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Page 1

Pre-Feasibility Report
For
M/s Matrix Fine Sciences Pvt. Ltd.
Plot No. D-8, MIDC Paithan, Taluka-Paithan,
District- Aurangabad- MS

[Environmental Consultant]
sd engineering services pvt. ltd.
14 Age Arcade, New Osmanpura,
Near Sant Eknath Rang Mandir,
Aurangabad- 431005 (MS)
NABET/EIA/1619/RA 0068

February 2018
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Pre-feasibility Report for M/s Matrix Fine Sciences Pvt. Ltd. 2018

INDEX

1. Executive Summary

2. Introduction of the Project/ Background Information

2.1 Identification of the Project and Project Proponent
2.2 Nature of the Project
2.3 Need of project with description for region and country
2.4 Demand and Supply Gap
2.5 Employment generation due to project

3. Project Description
3.1 Type of the Project
3.2 Location of the Project

3.3 Products & Raw Materials.

3.4 Manufacturing Process

3.5 Water Requirement

4. Site Analysis
4.1 Connectivity
4.2 Land form, Land use, Land ownership
4.3 Topography
4.4 Soil classification
4.5 Climate data for secondary sources
4.6 Social infrastructure Demand

5. Planning Brief

5.1 Planning Concept

5.2 Population Projection
5.3 Amenities /Facilities

6. Proposed Infrastructure

6.1 Industrial area

6.2 Residential area
6.3 Green belt
6.4 Connectivity
6.5 Water management

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6.6 Sewerage system/ETP

6.7 Air Pollution
6.8 Solid waste management
 6.9 Power requirement & supply /source

7. Rehabilitation and Resettlement

8. Project Schedule & Cost Estimate

8.1 Time schedule for the project

8.2 Estimated Project cost

9. Analysis of Proposal

9.1Financial and Social Benefit

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Pre-feasibility Report for M/s Matrix Fine Sciences Pvt. Ltd. 2018

Chapter 01
Executive Summary
M/s Matrix Fine Sciences Pvt. Ltd. is located at Plot No. D-8, MIDC Paithan, Tal.
Paithan, Dist. Aurangabad (MS). The company was incorporated in the year 2012
engaged in the manufacturing of products from wastes from edible oil industry. The
company proposes to expand its manufacturing facility by addition of 07 derivatives of
natural Vitamin E.
The list of existing and proposed products is presented in Table 1.1. The existing
products are manufactured by employing simple extraction & purification process.
 The Company now proposes Extraction along with Synthesis employing processes like
hydrogenation, esterification using catalyst systems on commercial scales. The products
Mixed Tocopherol, D Alpha Tocopherol, D Alpha Tocopheryl Acetate / Succinates will
be manufactured for the first time in India by using this technology. The products are
produced using a novel & eco-friendly process. All the products are import substitutes
and have very good export potential.

The proposed products fall under category of Synthetic Organic Chemicals. As per the
EIA Notification 2006 & amendments thereof, for manufacturing of bulk drug &
intermediate chemicals, requires environmental clearance from MOEF&CC under the 5
(f) project activities.

Table 1.1: List of existing and proposed products along with their capacities

Sr. Name of Products Existing Proposed Total (MT/A)

No. Quantity expansion
(MT/A) (MT/A)
1. FAME/Biodiesel/ 7600 0 7600
Distillated Fatty Acid
2. Phytosterol 450 0 450
Tocopherol & Its 600 0 600
3. Derivatives
4. Oil Residue 600 0 600
5. Squalene 50 0 50
6. Tocotrieols 550 0 550

7. Bixin or Nor-Bixin 52 0 52

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8. Omega 3 Fatty Acid 53 0 53

9. Beta Carotene 50 0 50

10 D Alpha Tocopherol 0 720 720

11. D Alpha Tocopherol

Acetate 0 720 720
12. D Alpha Tocopheryl
Succinate 0 720 720
13. Vitamin E TPGS 0 720 720
14. Steryl Ester 0 720 720
15. Squalane 0 720 720
16. Vitamin E Powder 0 600 600
By Products
17. Acetic Acid 0 3 3
18. Succinic Acid 0 5 5

Total 10005 4928 14933

The existing manufacturing capacity of various natural Vitamin E products is 10005MT/A.

 The proposed addition of Vitamin E derivatives shall be 4928 MT/A.
Area Requirement: The total plot area in possession is 40,000 sq m.
Water Requirement: The total water requirement will be 340 CMD and shall be supplied by
[MIDC] Maharashtra Industrial Development Corporation, Paithan.
Power Requirement: The total power requirement will be Existing 420 KVA & Proposed
1250 KVA. The source of electricity supply is (MSEDCL).
Man Power: The total manpower requirement will be 200 numbers including skilled and
unskilled category.

Project Cost: The total cost of the project will be around Rs.28 Cr. including approximately
Rs. 22 Cr. for Plant & Machinery and Rs.4 Cr. for building construction.
Total Cost (Rs in Cr).
Description
00.7
CSR Cost
1.95
EMP Cost
22.00
Plant & Machinery
Building Construction
4.00
Total cost
28.00

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Chapter 02

Introduction of the Project/Background Information

2. Introduction.

M/s Matrix Fine Sciences Pvt. Ltd. is Extracting and manufacturing Natural Vitamin E
and its derivatives which are import substitutes apart from good export potential, as
much as 70% of the production is being exported to more than 15 countries. This helps
directly in minimizing the imports of these products and savings in foreign exchange to
the country.
As the name suggests, it is all about Matrix a building block and focused on extracting
value added products from ‘Industry Wastes’. The company’s promoters are
technocrats with the experience ranging from 25 to 30 years in chemical &
pharmaceutical industries. The Company is accredited with ISO 9001, 14001 & OHSAS
18001& 22000 along with global certifications like CERT ID NON GMO, STAR K
Kosher, NON PROJECT VERIFIED by US and Halal. The Company now has customer
base all over 15 countries and distributors across the globe.

The R & D is a key component of the Company’s strategy. R&D lab is approved by

DSIR. Current R & D site is located at factory & operations are carried out in all the
shifts. All products are outcome of their R&D efforts. About 14 scientists are engaged in

R&D round the clock.

 The existing products are based on purification, Extraction process and did not fall under
purview of EC. The proposed products are synthesis of downstream and value added
products would come under 5 (f) Category ‘A’. This Pre-Feasibility Report is prepared
for forming a framework for EIA study, Scoping and finalizing the Terms of Reference.
M/s Matrix Fine Sciences Pvt. Ltd. has retained the services of M/s sd engineering
services pvt. Ltd. as an environmental consultant for assessing the impact of the
Industry on various environmental parameters in the study area and to prepare EIA
reports and Environment Management Plan for mitigating the adverse impacts of the
project. The Board of Directors consists of recognized personalities from academic &
chemical industry background.

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2.1 Identification of Project & Project proponent

M/s Matrix Fine Sciences Pvt. Ltd. is engaged in manufacturing of Vitamin E related
products namely Derivatives of Natural Vitamin E, Located at Plot No. D-8, MIDC,
Paithan. Tal. Paithan, Dist. Aurangabad. M/s Matrix Fine Sciences Pvt. Ltd. was

incorporated in the year 2012. The Company is proposing expansion of existing facility
by adding manufacture of Vitamin E based Derivatives.
The major reason for capacity expansion is the fact that higher production capacity
would help them to compete with competitors from China & Europe. Also, this would
help them to reduce fixed costs making them more competitively against our
competitors. The higher capacity would also help cater to all global customers
Details of Director of MSPL
• Mr. Kunal Sikchi, Managing Director Qualification: B.E. Chemical from

Mumbai University. Experience: Nine years in the Chemical Industry. He has

recently received ‘Sir Ratan Tata Scholarship’ for excellent Academic records
during engineering. He is Gold Medalist from Mumbai University.
• Mr. Madhusudan Rathi - Chairman & Independent Director, B.Sc. - Pune

University, D.M.E. - Cusrow Wadia Institute, Pune Chairman & Managing

Director Rathi Transpower Pvt. Ltd., Pune, 52 Years as Industrialist, Also
holding Directorship in various other companies, Chairman: Polybond India
Pvt. Ltd., Pune, Rathi Polybond Pty. Ltd., Australia, Managing Partner:
Rathi Engineering Services
• Mr. Ashok Boob –Independent Director, Qualification: B. Chem. Eng from

ICT, Mumbai, Experience: Over 35yearsof experience in the chemical industry.

• Mr. Ashok Sikchi, Executive Director, Qualification: B.Sc. from Marathwada

University, Experience: More than 25 years in Chemical &Pharmaceutical

Industry.
• Mr. Siddharth Sikchi, Executive Director Qualification: M.Sc. in Synthetic

Organic Chemistry from University of Manitoba, Canada and B. Tech from ICT,
 Mumbai. Experience: Eight years in the Chemical Industry. He has recently
received a “Young Entrepreneur Award” from Dr. Anil Kakodkar Padma
Vibhushan, for commercializing unique & eco-friendly process in India.

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2.2 Nature & Magnitude of project

M/s Matrix Fine Sciences Pvt. Ltd. is engaged in the Extraction and production of
Natural Vitamin E & their derivatives. The company proposes to expand its
manufacturing facility by addition of Natural Vitamin E based derivation namely- D-
Alpha Tocopherol, D Alpha Tocopherol Acetate, D Alpha Tocopheryl Succinate,
Vitamin E TPGS, Steryl Ester, Squalane & Vitamin E Powder
2.3 Need of project and its importance to the country and region
The Raw Materials for Matrix is a byproduct from Edible Oil Industry which was earlier
used for Soap Manufacturing or Fatty Acid recovery and with efforts of R & D of the
company, natural Vitamin E products are extracted from it. This is a very good addition
to a waste product. Hence it is utmost important for country like ours which has rich
natural resources companies like us which can extract value out of it for our customers,
suppliers and employees alike.
Fragmented nature of industry makes it difficult for the companies to optimize
operational costs, realize economics of scale and adopt latest technologies, making them
uncompetitive globally. The industry should actively move towards investing in new
capacities with scale and size matching global standards to achieve world scale of plants
and reap economies of scale and adopting cutting edge technologies. Product
innovations for meeting local needs rely heavily on the chemical industry for inputs and
support. The areas for strengthening are R&D activities in Natural industry for the
improvements in catalysis, manufacturing& extraction process, reduction in cost of
production, development and design of new products relevant to the Indian market
needs.
In the Indian sub-continent population growth is more than that of developed countries.
Strong end use industry demand is expected to boost growth for the Indian chemical
companies, both domestic & multinational. To meet the needs and comforts of ever-
growing population industrialization became inevitable. The project is envisaged to meet
the demand supply gap in both domestic and export market. The project meets to reduce
imports in some of the intermediate products and also enhance the foreign exchange
reserves in view of the exports of few products.
2.4 Demand supply gap and market scenario
Natural Product and broadly Chemical Industry is one of the oldest industries in India,
which contributes significantly towards industrial and economic growth of the nation. It

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is highly scientific type of industry and provides valuable raw material/chemicals for
various types of industries such as Food, Feed, Pharma, Nutraceutical and Personal Care
etc., are required in almost all walks of life. The Indian Chemical Industry forms the
backbone of the industrial and agricultural development of India and provides building
blocks for downstream industries.
India’s chemical / Nutraceutical / Pharma industry is one of the largest and most
diversified industries in the country and it consist of several small industries that cover
hundreds of segments. Products are generally used to make a wide variety of consumer
goods and are also used in agriculture, manufacturing, construction, and service
industries. The chemical industry itself consumes 26% of its own output. Major
industrial customers include Food and Feed products, Pharma, Nutraceutical, Personal
Care and Cosmetic. With the chemical industry contributing indirectly to almost every
sector of the economy, it plays a vital role in a country’s economic growth. The
domestic chemical industry contributes 3-4% in India’s GDP while India accounts for
8.3% of the Asia-Pacific chemicals market's value. India’s chemical industry’s size in
2010-11 is estimated to be around $83 billion and is expected to reach $120 billion by
2013. India sales are projected to reach $250 billion by 2020.
The total investment in Indian Chemical Sector is approx. US$ 60 billion and total
employment generated is about 1 million. The Indian Chemical sector accounts for 13-
14% of total exports and 8-9% of total imports of the country. In terms of volume, it is
12th largest in the world and 3rd largest in Asia. Currently, per capita consumption of
products of chemical industry in India is about 1/10th of the world average. Over the last
decade, the Indian Chemical / Pharma industry has evolved from being a basic chemical
producer to becoming an innovative industry. With investments in R&D, the industry is
registering significant growth in the knowledge sector comprising of Nutraceuticals, fine
chemicals and pharmaceuticals.
Companies in this industry manufacture basic, intermediate and Synthetic Organic
Chemicals. Major companies include Dow and DuPont (both based in the US), BASF
(Germany), INEOS Group (UK), Lyondell Basel (The Netherlands), Mitsubishi
Chemical (Japan), and Roche (Switzerland).
Per capita chemical consumption in India is low as compared to world standards
(estimated to be one tenth of world average). Increasing consumption level in the
domestic market would ignite the prevailing latent demand. To achieve global standards,

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the industry needs to put efforts in critical areas so as to adopt aggressive growth and
focus on exports, R&D, co-marketing alliances, up-gradation of manufacturing facility,
 contract manufacturing with companies having established markets, identification of
areas of core competence, consolidation, collaboration by cluster development,
outsourcing, environmental consciousness, cost reduction etc.

2.5 Employment Generation

The Project creates direct & indirect employment opportunities to people living in the
surrounding region. The Management of the Company has always preferred to engage
(employment) local people from the nearby villages depending upon skilled & un-
skilled man-power available and train them in the required field. Total direct
employment is around 200 people. Apart from direct employment, there is substantial
indirect employment to the people giving support services in various fields. It enhances
the earnings due to various direct or indirect businesses in the areas.

2.6 Approvals from various Departments

Sr.
Approvals Authority Status
No
1. Building Plan Approval Executive Engineer (SPA), Aurangabad In place

2. Factory License Directorate of Industries Safety & In place

Health, Aurangabad

3. Petroleum & Explosive Chief Controller of Explosive, Nagpur In place

License
IEM (Industrial GM, District Industries Centre, In place
4. Entrepreneurs Aurangabad
Memorandum)
5. MSEDCL load Sanction Superintendent Engineer, MSEDCL In place
Letter Rural
6. MPCB Consent of MPCB, Mumbai In place
operate (For Existing
Products)
7. Fire NOC (Provisional) Chief Fire Officer & Fire Advisor, In place
Mumbai
In place
8. MIDC Possession Letter Executive Engineer (SPA), MIDC,
Aurangabad

9. Water Supply Executive Engineer, MIDC, In place

Aurangabad

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Chapter 03

Project Description
3.1 Type of project
M/s Matrix Fine Sciences Pvt. Ltd is engaged in extraction and manufacturing of
Natural Vitamin E and its various derivatives and co-products. Company proposes to
increase the production capacity to manufacture D- Alpha Tocopherol & their
derivatives. This expansion is not interlinked with any other project.
The details of the Project are given in the Table 3.1.
 Table 3.1: Project Details

1. Name of the Proponent M/s Matrix Fine Sciences Pvt. Ltd.

2. Project Extraction and Manufacturing of Natural Vitamin E and

its various derivatives

3. Location of the project Plot No D-8, Paithan MIDC, Tal. Paithan,

Dist. Aurangabad

4. Land Requirement Total exiting built-up area: 10394.76 sq. m.

Proposed built-up area: 3300.85 sq.m
Total area in possession: 40,000 sq. m.
Area available for green belt: 9947.61sq. m.
5. Product Existing Products
1. FAME/Biodiesel/Fatty Acid Distillate
2. Phytosterols
3. Tocopherol & its derivatives
4. Oil Residue
5. Squalane
6. Tocotrieols
7. Bixin or Nor-Bixin
8. Omega 3 Fatty Acid
9. Beta Carotene
Proposed Products
1. D Alpha Tocopherol
2. D Alpha Tocopherol Acetate
3. D Alpha Tocopherol Succinate
4. Vitamin E TPGS
5. Steryl Ester
6. Squalane
7. Vitamin E Powder

By Product
1. Acetic Acid

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2. Succinic Acid

6. Operation Days 350 days

7. Raw materials 1. Mixed Tocopherol

2. Paraformaldehyde
3. Acetic Anhydride
4. Succinic Anhydride
5. Heptane
6. Methanol
7. Acetone
8. Oleic Acid
9. Precipitated Silica
10. Polyethylene Glycol
11. P Toluene Sulfonic acid
12. Activated Charcoal
13. Potassium Hydroxide
14. Potassium Acetate
15. Sodium Acetate
 16. Sulphuric acid
17.Fatty Acid Distillate / Deo Distillate of Soya,
sunflower & Rapeseed
8. Total Water requirement Existing + Proposed =340 CMD

9. Electricity requirement Exiting: 420 KVA

Proposed: 1250 KVA
10. Boiler Existing: 3 MT/Hr (Fuel Required: coal- 8 MT/D)
Proposed: 7 MT/Hr.(Fuel Required: coal- 16 MT/D)
11. Thermopack Existing: 4 Lack Kcal ( Fuel required- Coal- 140 kgs
/ hour)
Proposed:10 Lack Kcal (Fuel required -300
kgs/hour)
12. DG Existing: 320 KVA ( HSD- 35 Lit/ Hrs)
750 KVA (HSD- 75 Lit/ Hrs)

Proposed: 750 KVA (HSD- 75 Lit/Hrs)

13. Effluent Treatment Proposed aerobic treatment system 180 m3
System (capacity) will be sufficient for proposed effluent load.

14. Man power Existing: 100 Nos.

Proposed: 200 Nos.
15. Total Project Cost Rs. 28 Cr.

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16. Total cost for EMP Cost: Rs. 1.95 Cr.

Environment CSR: Rs. 0.7 Cr.
management

3.2 Location of Project

M/s Matrix Fine Sciences Pvt. Ltd. is an existing extraction cum formulation industry
located at Plot No. D-8, MIDC Paithan, Tal. Paithan, Dist. Aurangabad. Location map
of the project site is shown in Figure 3.1. Project site is located at 36 km in South of
Aurangabad city & 7 km in North of Paithan. Geographical location of project is
19°33’00.6” N 75°23’11.8” E with 471 m MSL. The Total project area is 40,000 sq m

located at Paithan MIDC. The MIDC Layout is given in as (Annexure-III)

Figure 3.1: Location map of the Project
 3.3 D

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3.3 Details of Alternate Site

It is the expansions of existing industry in MIDC area hence alternative site are not
examined.

3.4 Products and Raw Materials

Company Extracts 10005 MT/Annum of Natural Products and proposes to enhance capacity
and further process these products by Synthetic Chemistry by 4928 MT/A. The Table 3.1
below provides details of products manufactured and proposed along with quantity, and list
of raw materials required per metric ton given in Table 3.2
Table 3.1: List of existing and proposed products along with their capacities

Name of Products Existing Proposed Total (MT/A)

Sr. No. Quantity expansion
(MT/A) (MT/A)
1. FAME/Biodiesel/ 7600 0 7600
Distilled Fatty Acid
2. Phytosterols 450 0 450
Tocopherol & its
3. derivatives 600 0 600
4. Oil Residue 600 0 600
5. Squalane 50 0 50
6. Tocotrieols 550 0 550

7. Bixin or Nor-Bixin 52 0 52

8. Omega 3 Fatty Acid 53 0 53

9. Beta Carotene 50 0 50

10 D Alpha Tocopherol 0 720 720

11. D Alpha Tocopherol 0 720 720

Acetate
12. D Alpha Tocopheryl
Succinate 0 720 720
13. Vitamin E TPGS 0 720 720
14. Steryl Ester 0 720 720
15. Squalane 0 720 720
 16. Vitamin E Powder 0 600 600
By Product
17. Acetic Acid 0 3 3
18. Succinic Acid 0 5 5

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Table 3.2: List of Raw Materials

Sr. Name of the Raw material Qty(ton)
No. Proposed Product

1. D Alpha Tocopherol Mixed Tocopherol 0.97

Palladium Charcoal 5%(Catalyst-1) 0.03
Para Formaldehyde 0.15
P-Toluenesulfonic Acid(Catalyst-2) 0.009
Methanol(Initial) 2.62
Methanol(makeup) 0.12
Heptane(initial) 2.62
Heptane(Makeup) 0.04
Solid Waste 0.009
Effluent 0.97
Finish Product(final product) 1
2. Steryl Ester Refined Phytosterol (98%) 0.61
Oleic Acid 0.45
P-Toluenesulfonic Acid 0.01
Heptane(Initial) 1.8
Heptane(Makeup) 0.03
Potassium Hydroxide 0.01
Sulphuric Acid (35%) 0.006
Unreacted Oleic Acid 0.04
Solid Waste 0.01
Water 0.02
Effluent 1.2
Steryl Ester(Finish Product) 1
3. Tocopheryl Acetate D-alpha Tocopherol 0.91
Acetic Anhydride 0.42
Sodium Acetate 0.004
Liquid Waste(Acetic Acid) 0.71
Unreacted Acetic Anhydride 0.12
Water 0.45
Tocopherol Acetate (Finish 1
Product)
4. Tocopheryl Succinate d-Alpha Tocopherol(1000IU-67%) 1.21
Succinic Unhydryed 0.57
Potassium Acetate 0.036
Heptane(Initial) 3.6
Hepane(Makeup) 0.73
Solid waste 0.036
Unreacted succinic unhydride 0.24
Acetic Acid (0.16%) 0.80
Residue 0.35
d-Alpha Tocopheryl Succinate 1

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5. Tocopheryl d-Alpha Tocopherol Succinate 0.34

Polyethylene Glycol
Polyethylene Glycol 1000 0.68
Succinate (Vitamin E p-toluenesulphonic Acid 0.01
TPGS) Toluene(Initial) 1.03
Toluene(Makeup) 0.02
Methanol(Initial) 1.03
Methanol(Makeup) 0.05
Heptane(Initial) 1.37
Heptane(Makeup) 0.02
Solid Waste 0.01
Unreacted Product 0.02
Water 0.01

TPGS(finish Product) 1

6. Squalane Crude Squalene 1

Ni Catalyst 0.03
Crude Squalane 1

7. Vitamin E 50 Powder Mixed Tocopherol (90%) 1

Silica 0.8

Manufacturing Process

1] D Alpha Tocopherol

Production per Month : 60 MT

No. of Working days : 30

Manufacturing Process : The objective of this process is that Non-Alpha

Tocopherols are hydroxy-methylated and hydrogenated to produce alpha-tocopherol in
one pot process by simultaneously reacting with para formaldehyde and hydrogen in the
presence of catalyst of benzene sulfonic acid and 5% palladium catalyst in an
Autoclave. The reaction is carried out in presence of Methanol at 150-200˚C for 8-10 hrs.
Then Heptane is added in reaction mixture to make the finished product completely
soluble which makes it easy to recover. Methanol with acid and formaldehyde is then
separated by layer separation to form the product mixed in heptane layer. Product is
recovered by distillation process with vacuum to remove residual solvent. 5% palladium
catalyst is recovered by the filtration process.

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Route of Synthesis
 Input, Output and Mass Balance for product @ 1 kg/day

Input Mass (Kg/day) Output Mass (Kg/day) Remarks

Mixed Tocopherol 1 D-alpha 1.03 Final
tocopherol Product
Palladium Charcoal 0.04 Palladium 0.04 Recovered
Charcoal and Reuse
P-Toluene Sulfonic Acid 0.01 Recovered 2.56 Recovered
Methanol and Reuse
Formaldehyde 0.16 Methanol 0.14 Solvent Loss
Distillation Loss
Methanol 2.7 Solid Waste 0.01 --
Heptane 2.7 Effluent 1.23 To ETP
Water 1 Recovered 2.6 Recovered
Heptane and Reuse
Total 7.61 Total 7.61

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Process Flow Diagram of D-Alpha Tocopherol

Mixed Tocopherol: 1 Kg
Palladium Charcoal:0.04
Kg
p-Toluene Sulfonic Acid:
Reactor
0.01 Kg
Formaldehyde: 0.16 Kg
Methanol: 2.7 Kg
Hydrogen: Kg
Water: 1 Kg
 Heptane: 2.7 Kg Mixing Recovered Palladium
Charcoal: 0.04 Kg

Filter

Product + Heptane

Separation

Methanol + p-Toluene
Sulfonic Acid

Recovered Heptane:
Distillation 2.6 Kg

Recovered Methanol:
2.56 kg

Methanol Loss: 0.14

Kg

Solid Waste: 0.01 kg

Effluent: 1.23 kg

Total: 7.61 Kg D-alpha Tocopherol : Total: 6.58 Kg

1.03 Kg

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2. Steryl Ester
Production per Month : 60 MT

No. of Working days : 30

Manufacturing Process : Hydroxyl group of Sterol at purity 98-100% is

esterifies with Oleic acid and formed Steryl Ester. Reaction is done in presence of
Acid catalyst i.e. PTSA along with the heptane solvent. Oleic acid converted into
Steryl Ester undergoes esterification reaction. While unreacted Oleic Acid is then
removed by formation of salt by neutralization process and the separated by water
wash two times. Product with solvent is then distillated under vacuum to remove all
residual solvent and then solvent is recovered to use in next process.

Route of Synthesis:
 Input, Output and Mass Balance for product @ 1 kg/day

Input Mass Output Mass Remarks

(Kg/day) (Kg/day)
Refined Phytosterol 1 Steryl Ester 1.63 Final
Product
Oleic Acid 0.74 Un-reacted Oleic 0.07 Recovered
Acid and Reuse
P-Toluene sulfonic Acid 0.02 Solid Waste 0.02 Recovered
and Reuse

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Heptane 2.7 Effluent 2.06 To ETP

Potassium Hydroxide 0.02

Water 2 Recovered Heptane 2.6 Recovered

and Reuse
Solvent Loss 0.1 Distillation
Loss
Total 6.48 Total 6.46

Process Flow Diagram of Steryl Ester

Phytosterol: 1 Kg
Oleic Acid :0.74 Kg
p-Toluene Sulfonic Acid: Reactor
0.02 Kg
Heptane : 2.7 kg

Potassium Hydroxide:
Neutralization
0.02 Kg
Aqueous Layer Un-
reacted Oleic Acid:
Water: 2 Kg 0.07 Kg
Separation
Organic Layer:
Effluent 2.06 Kg
 Recovered Heptane:
Distillation 2.6 Kg

Heptane Loss: 0.1 Kg

Solid Waste: 0.02 kg

Total: 6.48 Kg Steryl Ester: 1.63 Kg Total: 4.85 Kg

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3. Tocopheryl Acetate

Production per Month : 60 MT

No. of Working days : 30

Manufacturing Process : The objective of this process is to convert free D

Alpha tocopherol at 78% to 100% purity to its Acetate ester form. Purified Alpha
tocopherol at 78% to 100% is converted to the acetate ester by reaction with Acetic

Anhydride and Sodium acetate catalyst. The D Alpha Tocopherol is reacted with
excess Acetic Anhydride at 115-125˚C. the tocopherol esterifies at its free alcohol

group with acetic acid librated from the reaction. The excess acetic anhydride along
with acetic acid from the reacted anhydride tocoheryl acetate is then removed by
vacuum distillation. The resulting tocopheryl acetate then water washed 2 times to
remove acetic acid to trace level. Vacuum degassing are done by distillation.

Route of Synthesis
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Input, Output and Mass Balance for product @ 1 kg/day

Input Mass (Kg/day) Output Mass Remarks

(Kg/day)
1 Tocopherol 1.09 Final Product
D-alpha Tocopherol
Acetate
0.46 Liquid Waste 0.78 To ETP
Acetic Anhydride
(Acetic Acid)
0.05 Un-reacted Acetic 0.14 Recovered and
Sodium Acetate
Anhydride Reuse
Water 0.5

Total 2.01 Total 2.01

Process Flow Diagram of Tocopherol Acetate

D-alpha Tocopherol: 1 Kg
Acetic Anhydride :0.46 Kg Reactor
Sodium Acetate: 0.05 Kg

Water: 0.5 Kg Distillation Recovered Acetic

Anhydride: 0.14 Kg

Water + Acetic Acid

0.78 Kg To ETP

Total: 2.01 Kg Tocopherol Acetate: Total: 0.92 Kg

1.09 Kg

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4. Tocopheryl Succinate

Production per Month : 60 MT

No. of Working days : 30

Manufacturing Process : Purified Alpha Tocopherol product at 60-98%

purity is reacted with excess Succinic Anhydride along with Heptane at about 60-
90°C under reflux condition. The D-Alpha Tocopherol esterifies as its free tocopherol
group reacts with succinic anhydride to form D-Alpha Tocopheryl Succinate. Basic
Catalyst is used in the reaction. The excess Succinic Anhydride is removed by
filtration which is reused and remaining is removed by water wash during which the
Succinic Anhydride is extracted as Succinic acid. The reaction product is fully soluble
in Heptane. While Succinic anhydride is broken down to succinic acid which is more
soluble in water.

The crude D-Alpha Tocopheryl Succinate is purified to 99%+ specification by

crystallization from heptanes at 10°C. Filtrating of the resulting slurry to remove and
non tocopherol oil the impurity as a filtrate and yields purified TAS cake. The cake is
re-crystallized if needed and filtered second time for better purity. The filtrate is
continuously collected to recover the heptane. The heptane is recovered for the direct
use in next batch. The purified cake is collected. The heptane is distilled out and the
remaining TAS is degassed under vacuum with nitrogen purge to remove residual
solvent. The product is then cast molten to trays for Solidification which requires 20
hrs. Final product is a solid which is obtain by breaking the individually trays
manually.

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Route of Synthesis
 Input, Output and Mass Balance for product @ 1 kg/day

Input Mass Output Mass Remarks

(Kg/day) (Kg/day)
d-Alpha Tocopherol 1 d-Alpha Tocopheryl 0.82 Final Product
Succinate
Succinic Anhydride 0.47 Unreacted succinic 0.20 To ETP
anhydride
Potassium Acetate 0.03 Solid waste 0.03 Recovered and
Reuse
Water 0.5 Water + Succinic 0.66 To ETP
Acid
Heptane 3 Residue 0.29
Heptane 2.94
Total 5 Total 4.94

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Process Flow Diagram of Tocopheryl Succinate

D-alpha Tocopherol: 1 Kg
Succinic Anhydride :0.47
Kg Reactor
Potassium Acetate: 0.03 Kg
Heptane : 3 Kg

Recovered Succinic
Anhydride: 0.20 Kg
 Water: 0.5 Kg Filtration Water + Succinic Acid
0.66 Kg

Filtration Filter Oil

Distillation

Recovered Heptane :
2.94 Kg
Residue : 0.29 Kg

Solid Waste : 0.03 Kg

Total: 5 Kg d-Alpha Tocopheryl Total: 4.94 Kg

Succinate: 0.82 Kg

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5. Tocopheryl Polyethylene Glycol Succinate (Vitamin E TPGS)

Production per Month : 60 MT

No. of Working days : 30

Manufacturing Process : Tocopheryl polyethylene glycol succinate is

prepared by the reaction of D Alpha Tocopheryl Succinate with Polyethylene Glycol
1000 in presence of Methanol and Zinc Oxide catalyst. The reaction mixture is then

filtered and distillated to recover the Methanol and reaction mixture is then treated /
washed with water and heptane. Heptane and water is recovered by distillation so that
product is free from moisture.

Route of Synthesis:
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Input, Output and Mass Balance for product @ 1 kg/day

Input Mass Output Mass Remarks

(Kg/day) (Kg/day)
d-Alpha Tocopherol 1 TPGS 2.90 Final Product
Succinate

Polyethylene Glycol 2 Solid waste 0.03 To ETP

1000

p-toluenesulphonic Acid 0.03 Unreacted product 0.07 Recovered and

Reuse
Heptane 4 Water 0.03 To ETP

Methanol 3 Recovered 3.92 Recovered and

Heptane Reuse

Toluene 3 Recovered 2.85 Recovered and

methanol Reuse

Recovered 2.94 Recovered and

Toluene Reuse

Total 13.03 Total 12.74

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Process Flow Diagram of Tocopheryl Polyethylene Glycol Succinate

Polyethylene Glycol: 2 Kg
p-Toluene Sulfonic Acid :
0..03 Kg
Reactor
d-Alpha Tocopherol Succinate
:1 Kg
Toluene: 3 Kg
Water: 0.03 Kg

Filtration p-Toluene Sulfonic

Acid 0.03 Kg

Distillation Recovered Toluene:

2.94 Kg

Heptane: 4 Kg Tocopheryl Heptane + Residue

Methanol: 3 Kg polyethylene glycol
succinate Crude

Distillation
Layer Separation

Recovered Heptane:
3.92 Kg
Product + Methanol Residue: 0.07 Kg

Distillation Recovered Methanol:

2.85 Kg
 Total: 13.03 Kg Tocopheryl Total: 12.71 Kg
polyethylene glycol
succinate: 2.90 Kg

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6. Squalane

Production per Month : 60 MT

No. of Working days : 30

Manufacturing Process : The objective of this process is to convert

Squalene into Squalane by Hydrogenation in presence of nickel catalyst and
hydrogen.

Route of Synthesis:

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Input, Output and Mass Balance for product @ 1 kg/day

Mass Mass
Input (Kg/day) Output (Kg/day) Remarks
Crude Squalene 1 Crude Squalane 1. Final Product

Ni Catalyst 0.03 Ni Catalyst 0.03 Recovered

and Reuse
Total 1.03 Total 1.03

Process Flow Diagram of Squalane

Crude Squalene: 1 Kg
Reactor
Nickel Catalyst: 0.03 Kg
H2 pressure: 30 bar

Separation Recovered
Nickel:
0.03 Kg

Total: 1.03 Kg Crude Squalane: Total: 0.03 Kg

1 Kg

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 7. Vitamin E 50 Powder
Production per Month : 60 MT

No. of Working days : 30

Manufacturing Process : Natural Mixed Tocopherol Powder used as a

Natural antioxidant in food and cosmetic prepared by slowly mixing with Precipitated
Silica in blender.

Input, Output and Mass Balance for product @ 1 kg/day

Input Mass (Kg/day) Output Mass Remarks

(Kg/day)
Mixed Tocopherol 1 Mixed Tocopherol 1.8 Final
(90%) Powder (50%) Product

Silica 0.8

Total 1.8 Total 1.8

Process Flow Diagram of Mixed Tocopherol Powder

Mixed Tocopherol: 1 Kg Blender

Silica: 0.8 Kg

Total: 1.8 Kg Mixed Tocopherol

Powder: 1.8 Kg

3.6 Technology Selection

1. The process used is based on raw materials that value added products from
Industry Waste.
2. The process is developed by MFSL Team & R&D efforts.
3. The products are produced using a novel & eco-friendly process.
4. Solvents used are recoverable and also so recovered.

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3.7 Availability of Resources (Water, Energy/Power Requirement)

Power: Existing power requirement is 400 KVA & Proposed power requirement is
1250 KVA.
Water Requirement
Total water requirement for the project shall be 340 CMD provided by MIDC Paithan.
The treated waste water shall be used for plantation. The total water balance for
existing and proposed is presented in the table below
 Table 3.2: Water balance

Sr. Particulars Input Loss Loss as Effluent Remark

No
CMD CMD CMD

1. Domestic 15 3 Consumption 12 Sent to ETP

& for treatment
Evaporation
2. Process & 25 0 No loss 25 Effluents from
process process and
washings reaction.
3. Cooling 300 275 Evaporation 25 Blow Down to
tower & (90% losses ETP
Boiler approx.)
4. Plantation 67* 67* Absorption 0.0 --
by soil
5. DM / Soft - -- 5 Back wash of
water plant DM plant to
ETP

Total 340 278 -- 67* Used for

Plantation

• Total water consumption: 340 CMD

• Loss due to consumption and evaporation: 278 CMD
• Total effluent generation & used for plantation: 67 CMD

Manpower: During Operation Phase total man power available with industry is
around 100 including permanent and contractual labors and for proposed expansion
200 Nos. of man power will be required.

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Fuel for Boiler: Capacity of existing Boiler is 3MT/hr (fuel required – Coal- 8
MT/D} & proposed Boiler capacity will be 7MT /hr. (Fuel required – Coal- 16
MT/Day}

DG Set: Existing DG Set capacity 320 KVA & 750 KVA is proposed is used as a
stand –by source of electricity, (HSD 35 lit /hr. & 75 Lit/Hr respectively). Proposed
Capacity of DG Set will be 750 KVA (HSD- 75 Lit/Hrs.)

3.7 Quantity of wastes to be generated

The main sold waste from the industry will be non hazardous waste & hazardous from
process. Non hazardous waste will be segregated as recyclable/ salable.

The plant will produce very less amount of scrap material. All these will however be
stored carefully on raised platform, with dwarf toe- walls all around and an overhead
roof. The contents will not be stored in the factory for more than a fortnight.
 The empty drums will be recycled or given back to the original vendors for
utilization.

The main solid waste from industry will be in form of process waste/residue. This
waste will be disposed off through CHWTSDF.
Table 3.3: Non Hazardous Solid Waste

Category Quantity
Remark

Existing

Coal Ash- 200 Kg/M 200 Kg/M To sell authorized vendor

Proposed

Packaging material 200 Kg/M ---

Canteen Waste
10 Kg/M ---

Coal Ash 691.2 kg/ Day To sell authorized vendor

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Table 3.4: Hazardous Waste

Existing
Category Quantity
Disposal

Sodium Chloride Salt/ Sludge from 35.5 200 Kg/M To CHWTSDF

neutralization/ settling Tank-

Proposed
Waste Oil 5.2 50 Lit/M
To CHWTSDF

Process Residue 28.1 1.7 MT/A To CHWTSDF

ETP Sludge --- 75 kg/Day To CHWTSDF

3.8 Reuse/ Recycle/ Recovery Systems proposed along with Details

Distillation column shall be installed for the recovery of the solvents. The generated
spent solvents shall be collected as Mix Liquor from production and will be sending
for distillation. The distilled solvents shall be reused for the reaction. To remaining /
distillation residue will be sent to CHWTSDF. This distillation activity shall be
carried out for minimizing the raw material cost and use if fresh solvent in the process
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Chapter 04

Site Analysis

4.1 Connectivity

This project site is in Plot No. D- 8, MIDC Paithan Tal. Paithan Aurangabad (MS)
well connected by roads, railways and airport. Nearest highway is SH-30. The Site is
36 km (aerial) from Airport and 36 km from Aurangabad railway Station. The land
and infrastructure is made available by MIDC. There is good road connectivity to
Aurangabad, Ahmednagar and other cities by road network

The raw material is easily available through the easy transport via road connectivity.
With all this consideration, this site was ranked first in our list and the same was
adopted.

4.2 Land form, Land use and Land ownership

The proposed project is located at Paithan, MIDC area. The total plot area is 40,000
sq m. Land use is for Industrial activity only and land ownership is on MIDC & taken
on lease by proponent. Toposheet of the project site is attached as (Annexure-I).

Land Form: Land is plain having no contour and it is flat terrain.

Land Ownership: Land ownership is on lease basis with the project proponent.
Project layout is given in (Annexure-II).

Existing Land use Pattern: The Land is reserved for Industrial use only. On site
existing trees will be retained for Landscape Development.

Existing Infrastructure: Project site is having MIDC’s infrastructure such as road,

water supply, electricity etc.

4.3 Topography
Marathwada region comprises of eight districts, viz. Aurangabad, Beed, Hingoli,
 Jalna, Latur, Nanded, Osmanabad and Parbhani. The location of Marathwada is on 70
5’ – 78 5’ E longitude and 17 5’ – 20 5’ N latitude forms the part of the vast Deccan
plateau all of India and is one of the six divisions of Maharashtra State.
The total area of Marathwada region is of 64,813 sq km. bounded by the Vidarbha
region on the North, by Andhra Pradesh on the East and Southeast, by Karnataka on

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the South and by Western Maharashtra on the West. The entire region is situated at an
average height of about 300-650 m. above Mean Sea Level gradually sloping from
West to East, and is traversed by hill ranges originating from the Sahyadris in the
West and the Satpudas in the North.

4.4 Soil Classification

The major part of the Aurangabad district is dominated by black cotton soil or ‘Regur’
formed by the weathering of Deccan Trap Basalt. It is rich in plant nutrients such as
lime, magnesia, iron and alkalis on which cotton and dry crops like Jowar, Bazra and
tur etc flourish. It swells and becomes sticky on watering while on drying it contracts
and develops many cracks. The soil varies both in texture and depth. In northern
portion of the district the soils are shallow and relatively poor while in south they
become deep and fairly rich in nutrients.

4.5 Climate data from secondary sources

Aurangabad has a semiarid climate under the Köppen climate classification.

Temperature: Annual mean temperatures in Aurangabad range from 17 to 33 °C,
with the most comfortable time to visit in the winter – October to February. The
highest maximum temperature ever recorded was 46 °C (114 °F) on 25 May 1905.
The lowest recorded temperature was 2 °C (36 °F) on 2 February 1911. In the cold
season, the district is sometimes affected by cold waves in association with the
eastward passage of western disturbances across north India, when the minimum
temperature may drop down to about 2 °C to 4 °C (35.6 °F to 39.2 °F).[14]
Rainfall: Most of the rainfall occurs in the monsoon season from June to September.
Thunderstorms occur between November and April. Average annual rainfall is
710 mm. The city is often cloudy during the monsoon season and the cloud cover may
remain together for days. The daily maximum temperature in the city often drops to
around 22 °C due to the cloud cover and heavy rains.

4.6 Social Infrastructure available

Many large and small scale industrial units have been established in MIDC is situated
in the command area of Mudhalwadi Grampanchayat. There are facilitates for the
workers to stay near MIDC. Aurangabad railway staion is at 36 km at North
Direction, state highway SH-30 from project site at 0.7 km towards West Direction.
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Fire station, Hospitals, Police station, Fire station & tourist place (Paithan) is at
accessible distance from the project site.

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 Chapter 05

Planning Brief

Planning Concept
Proposed expansion will be at M/s. Matrix Fine Sciences Pvt. Ltd. MIDC Paithan
already existing plant. Project proposes to manufacture 18 products as described

earlier. All basic infrastructure facilities will be provided to workers and office staff &
also ensure the social development work under its Corporate Social Responsibility
(CSR). All statutory requirements will be fulfilled before commissioning and during
operation of the plant.

5.1 Facilities

The company already has existing manufacturing facility at this site. This site is inside
the existing MIDC and means safe transportation, less need of Utilities, less
constructing buildings and roads, less fuel, less water with optimization of
infrastructure.

Government MIDC has provided all infrastructures like Electrical power, continuous
water supply, internal road network, external approach road, and networking.
5.2 Land use Planning
Land is already developed for Industrial purpose. Easting Area break-up are like
fooling
• Total Area in possession = 40,000 sq. m
• Total Built-up area = 10394.76 sq. m
• Area available for plantation = 9947.61 sq. m

5.3 Population Projection

Total 200 persons are required for proposed expansion. Local people will be preferred
for jobs based on their educational qualifications, experience and capabilities.

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Chapter 06

Proposed Infrastructure

6.1 Industrial area

M/s Matrix Fine Sciences Pvt. Ltd. is located in Paithan MIDC; no additional land
will be required for the expansion.
 6.2 Residential Area

In MFSPL no residential area has been proposed for the project. Facility will be
provided for emergency workers only, but no one will stay in the premises.

6.3 Green Belt

Industry already developed nearly, 9947.61 sq. m. Land has been used for green belt
development by planting various types of trees and area has also been beautified with
plantation of ornamental trees. About 400 trees of various plant species exist on site
U/R, including Neem, Palm & Coconut trees along with about 10,000 sq ft green lawn
in the said premises.

6.4 Connectivity

As the existing industry is located in Paithan MIDC, it is well connected through

highway & internal roads. No new roads are proposed.

6.6 Water Management:

MIDC has provided water supply scheme. Present consumption is around 70 CMD.
Proposed water requirement including existing will be around 340 CMD distribution
system is provided all over the MIDC area so that required water can be provided to
nearby Industries.

6.7 Sewage System/ ETP

The main source of effluent generation is from the plant / process, washings, blow
downs from utilities like cooling tower, boiler & domestic effluents. The process
effluents and domestic sewage is treated in Effluent treatment system. ETP is
provided with aerobic treatment facilities with the capacities of 180 m3 & 72 m3 /day
respectively to treat the generated effluent. Treated effluent is used for plantation.

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Figure 6.1: Block Diagram of Efleunt Treatment Plant

 6.8 Air Pollution
The air pollution is mainly from emissions of air pollutants from the stacks and dust
from the coal. Very little emission from fugitive sources is also predicted.
The other energy source is Coal Fired Boilers with the capacity of 3 MT/hr&
proposed one additional boiler of 7 MT/hr. The required quantity of coal is 8 MT/day
& 16 MT/Day. Thermopack of 4 Lac Kcal [fuel required-coal 140 Kgs/hour] and

proposed 10 Lac Kcal [fuel required-coal 300 Kgs/hour]. D.G. Set of 320 KVA & 750
KVA capacities (fuel required HSD – 35 liters/hrs) & proposed capacity of DG SET

will be 750 KVA Capacity (fuel requires HSD- 75 Lit/Hrs.) is used as a stand-by
source of electricity.
The emissions from the boilers are passed through Mechanical Dust Collectors, Single
Cyclone and Multiple Cyclone separator before releasing into atmosphere through a
stack.
The stack heights are provided as per the guidelines of MPCB. The process emissions
contain Hydrogen, CO2 and Nitrogen, which are let out into atmosphere.

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6.9 Solid Waste Management

The main solid waste from this factory will be non hazardous and hazardous from
process. Non hazardous will be segregated as recyclable / saleable. This will be so
done.

MFSL has in place the following mitigation policy future:

• Waste minimization at all levels for discharged products, empty containers,

packaging materials, uploading spillages.

• The empty drums will be recycled or given back to original vendors for

utilization.
• The process waste and residue from solvent recovery will be disposed off

CHWTSDF for treatment and ultimate disposal.

6.10 Power Requirement & Supply/ Source

Total power requirement is 400 KVA & for proposed 1250 KVA sourced from
Maharashtra State Electricity Distribution Company Limited (MSEDCL)
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Chapter 07

Rehabilitation and Resettlement (R & R Plan)

7.1 Policy to be adopted

The project site is located in MIDC area, hence there is no any kind of activity of
Rehabilitation and Resettlement envisaged.
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Chapter 08
Project Schedule & Cost Estimates
8.1 Time schedule of the Project

M/s Matrix Fine Sciences Pvt. Ltd. is existing industry in Paithan MIDC. MFSPL
has to expand their project within 12 to 15 Months after getting all relevant
permissions and clearances.

8.2 Estimated project cost

Estimated Project Cost for the project is given below
Table 8.1: Project cost

Sr. Existing Amount Proposed Amount

Fixed Assets Rs. in Lakhs
No. Rs. in Lakhs
1. Land & Land development 78.15 50.00
2. Building/Premises 421.84 400.00
3. Plant & Machinery/Equipment 1088.14 2200.00
4. Furniture & Fixture 15.39 75.00
5. Any other movable/immovable 37.85 75.00
fixed assets
Cost of total fixed assets 1641.37 2800.00

Table 8.2: Environment Management Cost

Sr. Description Capital Cost Recurring Cost per
No. (Rs. in Lakhs) annum (Rs. in Lakhs)
1. Air Pollution Control 30.0 20.0

2. Water Pollution Control 150.0 50.0

3. Environment monitoring - 4.0
and Management
4. Rain water Harvesting 5.0 5.0
5. Occupational Health - 4.0
6. Green Belt 10.0 8.0
7. Solid waste management - 3.0
8. CSR - 70.0
Total 195.0 164.0
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Chapter 09
Analysis of Proposal
9.1 Financial and Social Benefits
M/s Matrix Fine Sciences Pvt. Ltd. has created and will create direct & indirect
employment opportunities to the people residing in the surrounding area. The
management is also trying to recruit the locals by giving them in house training and
absorbing them as permanent employees. Work force is being recruited based on the
basic qualification as skilled, unskilled or semiskilled.
The existing project along with the proposed expansion will also help to generate
additional revenues for the government in the form of taxes, duties and other fees. An
additional benefit of the project also includes considerable growth of the industrial
and commercial activities in the state.

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 Annexure I: Toposheet of the Study Area

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Annexure II: Project Layout

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Annexure-III: MIDC Lay-Out

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