganga Cements Pvt Ltd located in the district of Tumkur, and 123 Kms from

Bangalore. Mr. D.K. Prabhudevaiah is the Managing Director and already an

entrepreneur from 1976 having couple of SSI units and he is well experienced in Cement

industry.

The main objective of M/s. Siddaganga Cements private Limited is manufacturing

Ordinary Portland cement and planning to manufacture Porzonlona Portland cement and

Portland slag cement with a capacity of 30 TPD To 200 TPD.

1.1 Quality Policy:

Siddaganga Cements Pvt Ltd manufacturing products of high quality and creates an

environment where each employee contributes to all aspects of our business processes.

The company recognizes that quality is not just another goal, but an essential strategy for

growth. Towards this objective of quality we advocate continuous improvement in all our

activities by fostering teamwork, innovation, providing good working environment and

effective training to our employees to make them more competent and quality conscious.

1.2 Quality Assurance:

The company’s quality focus encompasses all areas of the manufacturing operations-from

procurement of raw materials to best possible manufacturing technology, from on time

delivery of the customer’s requirements to promotional help pushing its product to

become the market brand thus ensuring a rapid penetration in the domestic markets-

nationwide.


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CHAPTER 2: INTRODUCTION OF THE PROJECT/BACKGROUND

INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

M/s Siddaganga Cements Pvt Ltd. has proposed for expansion of existing production

capacity from 30 TPD to 200TPD. at Sy.No. 61 Sadarahalli Village, Chikkanayakana

halli Taluk Karnataka State which measures 4acres 38 Guntas

M/s Siddaganga Cements Pvt Ltd located in the district of Tumkur, and 123 Kms from

Bangalore. Mr. D.K. Prabhudevaiah is the Managing Director and already an

entrepreneur from 1976 having couple of SSI units and he is well experienced in Cement

industry.

2.2 BRIEF DESCRIPTION OF THE NATURE OF THE PROJECT.

Presently company is manufacturing Ordinary Portland cement and planning to

manufacture Porzonlona Portland cement and Portland slag cement with a capacity of 30

TPD To 200 TPD. To increase the capacity further with the existing infrastructure the

company is going to adopt good production methodologies as pointed out below,

Optimization of existing grinding to increase capacity from Proposed Expansion

of grinding capacity from 30TPD to 200TPD.

Flyash from thermal power plants as additive in our cement mill to increase the

output of the mill

To improve the grinding facility efficiency, the improved quality of grinding balls

will be used.

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY

AND OR REGION.

Cement is one of the core industries which plays a very important role in the growth and

expansion of a nation. It is basically a mixture of compounds, consisting mainly of

silicates and aluminates of calcium, formed out of calcium oxide, silica, aluminium oxide


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and iron oxide. The demand for cement depends primarily on the rate of activities in the

business, financial, real estate and infrastructure sectors of the economy.

2.4 DEMAND AND SUPPLY GAP

Demand for Cement is high and as soon as Cement is produced it will be supplied to the

contractors by trucks covered with tarpaulins.

2.5 IMPORTS V/S. INDIGENOUS PRODUCTION

The major raw materials for the grinding unit are Clinker, Gypsum, Flyash and Slag and

the quantities of raw materials imported and their sources are as follows,

Sl.No Raw Materials Maximum Quantity

TPD

Sources

1 Ordinary port

land cement 53

grade

70 BMM Cements

Hospet

2 Granulated

Slag GGBS

17.5 JSW Steel plant

Bellary

3 Flyash 30 JSW Steel plant

Bellary

4 Gypsum 7.5 The Fertilizers &

Chemicals Travancore

limited, Cochin

5 Clinker 75 Heidelberg cements

india limited, Tumkur

6 PP Bags 4200 nos Tumkur

2.6 EXPORT POSSIBILITY

Cement is considered preferred building material and is used worldwide for all

construction works such as housing and industrial construction, as well as for creation of

infrastructures like ports, roads, power plants, bridges, dams, stadiums, etc. Indian

cement industry is globally competitive because the industry has witnessed healthy trends

such as cost control and continuous technology upgradation.The Indian cement industry

is extremely energy intensive and is the third largest user of coal in the country.


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2.7 DOMESTIC/EXPORT MARKETS

India is the second largest cement producing country in the world after China. The

country’s cement production was 330 million tonnes in 2013; the figure is expected to

double to reach almost 550 million tonnes by 2020, as per estimates by the Cement

Manufacturers Association(CMA).

2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE

PROJECT.

The total manpower in the present and for expansion of the plant is 45 no’s as Direct

employment & Indirect Employment will be about 20 persons.


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CHAPTER 3: PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND

INTERDEPENDENT PROJECT IF ANY.

The Project is proposed to increase production capacity from 30TPD to 200TPD in

existing infrastructure facility accompanied in existing factory shed. at Sy.No. 61

Sadarahalli Village, Chikkanayakana halli Taluk Karnataka State which measures 4acres

38 Guntas There is no any interlinked and intermediate project as the Project is an

individual one.

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC

LOCATION, AND PROJECT BOUNDARY & PROJECT SITE LAYOUT) WITH

COORDINATES.

Figure 3.2.1: Google image of the proposed project site


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Fig 3.2.2: PROJECT SITE LAYOUT MAP


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3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF

SELECTING THE PROPOSED SITE, PARTICULARLY THE

ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE

HIGHLIGHTED:

There is no any alternate site considered for the proposed project M/s Siddaganga

Cements Pvt Ltd. as it is existing unit.

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATIC

DIAGRAM/ FLOW CHART SHOWING THE PROJECT LAYOUT,

COMPONENTS OF THE PROJECT ETC, SHOULD BE GIVEN)

The capacity of the mill will be

1. Cement mill 200 TPD

i. The use of grinding aids – the multipurpose cement mill additive which helps in

increasing the mill out put & reducing the electricity cost and increase the efficiency of

grinding.

ii. Use flyash from thermal power plants as additive in our cement mill to increase the out

put of the mill

iii. We also plan to use improved quality of grinding balls in cement mills to improve

grinding efficiency.

iv. Now a days Government of Karnataka is ensuring continuous / dedicated power supply

to industries to enhance the productivity.


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MANUFACTURING PROCESS

Figure :3.4.1 Process Flow diagram of the OPC and PPC process.


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A detailed description of the cement making process at M/s Siddaganga Cements

Pvt Ltd

Secondary Raw Materials

Depending on availability and chemical composition, additional components may be

added to the raw mix. These are referred to as “Secondary” raw materials. Examples are

fly ash from JSW steel plant.

SCPL .manufactures below mentioned products

Port land pozzolana cement can be manufactured by intimately and uniformly

blending Portland cement an fine pozzolana.the company is going to adopt

grinding mill and requisite machinery like classifiers( to produce fine pozzolana

)to ensure uniformity of guaranteed quality

Portland slag cement is obtained by separately grinding Portland cement clinker

and BF Slag with gypsum and physical properties are similar to those of ordinary

Portland cement as per IS 445

Ordinary Portland cement is obtained by grinding cement clinker with gypsum

Cement dispatch

Cement is dispatched in 5O kg bags and distributed from the manufacturing plant via

road. The cement is marketed in Karnataka ,.


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Figure : 3.4.2 Process Flow diagram of the cement manufacturing process.

3.5 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY

LIKELY SOURCE MARKETING AREA OF FINAL PRODUCT/S,MODE OF

TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT.

The major raw materials for the grinding unit are Clinker, Gypsum, and Slag and the

quantities of raw materials imported and their sources are as follows,

Flyash/slag Clinker Gypsum

Horizontal Ball Mill

PPC/OPC/PSC Cement

Silo

Stationary packers

Dispatch


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Sl.No Raw Materials Maximum Quantity

TPD

Sources

Ordinary portland cement 43 grade - 50 TPD

1 Clinker 45 Heidelberg cements India

limited, Tumkur.

3 Gypsum 5.0 The Fertilizers & Chemicals

Travancore limited, Cochin

Portland slag cement – 50TPD

1 Clinker 30.0 Heidelberg cements India

limited,Tumkur.

2 Slag 17.5 JSW Steel Limited, Bellary

3 Gypsum 2.5 The Fertilizers & Chemicals

Travancore limited, Cochin

Porzonlona Portland cement – 100 TPD

1 OPC 53 grade 70 BMM Cements ltd, Hospet

2 Fly ash 30 JSW Steel Limited,Bellary

3.6 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN

THE PROJECT IF ANY SHOULD BE BRIEFLY OUTLINED:

There is no generation of wastewater from the proposed project. Domestic effluent will

be sent to septic tank followed by soak pit.

3.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY/ POWER

REQUIREMENT AND SOURCE SHOULD BE GIVEN.

Water source is from bore well in the project site, power requirement is 250 KVA

including existing work and power supply is from KPTCL


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CHAPTER 4: SITE ANALYSIS

(i) Connectivity: SH-19 is at a distance of around 5.4 Km towards west The

company has chosen this site mainly due to its proximity to raw material sources

and also better access to market.

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

Land is owned by the M/s Siddaganga Cements Pvt Ltd

(iii) Existing land use pattern (agriculture, non-agriculture, forest, water bodies

(including area under CRZ)), shortest distances from the periphery of the

project to periphery of the forests, national park, wild life sanctuary, eco

sensitive areas, water bodies (distance from the HFL of the river), CRZ, In

case of notified industrial area, a copy of the gazette:

Thirtharampura north west extension reserved forest. 1km east

(iv) Soil classification:

Red Sandy soil covers rest of the area except very small area in the

northwestern part of C.N. Halli Taluk where Mixed Red and Black soil occur. Red

soils have good drainage but poor in lime and bases.

(v) Existing Infrastructure.

Exiting infrastructure is shown in project site plan in fig 3.2.2

(vi) Climatic data from secondary sources:

The average temperature during the months of summer can reach up to 40 0C

and the minimum average temperature during the months of winter can be 12

0C. The average rainfall recorded is around 250 mm.


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CHAPTER 5: PLANNING BRIEF

Planning concept (type of industries, facilities, transportation etc) Town and

Country Planning/Development authority Classification:

The grinding & packing project will give the following benefits to State and Central

government:

Additional revenue by way of taxes like Vat, Excise Duty, Income Tax etc.

Provides direct 45 persons and indirect 20 persons employment to around people

from the nearby areas.

Enhances the per capita income and standard of lining of the local people.

i.Population Projection: the population projection of the nearby places are Tumkur

district

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

Land utilization details are shown below.

SL No Land usage Area in acres

1. Buidup area 1.250

2. Road area 1.125

3. Greenbelt area 1.825

4. Vacant land 0.75

Total land area 4.95


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CHAPTER 6: PROPOSED INFRASTRUCTURE.

i. Industrial area: There is no any industrial area around the proposed Project site.

ii. Residential area: Nearest major residential area around the Project Site is

chikkanayakana halli which is at a distance of around 9.7 Km .south

iii. Green belt: Green belt will be developed around the proposed project site in an

effective way to check pollutants and their dispersion into surrounding areas. The

degree of pollution attenuation by a green belt depends on its height and width,

foliage surface area and density. The main objective of green belt is as follows:

i. Mitigation of impacts due to fugitive emissions caused by vehicles

ii. Attenuation of noise levels

iii. Ecological restoration

iv. Creation of aesthetic environment

iv Drinking Water Management (Source and Supply of Water) Water Resources:

WATER REQUIREMENT

No water is required for the grinding unit except for domestic usage. Water is required

only for employees use. The total water requirement after commencement of full

production is estimated to be 2.025 KLD Water requirements for the domestic purpose is

met from Borewell existing in the project site.

Table 6.1 Water Balance

iv. Sewerage System: There is no effluent generated from the proposed project.

Domestic effluent from toilets will be sent to septic tank followed by soak pit.

Description Water requirement in KLD

Domestic 2.025

Total 2.025


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v. Industrial Waste Management: There is no any industrial waste generated in the

premises.

vi. Solid Waste Management: There is no solid waste generation..

vii. Power Requirements and Supply and Source:

Description For plant

Power supply from

electricity board

250 kVA

Total 250 kVA

CHAPTER 7: REHABILITATION AND RESETTLEMENT (R & R) PLAN.

Rehabilitation and Resettlement Plan Not applicable.

CHAPTER 8: PROJECT SCHEDULE AND COST ESTIMATE

8.1: Likely date of start of construction and likely date of completion (Time schedule

for the project to be given)

As soon as we obtain Environmental Clearance we will go for expansion of the Cement

Industry.

8.2: Estimated project cost along with analysis in terms of economic viability of the

project.

The total project cost estimated is Rs.6.95 Crores.


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CHAPTER 9: ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

The Indian cement industry is the second largest producer of quality cement. Indian

Cement Industry is engaged in the production of several varieties of cement such as

Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC), Portland Blast

Furnace Slag Cement (PBFS), Oil Well Cement, Rapid Hardening Portland Cement,

Sulphate Resisting Portland Cement, White Cement, etc. They are regulated to produce

strictly as per the Bureau of Indian Standards (BIS) specifications and their quality is

comparable with the best in the world. The Indian cement industry is the second largest in

the world. The industry occupies an important place in the national economy as it shares

large links with other sectors like construction, transportation, coal and power. It also

provides employment to thousands of people.

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