ENVIRONMENTAL IMPACT ASSESMENT REPORT FOR EXISTING DISTILLERY UNIT ESTABLISHED IN THE YEAR 1948 AMRUT DISTILLERIES PRIVATE LIMITED

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1 ENVIRONMENTAL IMPACT ASSESMENT REPORT FOR EXISTING DISTILLERY UNIT ESTABLISHED IN THE YEAR 1948 By AMRUT DISTILLERIES PRIVATE LIMITED At Kambipura No. 49, 13 th mile, kambipura, Kambipura Village Bangalore South Taluk Bangalore Rural District Bangalore By M/s. Mahesh & Dev No 17/1VSN Road Tasker Town Bangalore

2 TABLE OF CONTENTS 1. EXECUTIVE SUMMARY INTRODUCTION OF THE PROJECT About the project proponent About the project PROJECT DESCRIPTION Type of Project Project Location Major products of the company Details of alternate sites Size of Operation Project Description Raw Material Required Resource optimization/recycling and reuse Power and fuels Manpower WATER REQUIREMENT Utilities Liquid waste management Air pollution control measures Hazardous and solid waste management SITE ANALYSIS Connectivity Landform, Land use, Landownership Existing Land use pattern Existing Infrastructure: Soil Classification: Climatic data from secondary sources: Social Infrastructure available: Planning concept Population Projection Land use planning... 2

3 5.4. Assessment of Infrastructure Demand Amenities/Facilities... 6 PROPOSED INFRASTRUCTURE Industrial Area: Residential Area Green belt Social Infrastructure Connectivity Drinking Water Management Sewerage system Industrial waste management Solid waste management Power Requirements and Supply/ Source... 7 REHABILITATION AND RESETTLEMENT (R & R) PLAN Policy to be adopted (Central/ State)... 8 PROJECT SCHEDULE AND COST ESTIMATE Likely date of start of construction and likely date of completion Estimated project cost... 9 ANALYSIS OF PROPOSAL Financial and social benefits CONCLUSION.... Project Site 10 km Radius around project site TOPO SHEET LIST OF FIGURES LIST OF ABBREVIATIONS ETP STP kwh Amrut distilleries pvt ltd Effluent Treatment Plant Sewage Treatment Plant Kilowatt per hour 3

4 List of annexure (i) Process description and process flow of products Annexure-1 (ii) ETP Layout Annexure- 2 (iii) Agreement for water supply Annexure-3 (iv) Plant layout of proposed facility - Annexure -4. (v) MB of raw materials and products Annexure -5 EXECUTIVE SUMMARY Sl No. Particulars Details 1 Name of Company AMRUT DISTILLERIES PVT LTD Estd in the year Location Existing :---Plot No. 49,13 TH Mile, Kambipura, Bangalore Project Activity, Category as per amendments Project schedule 5(g) Category B 4 products of the project Malt & Grape spirit,jaggery spirit, Bottling of IMFL, 5 Total Land area 4 acres, 6 Existing built up area m2 7 Proposed additional 2500 m2 built up area 8 Total built up area m2 9 Existing production capacity Extra Neutral Alcohol 9231 LPD Proposed product with capacity Malt & Grape spirit LPD Bottling of IMFL 5770 cases/day Malt & Grape spirit LPD Jaggery spirit LPD Bottling of IMF L cases/day 10 Raw material Details as listed in page No.s 14 & 15 as below ( material balance sheet attached 11 Fresh water requirement Details as listed in Pages 96 & Waste water and mode of disposal Effluent shall be treated in existing system and proposed ETP Treated effluent shall be recycled/reused to the extent and Remaining shall be disposed on land for gardening within premises There will be no discharge of effluent outside factory premises; The unit shall be zero liquid discharge. 13 Power Contract demand kwh 4

5 (From BESCOM). Existing emergency, DG sets of 625 kva,250kva,125kva,40 kva totalling 1040kva) 3 ton boiler, 4 ton boiler 14 Manpower Work force existing 5oo No.s sufficient. 15 Solid and hazardous waste Refer chapter 3, section 3.15, pg Project cost (estimate) 12 Crores 2.1 About the project proponent 2. INTRODUCTION OF THE PROJECT M/s Amrut distilleries Pvt ltd was established in the year 1948 by the JAGDALE family and has a rich heritage status in the distillery industry. They have a niche market for their products and have carved a reputation of exporting single malt whiskies to the home land of whiskey that is Scotland and the growth is phenomenally reaching heights in the high bracket premium single malt whiskies. 1. Introduction of the project/background information i. Identification of project and project proponent. In case of mining project, a copy of mining lease/letter of intent should be given. AMRUT DISTILLERIES PRIVATE LIMITED #49, 13th Mile, Kambipura, Kambipura Village Bangalore South Taluk Bengaluru rural Bangalore Mr. MEYYAPPAN Director Technical 7 th Floor, J N R City Centre, # 30, Raja Ram Mohan Roy Road, Bangalore

6 1. BACK GROUND Project site discreption in general Location of the proposed site National park Wild life sanctuary National reserve Mangrove forest Biosphere reserve Rain forest Wet lands Residential area Grazing land Historical monuments Nearest railway station Nearest national highway Nearest air port Rivers Hills & vales Details of forests land in study area Flora Fauna Topography Weather it is a part of national park Weather it is a part of Wildlife sanctuary Weather it is a part of Biosphere reserve Rare and endangered flora & fauna Habitat for migratory birds Displacement of population Requirement of raw material from any forest area No. 49, 13 th mile, kambipura, kambipura village, Bangalore south taluk Bangalore Bannerghatta about 48 Kms None None None None None Not very significant Kambipura village 1.5 kms, Bidadi town 1km, None none Kengeri - about 4kms NH 207 about 21 kms Bangalore air port about 52 kms None Vrishbavathi valley none Coconut, tamarind, neem, etc Domestic animals Latitude N Longitude E No No No None No No Not directly 6

7 PREAMBLE: AMRUT DISTILLERIES PVT LTD () is a company with a history dating back to the late 1940 s. In the six decades and more since its inception as a fledgling and novice organization in the field of liquor making, has made giant strides in the quality of its products, diversity of its product portfolio, nature of its clientele and in the geographic spread of its market. While is today acknowledged as an important player in the IMFL industry in the country, its products have created waves even outside India, most notably in the European Union and in the North American continent. Its product AMRUT INDIAN SINGLE MALT WHISKY (ASM) and its variants are today accepted as among the best Single Malt products that the world has to offer. Evidence of its global standing is the plethora of awards that ASM and its variants have won at no less than 25 different international forums. The crowning glory is of course the rating as the 3rd Finest Whisky in the world that was accorded to AMRUT FUSION Single Malt Whisky. Apart from ASM, our premium rum, TWO INDIES, another premium whisky MAQINTOSH SILVER EDITION WHISKY, etc have also gained widespread appreciation and acceptance. It is therefore no exaggeration to state that the company is poised to build on its well-earned reputation to scale ever greater heights. With appreciation pouring from all directions, demand for the company s products has also been rising continuously over the past few years. To meet the rising demand while maintaining and enhancing the quality of its products, the company has drawn up expansion plans comprising (vi) Production of 10,000 liters per month of spirit out of jiggery; and (vii) Increase in malt & grape distillation capacity from the existing 7,500 liters per month to 60,000 liters of Malt Spirit and 7,500 liters of Grape Spirit per month; (viii) Increase in the bottling capacity from the present 1, 50,000 cases per month to 2, and 50,000 cases per month. (i) The table below shows the existing capacity of all products and the expected capacity after expansion plans proposed to be implemented. 7

8 Sl. Item Unit Capacity Present Proposed 1 Extra Neutral Alcohol liters p.m. 5,00,000 5,00,000 (Re-distillation of Rectified Spirit) 2 Malt Spirit & Grape Spirit - do - 7,500 67,500 3 Jiggery Spirit - do ,000 4 Bottling of IML cases p.m. 1,50,000 2,50,000 MANUFACTURING PROCESS WRITE UP: PRODUCTION OF SPIRIT OUT OF JAGGERY Process Description: Commercial Jaggery will be used for the manufacture of spirit out of jaggery. In this process, jaggery is broken into smaller size and pitched into the ferment or by adding soft water in the ratio of 1 unit of jaggery to 4.8 units of water. The mixture is stirred well till all the jaggery is completely and well dissolved in the water. The ph of the wash is adjusted to 4.5 and Brix is checked in the ferment or. Special yeast is added to the mixture in the ferment or and fermentation is allowed at ambient temperature. Fermentation usually takes 3 to 4 days to complete. Once fermentation is complete, the fermented wash is filled in the Typical Brandy Pot still. This is a special pot-still and has small column still wash plates attached to it which help in rectifying the spirit to the desired level while also retaining the natural molasses congeners. Low wines are collected in this distillation. The Low Wines, along with the Heads and Tails of the previous batch are charged into the still and the second distillation is carried out by Fractional Distillation in which Heads, Hearts and Tails are distilled off based on boiling points. The Hearts, that is, the pure Jaggery Spirit is reduced to 63% above and filled in Oakwood casks for maturation. After the spirit attains the desired level of maturation, the matured jaggery spirit is used in Rum 8

9 blending as a component, contributing typical sweetish sugarcane and spicy character to the product. Addition of matured jaggery spirit with all natural congeners intact lends a special edge to the Rum over the conventional flavoured rums. Annexure 1 is enclosed in the project report. It shows the process flow for production of spirit out of Jaggery. Investment: The infrastructure and manpower available at the existing Kumbalgodu unit are adequate for production of spirit out of jaggery. As production of grape spirit at this unit has been on the decline in the recent past, there is surplus capacity available which could be easily deployed towards production of jaggery spirit. Hence no additional investment is required for this purpose. 3. PRODUCTION OF MALT SPIRIT PROCESS DESCRIPTION: Mashing: Barley malt is milled and mashed with hot water and allowed to rest for an hour and drained, cooled and pumped into the ferment or. Yeast is immediately pitched to the ferment or. Thereafter, the second hot water is added and the mix is allowed to rest for 40 minutes. After 40 minutes, the mix is drained, cooled and then pumped into the ferment or. The third hot water is added and collected and pumped to the third water tank for use of first water of the next brew at required temperature. The whole cycle of mashing takes about 6 hours. Fermentation: Two such brews are put in one ferment or under sterile conditions and allowed to ferment in a temperature controlled environment. Fermentation usually takes about 5 days to complete. 9

10 Distillation: The fermented wash is distilled in typical copper pot-stills to get low wind at 18 19% above and this wash distillation takes approximately 9 hours. The next charge of wash is repeated in the same manner to get another low wine. Tow such low wines with Heads & Tails of previous batches are mixed together and distilled in spirit still to collect the middle fraction and Heads & Tails. The second distillation takes around hours to complete. Maturation: The new make spirit is reduced to 62.8% Above by adding de-mineralized water (DM Water) and filled in American Oakwood barrels for a minimum period of 4 years. Bottling: The required quantity of matured malt spirit is drawn from the selected barrels in the required proportions and blended with Extra Neutral Alcohol (ENA). Where required, DM Water is further added to reduce the strength to the required levels. The colour of the blend is adjusted as per quality specifications and then filtered through sparkler filter before bottling. Process Flow Diagram & Project Investment are enclosed separately in the project report: BOTTLING PLANT The existing infrastructure and other facilities are sufficient for bottling of 2, 50,000 c/s per month and no additional investment is required. As and when required, the plant may be operated on two shifts to meet production requirements. The bottling plant does not generate any effluents. The Rum market in India is dominated mostly by artificially Flavoured Rums with the quality differential between low-range And premium range Rums attributable more to the quality of Encased and the period, if any, over which the Rum has been matured. Internationally, however, 10

11 premium, genuine rums are directly distilled from molasses or sugarcane juice and yield a unique Flavour that cannot be mimicked by artificially flavoured rums. We at ADL have focused our efforts in producing genuine Rum that will additionally underline its Indian origins. Our R & D In this direction has shown that rum made with spirit produced out Of jiggery is extremely close to genuine rums as they share most of the characteristics of the latter. Besides, jiggery being an article not Produced elsewhere, Rum made with jiggeryspirit also emphasizes Its Indian origin and uniqueness. Our market survey has also shown that there a substantial Demand for genuine rums, particularly in Europe where rums of Caribbean origins are currently dominant among imported rums. As we already have an established marketing network for marketing AMRUT SINGLE MALT, we are also in strong position to market genuine rums of Indian origin. There is thus a market overseas waiting to be tapped. It is in this background that we have conceived the proposal To produce spirit out of jiggery for use in making premium quality Rums meant mostly for exports outside India. II PROCESS FLOW AND EQUIPMENT Following is a brief description of the process involved in Producing spirit out of Jaggery. Enclosed at Annexure I & II is a flow chart that graphically demonstrates the above process flow. Taking into account the demand for premium quality rums, The period needed for launching and popularizing our Product and other relevant factors, we plan to initially Introduce a small quantity of rum with spirit made out of Jaggery; most of this production would be exported out of India though a portion could be sold within Karnataka/India. Production of this quantity/quality of rum would require Jaggery-spirit of a suitable maturation period. The infrastructure and manpower available at our Kumbalgodu unit are adequate for production of spirit out of Jaggery. As production of grape spirit at this unit has been on The decline in the recent past, there is surplus capacity Available which could be easily deployed towards production Of spirit out of Jaggery. This production of Jaggery spirit can be Easily handled by the existing infrastructure and does not Require any additional investment worth mentioning. III RAW MATERIAL The primary raw material is Jaggery which is locally produced In the state. As is well- known, Karnataka, being a net Exporter, is a surplus state in so far as availability of Jaggery is Concerned. Besides, our requirement is a mere 0.2% of total Production of Jaggery within the state. Considering all these, We anticipate no difficulties in sourcing Jaggery in sufficient 11

12 Quantities to meet out requirements. Other material such as yeast, etc is already part of our Existing procurement routines and would pose no logistical Or other difficulties in sourcing. ANNEXURE-I Commercial Jaggery can be used for the manufacturing of Spirit out jjggery. In this process we take the Jaggery and break it Into the smaller size and pitched it into the ferment or by adding The soft water in the ratio. It is stirred well till all the Jaggery gats Completely dissolved in the water. The ph of the wash is adjusted to 4.5, Brix is checked in the ferment or. Special yeast is added in The ferment or and fermentation is allowed at ambient Temperature. Fermentation may take 3 to 4 days to complete. Once the fermentation is complete, the fermented wash is Taken in the typical Brandy pot still which is special in the sense That it has a small column still wash plates attached to it that helps In rectifying the spirit to our desired level so that the natural Molasses congeners are retained in the spirit. Low wines are Collected in this distillation. These Low wines along with the Heads And Tails of the previous batch are charged into the still and the Second distillation is carried out by following the Fractional Distillation in which we distil off the Heads the hearts and the tails Based on the boiling points. The hearts that is the pure Jaggery Spirit is reduced to 63% above. And filled in the casks for Maturation. After attaining the desired maturation, it can be used In the Rum Blending as a component, contributing the typical Sweetish sugarcane and spicy character to the product as all these Natural congeners are retained in the by following a specially Developed technique of fractional Distillation in the typical pot still Thereby giving a special edge to the Rum product over the Conventional flavoured rums. ii. Brief description of nature of the project a. is today acknowledged as an important player in the IMFL industry in the country; its products have created waves even outside India, most notably in the European Union and in the North American continent. Its product AMRUT INDIAN SINGLE MALT WHISKY (ASM) and its variants are today accepted as among the best Single Malt products that the world has to offer. Evidence of its global standing is the plethora of awards that ASM and its variants have won at no less than 25 different international forums. The crowning glory is of course the rating as the 3rd Finest Whisky in the world that was accorded to AMRUT FUSION Single Malt Whisky. iii. Need for the project and its importance to the country and or region. 12

13 The industry was started in the year 1948 and shifted to the present location in the 80 s and it is well reputed for labour generation and alot of families are dependent on the employment opportunities iv. Demand-supply Gap. Demand for the company s products has also been rising continuously over the past few years. To meet the rising demand while maintaining and enhancing the quality of its products, the company has drawn up expansion plans comprising Production of 10,000 liters per month of spirit out of jiggery; and Increase in malt & grape distillation capacity from the existing 7,500 liters per month to 60,000 liters of Malt Spirit and 7,500 liters of Grape Spirit per month; v. Imports vs. Indigenous production. We have a fraction of the raw materials as imports like the casks and peat. vi. Domestic/export markets. We have niche market in the local geography and an excellent reputation in the export market hence this expansion vii. Employment Generation (Direct and Indirect) due to the project We are directly employing 500 workers and supporting the villagers nearby with indirect employment. 2. Project description i. Type of project including interlinked and interdependent projects, if any. The project is a blending and bottling activity ii. Location (map showing general location, specific location, and project boundary & project site layout) with coordinates. Google map enclosed 13

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16 iii. Details of alternate sites, considered and the basis of selecting the proposed site particularly the environmental considerations gone into should be highlighted. iv. Size or magnitude of operation. Malt & Grape spirit lts/d Jaggery Spirit lts/d Bottling of IML Existing land area cases/d - 4 acres Additional leased area - 6 acres (Lease agreement attached) Existing Additional sqmts sqmts (1750 sqmts of Ware house and 750 sqmts bottling plant for Malt) Total BUA sqmts Cost of the proposed modernization and additional facility will be 12 crores. 16

17 v. Project description with process details (a schematic diagram/flow chart showing the project layout components of the project etc. Should be given) Annexure

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19 FLOW DIAGRAME vi. JAGGERY PULVERIZATION FERMENTATION DISTILLATION JAGGERY SPIRIT MATURATION BLENDING & BOTTLING 19

20 FLOW DIAGRAM-MALT PLANT MILLING SECTION vii. CIP TANKS GRIST STORAGE viii. ix. MASH TUN PLATE HEAT EXCHANGER CLEARWORTTO FERMENTOR HOT WATER TANK TO SPENT GRAIN SILO WASH STILL CHILLED WATER TANK MALT RECEIVER+LOW WINE RECEIVER SPIRIT STILL 20

21 vi. Raw material required along with estimated quantity, likely source, marketing area of final product/s, made of transport of raw material and finished product. Annexure - 2 RAW MATERIAL The primary raw material is Jaggery which is locally produced in the state. As is well- known, Karnataka, being a net exporter, is a surplus state in so far as availability of Jaggery is concerned. Besides, our requirement is a mere 0.2% of total production of Jaggery within the state. Considering all these, we anticipate no difficulties in sourcing Jaggery in sufficient quantities to meet out requirements. Other material such as yeast, etc is already part of our existing procurement routines and would pose no logistical or other difficulties in sourcing. 21

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24 Vii Resource optimization/recycling and reuse envisaged in the project, if any should be briefly outlined. 09 kld Existing ETP is proposed to be upgraded to 90kld to handle the effluents Adequacy report is prepared to check the adequacy of the existing ETP, and recommend the required up-gradation of CETP as necessary to meet the combined existing and proposed effluent load due to the proposed expansion and for treating the same and conserving the entire treated effluent on own land for irrigation confirming to KSPCB on land discharge standards. Further, it is to be noted that there will not be any additional Air Pollution Sources envisaged due to the proposed expansion. Broken bottles/glass tons/m Paper waste Spent Grain ETP sludge ton/m ton/M -- 45Kgs/Day Waste oils -- 80lts/M The wastes are segregated at source and disposed as under Glass factory, Paper Recycling units Animal feed manufacturers Manure for gardening Official recyclers approved by KSPCB MOU with agencies annexed Viii Availability of water its source, Energy/power requirement and source should be given. Details are attached under XI. Quantity of wastes to be generated (liquid and solid) and scheme for their Management/disposal. Details are attached as under X. Schematic representations of the feasibility drawing which give information of EIA purpose. Flow charts production lay outs are attached 3 Site Analysis 24

25 i. Connectivity. The plant is very well connected to the SH 17 connecting Bangalore to Mysore ii. Land Form, Land use and Land ownership. Land owned by the promoters iii. Topography (along with map). Attached as under iv. 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 Ufa sanctuary, eco sensitive areas, water bodies (distance form, the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given. Located in the midst of industrial activity zone v. Existing Infrastructure. We are well equipped to undertake production with the existing infrastructure and we are only building a ware house and excise bonded space. vi. Soil classification Report with specifications attached 25

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28 vii. Climatic data from secondary sources FEB 28

29 MARCH 29

30 APRIL 30

31 Statistics based on observations taken between 10/ /2016 daily from 7am to 7pm local time in Bangalore Sl no. Direction % Wind 1 N NNE 1 3 NE ENE ENE ESE SE SSE S 2 10 SSW SW WSW WSW WNW NW NNW 0.5 Bangalore weather station: 921 m.a.s.l., 11.0 km away from Kengeri Satellite Town 31

32 Sl. Second Revision IS ics no Results Observed No. Unit max Required Permissible Protocol 1 Color hazen units Max IS 3025( Part-4) Odor Agreeable Agreeable IS 3025( Part-5) Turbidity NTU IS 3025( Part-10) Conductivity in µs/cm IS 3025( Part-14) Total Dissolved mg/l IS 3025( Part-16) 1984 Solids 6 ph Value Value 6.5 to IS 3025( Part-11) Total Hardness as mg/l IS 3025( Part -21) 2009 CaCO 3 8 Calcium as Ca mg/l IS 3025( Part -40) Magnesium as Mg mg/l IS 3025( Part -46) Iron (as Fe) mg/l 0.3 NR ND IS 3025( Part -53) Chlorides (as Cl) mg/l IS 3025( Part -32) Sulphates as SO 4 mg/l IS 3025( Part -24) Nitrates (as No3) mg/l 45 NR 12 IS 3025( Part -34) Fluoride as F mg/l IS 3025( Part -60) Total Alkalinity mg/l IS 3025( Part -23)1986 Sl. PARAMETERS No. 1 Color hazen units Max Second Revision IS ics no Unit max Required Permissible Results Observed Protocol IS 3025( Part-4) Odor Agreeable Agreeable IS 3025( Part-5) Turbidity NTU IS 3025( Part-10) Conductivity in µs/cm IS 3025( Part-14) Total Dissolved Solids mg/l IS 3025( Part-16) ph Value Value 6.5 to IS 3025( Part-11) Total Hardness as mg/l IS 3025( Part -21) 2009 CaCO 8 Calcium 3 as Ca mg/l IS 3025( Part -40) Magnesium as Mg mg/l IS 3025( Part -46) Iron (as Fe) mg/l 0.3 NR ND IS 3025( Part -53) Chlorides (as Cl) mg/l IS 3025( Part -32) Sulphates as SO 4 mg/l IS 3025( Part -24) Nitrates (as No3) mg/l 45 NR 6 IS 3025( Part -34) Fluoride as F mg/l IS 3025( Part -60) Total Alkalinity mg/l IS 3025( Part -23)

33 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Poul IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Poul IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) 33

34 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Pungent IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) Sl. PARAMETERS Second Revision IS ics no Results Protocol Observed No. Unit max Required Permissible 1 Color hazen units IS 3025( Part-4) 1987 Max 2 Odor Agreeable agreeable IS 3025( Part-5) Turbidity NTU IS 3025( Part-10) Conductivity in µs/cm IS 3025( Part-14) Total Dissolved mg/l IS 3025( Part-16) 1984 Solids 6 ph Value Value 6.5 to IS 3025( Part-11) Total Hardness as CaCO 3 mg/l IS 3025( Part -21) Calcium as Ca mg/l IS 3025( Part -40) Magnesium as Mg mg/l IS 3025( Part -46) Iron (as Fe) mg/l 0.3 NR 0.1 IS 3025( Part -53) Chlorides (as Cl) mg/l IS 3025( Part -32) Sulphates as SO 4 mg/l IS 3025( Part -24) Nitrates (as No3) mg/l 45 NR 12 IS 3025( Part -34) Fluoride as F mg/l IS 3025( Part -60) Total Alkalinity mg/l IS 3025( Part -23)

35 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Odorless IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 Chloride mg/l IS 3025 (Part.32) 10 Sulphate mg/l IS 3025 (Part.24) Sl. No. PARAMETERS Unit Limits Observed values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Poul IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 Chloride mg/l IS 3025 (Part.32) 10 Sulphate mg/l IS 3025 (Part.24) 35

36 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Poul IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 Chloride mg/l IS 3025 (Part.32) 10 Sulphate mg/l IS 3025 (Part.24) Sl. Second Revision IS ics no Results Observed No. Unit max Required Permissible Protocol 1 Color hazen units IS 3025( Part-4) 1987 Max 2 Odor Agreeable Pungent IS 3025( Part-5) Turbidity NTU IS 3025( Part-10) Conductivity in µs/cm IS 3025( Part-14) Total Dissolved mg/l IS 3025( Part-16) 1984 Solids 6 ph Value Value 6.5 to IS 3025( Part-11) Total Hardness as mg/l IS 3025( Part -21) 2009 CaCO 8 Calcium as Ca mg/l IS 3025( Part -40) Magnesium as Mg mg/l ND IS 3025( Part -46) Iron (as Fe) mg/l 0.3 NR 0.1 IS 3025( Part -53) Chlorides (as Cl) mg/l IS 3025( Part -32) Sulphates as SO 4 mg/l IS 3025( Part -24) Nitrates (as No3) mg/l 45 NR 12 IS 3025( Part -34) Fluoride as F mg/l ND IS 3025( Part -60) Bacteriological MPN Nos 16 Ecoli or Thermotolornet Coliform Bacteria Nos Must not be detectable in any 100 ml sample Must not be detectable in any 100 ml sample 7 Absent IS Amendment No 4 May 2003 IS Amendment No 4 May Total Alkalinity mg/l IS 3025( Part -23)

37 Sl. Second Revision IS ics no Results Observed No. Unit max Required Permissible Protocol 1 Color hazen units Max IS 3025( Part-4) Odor Agreeable Pungent IS 3025( Part-5) Turbidity NTU IS 3025( Part-10) Conductivity in µs/cm IS 3025( Part-14) Total Dissolved Solids mg/l IS 3025( Part-16) ph Value Value 6.5 to IS 3025( Part-11) Total Hardness as mg/l IS 3025( Part -21) 2009 CaCO 3 8 Calcium as Ca mg/l IS 3025( Part -40) Magnesium as Mg mg/l ND IS 3025( Part -46) Iron (as Fe) mg/l 0.3 NR 0.1 IS 3025( Part -53) Chlorides (as Cl) mg/l IS 3025( Part -32) Sulphates as SO 4 mg/l IS 3025( Part -24) Nitrates (as No3) mg/l 45 NR 12 IS 3025( Part -34) Fluoride as F mg/l ND IS 3025( Part -60) Bacteriological MPN Nos 16 Ecoli or Thermotolornet Coliform Bacteria Nos Must not be detectable in any 100 ml sample 11 IS Amendment No 4 May 2003 Must not be detectable in any 100 ml sample Absent IS Amendment No 4 May Total Alkalinity mg/l IS 3025( Part -23)

38 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Poul IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ µs/cm IS 3025( Part-14) cm Max 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Odorless IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) 38

39 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Poul IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) Second Revision IS ics no Results Sl. PARAMETERS Protocol Observed No. Unit max Required Permissible 1 Color hazen units Max IS 3025( Part-4) Odor Agreeable Pungent IS 3025( Part-5) Turbidity NTU IS 3025( Part-10) Conductivity in µs/cm IS 3025( Part-14) Total Dissolved Solids mg/l IS 3025( Part-16) ph Value Value 6.5 to IS 3025( Part-11) Total Hardness as mg/l IS 3025( Part -21) 2009 CaCO 8 Calcium as Ca mg/l IS 3025( Part -40) Magnesium as Mg mg/l IS 3025( Part -46) Iron (as Fe) mg/l 0.3 NR ND IS 3025( Part -53) Chlorides (as Cl) mg/l IS 3025( Part -32) Sulphates as SO 4 mg/l IS 3025( Part -24) Nitrates (as No3) mg/l 45 NR 12 IS 3025( Part -34) Fluoride as F mg/l ND IS 3025( Part -60) Bacteriological MPN 16 Ecoli or Ther moto lorne t Colif orm Bacte ria Nos Nos Must not be detectable in any 100 ml sample Must not be detectable in any 100 ml sample ND Absent IS Amendment No 4 May IS Amendment No 4 May Total Alkalinity mg/l IS 3025( Part - 23)

40 Sl. PARAMETERS Second Revision IS ics no Results Protocol Observe No. Unit max Required Permissible 1 Color hazen IS 3025( Part-4) 1987 units Max 2 Odor Agreeable Pungent IS 3025( Part-5) Turbidity NTU IS 3025( Part-10) Conductivity in µs/cm IS 3025( Part-14) Total Dissolved Solids mg/l IS 3025( Part-16) ph Value Value 6.5 to IS 3025( Part-11) Total Hardness mg/l IS 3025( Part -21) 2009 as CaCO 3 8 Calcium as Ca mg/l IS 3025( Part -40) Magnesium as mg/l IS 3025( Part -46) 2003 Mg 10 Iron (as Fe) mg/l 0.3 NR ND IS 3025( Part -53) Chlorides (as mg/l IS 3025( Part -32) 1988 Cl) 12 Sulphates as SO 4 mg/l IS 3025( Part -24) Nitrates (as No3) mg/l 45 NR 14 IS 3025( Part -34) Fluoride as F mg/l ND IS 3025( Part -60) Bacteriological MPN Nos 16 Ecoli or Thermotolornet Coliform Bacteria Nos Must not be detectable in any Must not be detectable in any ND Present IS Amendment No 4 May 2003 IS Amendment No 4 May Total Alkalinity mg/l IS 3025( Part - 23)

41 Sl. Second Revision IS ics no Results Observed No. Unit max Required Permissible Protocol 1 Color hazen units Max IS 3025( Part-4) Odor Agreeable agreeable IS 3025( Part-5) Turbidity NTU IS 3025( Part-10) Conductivity in µs/cm IS 3025( Part-14) Total Dissolved mg/l IS 3025( Part-16) 1984 Solids 6 ph Value Value 6.5 to IS 3025( Part-11) Total Hardness as CaCO 3 mg/l IS 3025( Part -21) Calcium as Ca mg/l IS 3025( Part -40) Magnesium as Mg mg/l IS 3025( Part -46) Iron (as Fe) mg/l 0.3 NR ND IS 3025( Part -53) Chlorides (as Cl) mg/l IS 3025( Part -32) Sulphates as SO 4 mg/l IS 3025( Part -24) Nitrates (as No3) mg/l 45 NR 6 IS 3025( Part -34) Fluoride as F mg/l IS 3025( Part -60) Total Alkalinity mg/l IS 3025( Part -23)1986 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Pungent IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) 41

42 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Pungent IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) Sl. PARAMETERS Second Revision IS ics no Results Protocol Observed No. Unit max Required Permissible 1 Color hazen units IS 3025( Part-4) 1987 Max 2 Odor Agreeable agreeable IS 3025( Part-5) Turbidity NTU IS 3025( Part-10) Conductivity in µs/cm IS 3025( Part-14) Total Dissolved Solids mg/l IS 3025( Part-16) ph Value Value 6.5 to IS 3025( Part-11) Total Hardness as CaCO 3 mg/l IS 3025( Part -21) Calcium as Ca mg/l IS 3025( Part -40) Magnesium as Mg mg/l IS 3025( Part -46) Iron (as Fe) mg/l 0.3 NR ND IS 3025( Part -53) Chlorides (as Cl) mg/l IS 3025( Part -32) Sulphates as SO 4 mg/l IS 3025( Part -24) Nitrates (as No3) mg/l 45 NR 14 IS 3025( Part -34) Fluoride as F mg/l IS 3025( Part -60) Bacteriological MPN Nos Must not be detectable in any 100 ml sample ND IS Amendment No 4 May Ecoli or Thermotolornet Coliform Bacteris Nos Must not be detectable in any 100 ml sample Absent IS Amendment No 4 May Total Alkalinity mg/l IS 3025( Part -23)

43 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Poul IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Poul IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) 43

44 Sl. No. PARAMETERS Unit Limits Observed Values Protocol 1 ph Value IS 3025 (Part.11) 2 Color Pt.Co IS 3025 (Part.4) 3 Odor Poul IS 3025 (Part.5) 4 Oil & Grease mg/l IS 3025 (Part.39) 5 Conductivity Micro ohms/ cm Max µs/cm IS 3025( Part-14) 6 Total Dissolved Solids mg/l IS 3025 (Part 16) 7 Total Suspended Solids mg/l IS 3025 (Part.17) 8 BOD 3 days at 27 o C mg/l IS 3025 (Part.44) 9 COD mg/l IS 3025 (Part.58) 10 Chloride mg/l IS 3025 (Part.32) 11 Sulphate mg/l IS 3025 (Part.24) 44

45 45

46 46

47 47

48 48

49 49

50 50

51 Ambient Air Quality Studies (L1 to L6) 51

52 Ambient Air Quality Studies (L1 to L6) 52

53 Ambient Air Quality Studies (L1 to L6) 53

54 Ambient Air Quality Studies (L1 to L6) 54

55 Ambient Air Quality Studies (L1 to L6) 55

56 Ambient Air Quality Studies (L1 to L6) 56

57 Ambient Air Quality Studies (L1 to L6) 57

58 Ambient Air Quality Studies (L1 to L6) 58

59 Ambient Air Quality Studies (L1 to L6) 59

60 viii. Social Infrastructure available. Well developed area with industries surrounding and very socially forward. 5. Planning Brief i. Planning concept (type of industries, facilities, transportation etc) Town and country planning/development authority classification. Permission obtained for industry license issued by the Dept of industries ii. Population Projection Static population growth since it is an existing industry with no increase of labour the natural phenomenon of population increase is imminent iii. Land use planning (breakup along with green belt etc). Plant layout attached iv. Assessment of Infrastructure Demand (Physical & Social). Very sufficient v. Amenities/Facilities. As described in the worker welfare description notes attached along with 60

61 6. Proposed Infrastructure i. Industrial Area (Processing Area).Details as per below 61

62 Site plan Annexure 3 62

63 ii. Residential Area (Non Processing Area). N A iii. Green Belt. iv. Social Infrastructure. Sufficiently adequate v. Connectivity (Traffic and Transportation Road/Rail/metro/water ways etc) 63

64 Attached to the SH 17 vi. Drinking water Management (source & supply of water) As described below WATER REQUIRMENT SUMMARY 1. Malt Spirit Production 33, Jiggery Spirit Production 4, Grape Spirit Plant RD Plant (dilution water only) 40, Boiler House (net requirement) 20, R/O Plant 65, Wash water for IML Bottling Plant 2, Cooling Tower (make up water) 15,000 Total 1, 81,100 64

65 65

66 66

67 VII. Sewerage system. 67

68 WATER The Water Balance of the entire plant both existing and after expansion is shown in Annexure 1 of this report. BRIEF DESCRIPTION OF EXISTING EFFLUENT TREATMENT PLANT: The entire process effluent classified as Stream-1 after ph correction flows in to Anaerobic Lagoon, followed by Up-flow filter and is further treated by single stage Extended Aeration Activated Sludge Plant. The domestic effluent classified as stream-2 is collected in an independent equalization, from here it is pumped inlet of the Aeration tank where in it mixes with stream-1 effluent. The combined effluent stream-1 and stream-2 are treated by Single Stage Extended Aeration Activated Sludge Plant. And the entire treated effluent confirming to KSPCB Standards are disposed on land for gardening. WASTE WATER QUANTITY AND QUALITY: (Existing + Proposed Expansion) (Vide Water Balance Chart-Annexure-1) The entire effluent streams are classified in to 4 Streams based on their Organic strength as detailed below: STREAM-1 LOW STRENGTH WASTE STREAM will have a total work force of around 400 persons which includes both existing and proposed expansion completed. With in house canteen facility. (Accordingly considering the per capita consumption at 55 LPCD Daily water requirement for domestic consumption will be 400x55= 22 KLD Sewage Generation Quantity at 85% of domestic consumption will be 18.7 OR Say 19KLD. The total sewage quantity with the expansion completed will be 19 KLD. STREAM-I Domestic Effluent: Design Flow: 19 KLD 68

69 BOD mg/lt COD mg/lt TSS mg/lt PH-6-8 STREAM-2 LOW STRENGTH WASTE STREAM Washing Effluent Viz: Filter Back wash, RO-reject, Boiler Blow down, Softeners Regeneration Design Flow: 16 KLD PH- 9.8 TDS-1382 mg/lt STREAM -2& 3-MEDIUM STRENGTH WASTE STREAM Washing Effluent Viz: RO Reject, RO back wash, Bottling Washing Machines, Blending Cleaning, Kettle Cleaning Design Flow: (Stream2 + Stream3)16KLD +38KLD=54KLD BOD mg/lt COD mg/lt TSS mg/lt ph STREAM -4 - HIGH STRENGTH WASTE STREAM + PRE TREATED STREAM2+STREAM-3 Effluent: Spent wash +Spent Leese Design Flow: Stream2,3 & Stream 4 (54KLD+17 KLD=71 KLD) BOD mg/lt 69

70 COD -10,441 mg/lt TSS mg/lt ph BRIEF DESCRIPTION OF PROPOSED EFFLUENT TREATMENT- PLANT: Stream-1 : Domestic effluent with a maximum flow of 19KLD is gravitated as an independent stream in to Bar Screen chamber for physical separation of solids, followed by equalization for flow balancing with pre-aeration, which will be further pumped in to the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage Extended Aeration Activated Sludge Process (EAASP). Stream-2 & Stream-3: The stream-2 &3 effluents with a maximum flow of (16KLD + 38KLD ) will be gravitated as an common stream in to Bar Screen chamber for physical separation of solids, followed by equalization/neutralization for flow balancing with pre-aeration, and ph adjustment The neutralized effluent will be further mixed with stream-4 at the inlet of existing Anaerobic lagoon. and further treated in the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage EAASP. Where in it mixes with stream-1 effluent for further treatment. Stream-4: The Stream-4 effluents with a maximum flow of 16.76KLD 0R say 17KLD will be gravitated as an independent stream in to Bar Screen chamber for physical separation of solids, and then after ph correction flows in to the existing Anaerobic lagoon, where it mixes with stream 2&3 and than the pre treated stream-4 effluent flows in to the existing aeration tank which shall be used as intermediate equalization tank. The combined stream will be further treated by II stage EAASP. After 2 stage biological treatment. The combined treated effluent post filtration and chlorination will be used on own land for gardening, floor wash, DESIGN OF PROPOSED EFFLUENT TREATMENT PLANT UNITS: 70

71 I. DESIGN OF STREAM-1 PRE-TREATMENT UNITS: Solid Screening: Bar Screen Chamber :( Stream-1-Domestic Effluent) (Proposed): The entire domestic effluent classified as Stream-1 with a maximum quantity of 19 KLD, will be gravitated through a separate network of underground pipe work into the Bar screen chamber of size:1.0mx1.0mx 1.5m TD.. Provide a chamber of size 1.0m x 1.0m depth to suit sewer gradient, accommodate an inclined bar screen with opening less than 10 mm. Provide a bar screen of 20x6 mm flats with 10 mm spacing in between. Design criteria: Design flow = 19 KLD (Existing=3KLD+Proposed =16KLD) Velocity through screen = 0.8 m/sec Net area of screen = /0.8 = sq. m Gross area = 1.2 times the net area of opening Gross area = 1.2x = sq. m. Proposed Size of the screen = 1.0 meter wide x1.0 meter long x 1.5 m TD is adequate. Equalisation Tank: (Proposed) The effluent from the Bar Screen Chamber will flow in to the existing equalization tank, of minimum 24hrs capacity. This tank is provided to even out the flow variation, and to provide a continuous feed in to the secondary biological treatment units. Design Flow = 19 cum/day (Existing=3KLD+Proposed =16KLD) Holding capacity proposed = 24 hours Proposed Size of Tank = 3mx3mx 2.1 SWD +0.9m Free board Mode of mixing Proposed = fine bubble diffused aeration for Pre-aeration Hence Adequate 71

72 Raw Sewage Pumps: (Proposed) Since the secondary treatment plant are located on a higher contour, the effluent will be pumped from the equalisation tank in to the Aeration tank. Pumps - 2 No. s = one working and one standby. Type = open impeller non clog pumps. Capacity = m Head Hence Adequate DESIGN OF STREAM-2 & STREAM-3 PRE-TREATMENT UNITS: The Stream-2 &3 effluents with a maximum flow of (16 KLD + 38 KLD ) will be gravitated as an common stream in to Bar Screen chamber for physical separation of solids, followed by equalization/neutralization for flow balancing with pre-aeration, and ph adjustment The neutralized effluent will be further pumped in to the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage EAASP. Where in it mixes with stream-1 effluent for further treatment. STREAM-2 & 3: Solid Screening: Bar Screen Chamber: (Proposed). The entire effluent washings, with a maximum quantity of 54 KLD, will be gravitated through a network of underground pipe work into the Bar screen chamber of size:1.2mx1.5mx 1.5m TD. Provide a chamber of size 1.2m x 1.5m depth to suit sewer gradient, accommodate an inclined bar screen with opening less than 10 mm. Provide a bar screen of 20x6 mm flats with 10 mm spacing in between. Design criteria: Design flow = 54 KLD (Existing=6KLD+Proposed =48KLD) Velocity through screen = 0.8 m/sec Net area of screen = /0.8 = sq. m Gross area = 1.2 times the net area of opening Gross area = 1.2x = sq. m. Proposed Size of the screen = 1.2 meter wide x 1.5meter long x 1.5 m TD is adequate. 72

73 Equalization Tank & Neutralization Tank: (Proposed) The effluent from the Bar Screen Chamber will flow in to the existing equalization tank, of minimum 24 hrs capacity. This tank is provided to even out the flow variation, and to provide a continuous feed in to the secondary biological treatment units. Design Flow = 54 cum/day(existing=6kld+proposed =48KLD) Holding capacity Proposed = 24 hours Proposed volume of the tank = 40 cum.-2 No (Hence adequate) Provide 2 No tank each of size = 4mx4mx3.0m TD-2 No Provide 2 No. Agitators 1 No in each tank with necessary dozing arrangement for rapid mixing and ph correction. Raw Effluent Pumps :( Proposed): Since the secondary treatment plants are located on a higher contour, the equalized, neutralized effluent will be pumped from the equalization /neutralization tank in to I stage aeration tank. Pumps - 2 No. s = one working and one standby. Type = open impeller non clog pumps. Capacity = 8 12 m-15m Head DESIGN OF STREAM-4 PRE-TREATMENT UNITS: STREAM-4: a. SOLID SCREENING: INLET CHAMBER: (Existing): The entire effluent washings, with a maximum quantity of KLD or say 17KLD, will be gravitated through a network of underground pipe work into the existing inlet chamber of size: 1.0mx1.0mx 1.2m TD. Provided a chamber of size 1.0m x 1.0m depth to suit sewer gradient, accommodate an inclined bar screen with opening less than 10 mm. Provide a bar screen of 20x6 mm flats with 10 mm spacing in between. Design criteria: 73

74 Design flow = 17 KLD (Existing=3KLD+Proposed =14KLD) Velocity through screen = 0.8 m/sec Net area of screen = /0.8 = sq. m Gross area = 1.2 times the net area of opening Gross area = 1.2x = sq. m. Existing Size of the screen = 1.0 meter wide x 1.0meter long x 1.2 m TD Is adequate. ANAEROBIC LAGOON: (Existing) The effluent from the Inlet Chamber post neutralization will flow in to the existing anaerobic lagoon, of minimum 26 DAYS holding capacity. The anaerobic decomposition will take place specifically designed for high BOD & COD reductions. Design Flow = 17 cum/day (Existing=3KLD+Proposed =14KLD) Design Flow (Stream2+Stream3+Stream-4) = ( =71 KLD) Design BOD = 6000 mg/lt Envisaged Efficiency post treatment = 70% average BOD at the out let of Anaerobic lagoon = 1800 MG/LT Existing volume of the tank = 1800 cum. (Hence adequate) INTERMEDIATE EQUALIZATION TANK: (Existing Aeration Tank Used As Intermediate Equalization Tank) The effluent over flow from the Anaerobic Lagoon will flow in to the existing Aeration tank now proposed to be used as intermediate equalization tank, of minimum 24hrs capacity. The stream-1, stream2&3 from their respective equalization /neutralization tanks will be pumped in to this Combined Effluent Intermediate Equalization Tank. The combined all 4 streams from the equalization tank will be pumped in to the proposed II stage EAASP plant followed by filtration Design Flow = 90 cum/day (Stream- 1+Stream2&3+Stream-4) Holding capacity existing = 33 hours Existing volume of the tank = 125 cum. Existing Size of Tank = 10mx5mx 2.5m SWD 74

75 Mode of mixing Proposed Hence Adequate = F fine bubble diffused aeration for Pre-aeration RAW EFFLUENT TRANSFER PUMPS: (Proposed) Since the secondary treatment plant are located on a higher contour, the effluent will be pumped from the equalization tank in to the proposed I stage Aeration tank. Pumps - 2 No. s = one working and one standby. Type = open impeller non clog pumps. Capacity = m Head Hence Adequate TWO STAGE EXTENDED AERATION ACTIVATED SLUDGE TREATMENT: AERATION TANK I STAGE: (STREAM-1+ STREAM2+STREAM- 3+STREAM-4) : The Pre-treated effluent (Stream-1, 2, 3&4) is pumped from the respective equalization / neutralization tank in to first stage aeration tank & is further treated by second stage extended aeration activated sludge treatment which results in the reduction of BOD, and COD by 95 to 97%. Design Flow = 90 KLD DESIGN BOD = mg/lt ASSUMPTIONS MLSS = 4000 mg/lt F/M = 0.10 Total BOD load = 180 kg/day Aeration tank volume required = 450 cu. M 75

76 Provide Aeration tank size = 15 m x 9 m x 3.5m SWD -1no. Hence adequate. DIFFUSED AERATION SYSTEM: Kg of BOD/day = 180 Kg of oxygen required/day = 360 (Considering 2 kg of oxygen required/day for every Kg of BOD removed.) %age of oxygen in air = 0.23 Density of air = 1.2 %age of oxygen transfer at 3.5 m SWD = 0.20 Therefore air requirement in cum/hr = A Transfer rate of oxygen in 1mt long membrane diffusers = 10cum/hr Number of membranes required is 700/10 = 70 No Provide 70 meter (i.e 1 meter-70 No in suitable rows to be provided in I stage Aeration tank to ensure uniform air distribution). Hence adequate. SECONDARY CLARIFIER I STAGE: The over flow from the I stage aeration tank is taken in to the secondary clarifier for separation of biological floc. Average flow Design flow = 90 cu. m/day = 180 cu.m/day (Considering 2 times the average flow to accommodate for sludge volume) Sludge Re-circulation = 100% Surface loading Required Area of Clarifier = 7.2 sq. m = 25 cu. m/sq. m/day 76

77 Required Size of clarifier = 4m x4mx3m SWD Provide Size of clarifier = 4mx4mx 3m SWD Hence adequate. AERATION TANK-II STAGE: The over flow from the Clarifier is further treated by Second stage extended aeration activated sludge treatment which results in the reduction of BOD and COD by 95 to 97%. Design Flow = 90 KLD DESIGN BOD = 400 mg/lt (Considering 80% BOD removal in I stage treatment) ASSUMPTIONS MLSS = 4000 mg/lt F/M = 0.10 Total BOD load = 36 kg/day Aeration tank volume required = 90 cu. M Provide a Aeration tank size = 7 m x 4m x 3.5 m SWD -1No Hence adequate DIFFUSED AERATION SYSTEM: Kg of BOD/day = 36 Kg of oxygen required/day = 72 (Considering 2 kg of oxygen required/day for every Kg of BOD removed). %age of oxygen in air = 0.23 Density of air = 1.2 %age of oxygen transfer at 3.5 m SWD =

78 Therefore air requirement in cum/hr = B Transfer rate of oxygen in 1mt long membrane diffusers = 10cum/hr Number of membranes required is 150/10 = 15 Provide 15 meter (i.e 1 meter-15 No in suitable rows to be provided in II stage Aeration tank to ensure uniform air distribution). Provide capacity of blowers 2 No. blowers of capacity 300 cum/hr 2 Nos operating at a pressure of 0.5 KSC pressure, (The provided capacity of blower will meet air requirement for aeration tank II stage, Sewage & Effluent equalization tank for preaeration ). Hence adequate FINAL CLARIFIER: The over flow from the II stage aeration tank is taken in to the final clarifier separation of biological floc. for Average flow Design flow = 90 cu. m/day = 180 cu.m/day (Considering 2 times the average flow to accommodate for sludge volume) Sludge Re-circulation = 100% Surface loading Required Area of Clarifier Required Size of clarifier = 7.2 sq. m = 25 cu. m/sq. m/day = 4m x4mx3m SWD Provide Size of clarifier = 4mx4mx 3m SWD Hence adequate. 78

79 SLUDGE DRYING BEDS : -6 Nos To de-water & dry the excess sludge generated from the above treatment. Drying period : 10 days Sludge loading rate : 0.25 kg/sq. m Proposed minimum Size : 5m x 5m x 1.5 m-6 no.s Capacity : 150 Sq. m Hence adequate SLUDGE PUMPS: Available 4 No. pumps 2 no for the first stage clarifier & 2no for the second Stage clarifier. With one working and one standby) Capacity Type : m head-4 NOS : Open Impeller Non Clog centrifugal mono block pumps Solid handling size : up to 50 mm Hence adequate Duty: To pump the excess biological sludge from the second stage clarifier in to the sludge drying beds and return sludge to the respective I & II stage aeration tank. CLARIFIED EFFLUENT SUMP / FINAL TREATED EFFLUENT SUMP The overflow from the final clarifier are collected in an sump from where it is pumped into an Pressure Sand, and Activated Carbon filter for further polishing of the treated effluent. Design flow = 90 KLD Retention time proposed -22 hours storage =80 cum Proposed tank size = 8m x 4m x 3m TD - 2 No 79

80 Hence adequate. FILTER FEED PUMPING: Pumps - 2 nos. Capacity : One working and one standby. : 15 cum / 30m Head PRESSURE SAND FILTER & ACTIVATED CARBON FILTER : (ACF) The treated effluent are pumped into the Pressure sand filter followed by Activated carbon Filter for polishing the effluent and to reduce turbidity, suspended solids, color. Design Flow : 90 KLD Considering 10 hrs operating of the filter Flow/hr : 9 cum/hr Considering the loading rate at 5 cum/sq. m/hr Required area of the filter : 1.8 sq. m Required diameter of the filter : 2 m diameter -1 No each Hence adequate LAND REQUIRED FOR USING TREATED EFFLUENT: The daily generation of treated effluent = 90KLD Out of the total 90KLD of treated effluent about 10KLD will be used for floor Washings, Fire fighting make up water Balance 80KLD will be used for irrigation.. Since the soil is sandy loam Considering a loading 170 cum/sq.m/day 80

81 Land required for using treated effluent =80x2.47/170= 1.16 acres. Available vacant for utilizing treated effluent is 2.3 acres as against the requirement of 1.16 acres hence adequate. SUMMARY AND CONCLUSION: (WASTE WATER TREATMENT & DISPOSAL): Effluent Treatment and Disposal: This Adequacy report is prepared to check the adequacy of the existing ETP, and the recommend the required up-gradation of CETP as necessary to meet the combined existing and proposed effluent load due to the proposed expansion and for treating the same and conserving the entire treated effluent on own land for irrigation confirming to KSPCB on land discharge standards. Further, it is to be noted that their will not be any additional Air Pollution Sources envisaged due to the proposed expansion. The entire effluent stream are classified into 4 streams, based on their organic strength and BOD loading for source segregation and ease in treatment. Stream-1: Domestic effluent with a maximum flow of 19KLD is gravitated as an independent stream in to Bar Screen chamber for physical separation of solids, followed by equalization for flow balancing with pre-aeration, which will be further pumped in to the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage Extended Aeration Activated Sludge Process (EAASP). Stream-2& Stream-3: The stream-2 &3 effluents with a maximum flow of (16KLD +38KLD ) will be gravitated as an common stream in to Bar Screen chamber for physical separation of solids, followed by equalization/neutralization for flow balancing with pre-aeration, and ph adjustment The neutralized effluent will be further pumped in to the Anaerobic lagoon where it mixes with stream-4 effluent which is further treated in 81

82 the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage EAASP. Where in it mixes with stream-1 effluent for further treatment. Stream-4: The Stream-4 effluents with a maximum flow of 17KLD will be gravitated as an independent stream in to Bar Screen chamber for physical separation of solids, and than after ph correction flows in to the existing Anaerobic lagoon where it mixes with stream2 & stream3, and than the pre treated stream-4 along with stream2 &3 effluent flows in to the existing aeration tank which shall be used as intermediate equalization tank where it with the mixes with stream-1. The combined stream will be further treated by II stage EAASP. After 2 stage biological treatment. The combined treated effluent post filtration and chlorination will be used on own land for gardening, floor wash, The design details are presented in Section IV of this report. The project report is enclosed separately along with this report. The layout plan of CETP is enclosed in Annexure -2 of this report. The sludge generated from the ETP will be used as manure for irrigation. The quantity of solid waste it s collection, treatment and disposal are enclosed below. The proposal is submitted to KSPCB for approval. The entire CETP work will be completed in 5 months of time after getting the necessary approval from KSPCB Annexure

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84 vii. Industrial Waste Management. ANNEXURE 4 Vii. Effluent and wash water generated viii. SL. Particulars Effluent water Wash water 1. Malt Spirit Plant 19,128 9, Jiggery Spirit Plant 4, Grape Spirit Plant 4, IML Bottling 2, Domestic 15,000 Total 27,128 27,000 Solid waste management. SOLID WASTE MANAGEMENT: Quantities of solid wastes before and after expansion and the mode of disposal are detailed in Table given below Details of Solid Waste Management Sl Description of No. waste 1 Broken bottles/glass 2 Corrugated Paper waste Existing Quantity 14.2 tonnes/month 9.5 tonnes/month Proposed Quantity 0.12 Tonne/month tonnes/month Mode of Disposal Sent to glass factory Sent to box manufactures for reprocessing 3 Spent grain used barley malt 30.7 tonnes/month 200 tonnes/month To be sold as animal feed for dairy farms 4 ETP sludge 5kgs/day 40kgs/day Will be disposed a manure on land for gardening 5 Waste oil 60 lts/month 10lts/month MS drums to KSPCB authorized agencies. 6 Laminates Tonne/month Will be sold to recyclers 7 Aseptic Packs Tonne/month Will be sold to recyclers 8 PET Bottles Will be sold to Tonnes/month 9 Grape Musk Tonnes/month recyclers Composting and used as manure 84

85 X. Power Requirement & supply/source. 85

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87 VIII. Rehabilitation ad Resettlement (R&R) Plan i. Policy to be adopted (central/state ) in respect of the project affected persons including home outsets, land outsets, and landless labourers (a brief outline to be given) Existing industry from more than 3 decades,there is no R & R issues,what ever addition is well within our boundary. IX. Project schedule & cost estimates i. Likely date of start of construction and likely date of completion (time schedule for the project to be given). Shall begin with the issue of the Environmental clearance issued by the department. ii. Estimated project cost along with analysis in terms of economic viability of the project. The cost of the project will be 12 crores. 87

88 X. Analysis of proposal (Final Recommendations) 1. Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area. Employees are with us since the inception and are all provided with the best of facilities the industry demands. CONCLUSION Internationally, the trend is towards discouraging artificial flavours and encouraging natural products to the extent feasible. Survival of the IML industry would therefore depend largely on the extent to which it is able to adapt itself to the demands of modern consumers which alone would enable it to successfully face completion from multinational operators in the industry. Production of rum out of jiggery spirit is a step in this direction. Our position as an existing, well established IML manufacturer, Availability of capacity within our existing factory, the marketing set-up That we have already created in several countries across the globe all this Places us in a unique position to successfully develop and market newer and newer, natural and genuine products. We therefore propose to immediately commence production of jiggery-spirit as soon as procedural requirements including grant of Excise License are complete 88

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