pre feasibility report -...

PROJECT : EXPANSION AND CHANGE IN PRODUCT MIX OF EXISTING HERBAL EXTRACTS AND THEIR PURIFIED DERIVATIVES FOR MANUFACTURING OF HERBAL EXTRACTS AND ACTIVE PHARMACEUTICALS INGREDIENTS

PRE-FEASIBILITY REPORT

APPLICANT : LEPRO HERBALS PVT. LTD

DOCUMENT NO.: EESPL/LHPL/008/EC/Ind./2018-19/431

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

APRIL’2018 30

PRE – FEASIBILITY REPORT






APRIL’2018 31

INDEX

1.1 EXECUTIVE SUMMARY ......................................................................................................................... 34

1.2 SALIENT FEATURES OF THE PROJECT ............................................................................................ 34

1.3 PROPOSED PLANNING ......................................................................................................................... 40

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION .................................... 41

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................................... 41

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT .................................................................. 42

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION . 42

2.4 DEMAND - SUPPLY GAP ....................................................................................................................... 42

2.5 IMPORTS VS. INDIGENOUS PRODUCTION ..................................................................................... 43

2.6 EXPORT POSSIBILITY ........................................................................................................................... 43

2.7 DOMESTIC/ EXPORT MARKETS ........................................................................................................ 43

2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT .............. 43

2.8.1 DIRECT EMPLOYMENT ....................................................................................................................................... 43

2.8.2 INDIRECT EMPLOYMENT ................................................................................................................................. 43

3.0 PROJECT DESCRIPTION ....................................................................................................................... 44

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF

ANY. ............................................................................................................................................................ 44

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT

BOUNDARY AND PROJECT SITE LAYOUT) WITH COORDINATES. ........................................ 44

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE

PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GIVEN

INTO SHOULD BE HIGHLIGHTED. .................................................................................................... 44

3.4 SIZE OR MAGNITUDE OF OPERATION ............................................................................................ 44

3.5 RAW MATERIAL (Quantity and Source), PRODUCT AND MODE OF TRANSPORT ............ 45

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR

THEIR MANAGEMENT/ DISPOSAL. ............................................................................................... 179

3.9.1 SOLID ....................................................................................................................................................................... 179

3.9.2 WASTE WATER.................................................................................................................................................... 180

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE

INFORMATION OF EIA PURPOSE ................................................................................................... 188

4.0 SITE ANALYSIS ..................................................................................................................................... 189

4.1 CONNECTIVITY .................................................................................................................................... 189

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP .................................................................... 189

4.2.1 LANDFORM ........................................................................................................................................................... 189






APRIL’2018 32

4.2.2 LAND USE ............................................................................................................................................................... 189

4.2.3 LAND OWNERSHIP ............................................................................................................................................ 189

4.3 TOPOGRAPHY (ALONG WITH MAP) ........................................................................................................ 190

4.4 EXISTING LAND USE PATTERN .. ................................................................................................... 190

4.5 EXISTING INFRASTRUCTURE ......................................................................................................... 190

4.5.1 BASIC AMENITIES ............................................................................................................................................. 191

4.6 SOIL CLASSIFICATION ....................................................................................................................... 191

4.7 CLIMATE ................................................................................................................................................ 191

4.8 SOCIAL INFRASTRUCTURE AVAILABLE ...................................................................................... 191

5.0 PLANNING BRIEF ................................................................................................................................ 191

5.1 PLANNING CONCEPT .. ....................................................................................................................... 191

5.2 POPULATION PROJECTION ............................................................................................................. 192

5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC.) ................................. 192

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ....................... 193

5.5 AMENITIES/ FACILITIES ................................................................................................................... 193

6.0 PROPOSED INFRASTRUCTURE ...................................................................................................... 193

6.1 INDUSTRIAL AREA (PROCESSING AREA) ................................................................................... 193

6.2 RESIDENTIAL AREA (NON PROCESSING AREA) ............................................................................... 193

6.3 GREEN BELT ......................................................................................................................................... 193

6.4 SOCIAL INFRASTRUCTURE .............................................................................................................. 193

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/ METRO/WATER

WAYS ETC.) ........................................................................................................................................... 194

6.6 DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OF WATER) ......................... 194

6.7 SEWERAGE SYSTEM ........................................................................................................................... 194

6.8 INDUSTRIAL WASTE MANAGEMENT ........................................................................................... 194

6.9 SOLID WASTE MANAGEMENT ........................................................................................................ 194

6.10 POWER REQUIREMENT AND SUPPLY/ SOURCE ...................................................................... 194

7.0 REHABILITATION AND RESETTLEMENT (R & R PLAN) ........................................................ 194

7.1 POLICY TO BE ADOPTED .................................................................................................................. 194

8.0 PROJECT SCHEDULE AND COST ESTIMATES ............................................................................. 195

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION . .. 195

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC

VIABILITY OF THE PROJECT. .......................................................................................................... 195

9.0 ANALYSIS OF PROPOSAL .................................................................................................................. 195






APRIL’2018 33

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFITS TO

THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA. ........... 195

10.0 CONCLUSION......................................................................................................................................... 181






APRIL’2018 34

1.0 EXECUTIVE SUMMARY

1.1 EXECUTIVE SUMMARY

Lepro Herbals Private Limited was incorporated on 17th November 1991 and was set up on

17.04.1992 under the Companies Act 1956 and has been synonymous to Herbal Extracts

and their Purified derivatives in India located at Village - Jattipur, GT Road, Tehsil –

Samalkha, District - Panipat, Haryana.

The proposed expansion and change in product mix is for production capacity from

120kg/day to tune of 141kg/day. The total land area acquired by the unit is 33,254Sq.m.

The conversion of land for the industrial land use (CLU) has been done from Senior Town

Planner, Rohtak vide letter no.-Memo no. STP(R)/P.R.-I(3/5823 dated 29.11.2010. Copy is

enclosed as Annexure- XIII

The existing capital investment till 31.03.2017 is 3,537.98 Lacs by Lepro Herbals Pvt. Ltd.

The proposed expansion is expected to be to the tune of 870.00 Lacs in a phased manner

over a period of 5 years. Total project cost after expansion is 4407.98Lacs.

The existing products Herbal Extract & Its purified derivatives do not attract EIA Notification

2006 and its subsequent amendments thereafter as the products are simple herbal extract

and does not involve any synthesis. Now the expansion phase proposes semi synthesis in a

few products which attract the EIA Notification.

As per EIA Notification, published in Gazette of India, Extraordinary Part-II, Section-3, sub-

section (ii) of Ministry of Environment & Forest dated 14.09.2006 & subsequent

amendments, the proposed expansion and change in product mix of existing herbal extracts

and their purified derivatives for manufacturing of herbal extracts and active

pharmaceuticals ingredients falls in Activity 5(f), Category-A of “List of Projects or Activities

Requiring Prior Environmental Clearance”. As per the above notification, project will have to

obtain environmental clearance from MOEF&CC as the project falls on non notified

industrial plot with land is duly converted for industrial use.

1.2 SALIENT FEATURES OF THE PROJECT

Particulars Details

Coordinates NW NE

Latitude 290 17’57.22” N Latitude 290 17’57.16” N

Longitude 76 059’53.70” E Longitude 76 0 59’58.49” E

SE SW


Longitude 77 00’1.34” E Longitude 76 059’44.14” E






APRIL’2018 35

Toposheet No. 53C/15, 53G/3

Existing Production

Capacity

PURE HERBAL PRODUCTS MANUFACTURED IN THE FACTORY

S.

No

Product Raw Material

( Herb)

Annual

Quantity of

Herb used for

Extraction

( Tons )

Quantity of Final

Product

(Kg/Annum )

1. Boswellia

Seratta Extract Boswelia Gum

10 1000

2. Sambrani

Extract 1000

3. Coleus 97% Coleus Roots 80 200

4.

Selina Extract

Japanese

Atractylodes 60

200

5. Andographolide Kalmeg 5 100

6.

Anogessius

Anogessius

Seeds 3

200

7. Passiflora

Extract

Passiflora

Leaves 5

1000

8. Titrated Extract

of Centella

Centella

Leaves 250

4000

9. Valerian

Officinalis

Extract

Valerian Roots

13

4000

10. 18 Beta

Glyhetitinic Acid

Glycrrihizia

Glabra

50 500

11. Enoxolone 400 4000

12. De

Glycrrhizinated

Liquorice ( DGL

)

40

1000

13. Di Potassium

Glycrrhizinate

( DPG )

10

1000

14. Ammonium

Glycrrhizinate 74

2500






APRIL’2018 36

( MAG )

15. Acetyl

Glycrrhitinic

Acid (AGA)

550

-

8500

16. Glabradin ( 20

% ) 500

17. Glabradin ( 40

% )

18. Glabradin ( 60

% )

19. Glabradin ( 97

% )

20. Gingerol Ginger Roots 2 200

21. Escin Horse Chest

Nut

125 2500

22. Horse Chest Nut

Extract 4

500

23. Nutmeglignum Nutmeg Seeds 8 300

24.

Ruscogenin

Butchers

Broom 20

100

25. Euphorbia

Prostrata

Ethanolic dry

Extract

Euphorbia

Prostrata 30

1000

26. Humulus

Lupulus

Humulus

lupulus 0.5

100

27. Hydro tyrasol Olive leaves 6.5 100

28. Policosanol Sugar can

wax(Mud) 1

100

29. Tobacco

Absolute

Tobacco

absolute crude -

200

Total 1747 34,800

Proposed production

Capacity

PURE HERBAL PRODUCTS TO BE MANUFACTURED IN THE FACTORY

S.

No


( Herb)

Annual

Quantity of

Herb used for

Extraction (

Quantity of Final

Product

(Kg/Annum )






APRIL’2018 37

Tons )

1. Turmeric Extact Turmeric

Roots 2 500

2. Pomegranate

Extract

Pomegranate

Peels 2 500

3. Grape Seed

Extract

Grape Seeds 2 400

4. Nicotine Tobacco Dust 125 1000

5. Nicotine

Polacrilex

0 500

6. Pygeum Extract Prunus

Africana 20 100

7. Milk Thistle

Extract

Cardace Seeds 10 500

8. Red Clover

Extract

Red Clover 2 200

9. Nicotine Di

Hydrate Di

Tartrate

Tobacco Dust

0 500

10. TOTAL 163 4200

SEMI SYNTHETIC PRODUCTS PROPOSED TO BE MANUFACTURED IN THE

FACTORY

1. Hyoscine Butyl

Bromide

Dubosia

Leaves

In house

800

2. Hyoscine

Hydrobromide 100

3. Hyoscamine

Sulfate 50

4. Atropine Sulfate 700

5. Cimetropium

Bromide 50

6. Met

Scopolamine

Bromide 100

7. Homa Tropine

Methyl Bromide

Tropine 1

100






APRIL’2018 38

8. Reserpine Rauwolfia

Vomitoria 30

100

Total 31 2000

Estimated project cost Project Cost Amount (In Lacs)

Existing 3,537.98

Proposed 870.00 (Expansion)

Total 4407.98

Man Power Man Power in

Nos

Existing Proposed

198 34 (Expansion)

Total 232

Elevation Highest –237MSL; Lowest 232MSL.

Land use S.No Particulars Exiting

Area

(SQM)

Proposed

Area

(SQM)

Total

Area

(SQM)

Percentage

(%)

1 Buildings / Office /

Warehouses /QC/R&D /

Workshop/ DG Room

/Manufacturing

plants/ETP/RO

Plant/Boiler

18163 1400 19,563 58.83

2 Paved area/

Roads/corridors/parking

4569 301 4,870 14.64

3 Green belt 6700 -- 6,700 20.15

4 Open area 3822 -1701 2,121 6.38

TOTAL 33,254 -- 33,254 100%

Nearest Habitation/

Town

Jattipur-500m (E)

Nearest Airport Delhi International Airport –81.50 Km, S

Nearest Highway S. No. Particulars Connectivity Distance (m) Direction

(From Project Boundary)

1. NH-1 20m W S

2. SH-16 7.15 Km NW SW

Source: All distances are taken with respect to Google Earth.

Nearest railway track

from project boundary

Railway station - 2.59 Km, NNW

Power supply The unit has a total connected load of 810 kVA which is being supplied Haryana






APRIL’2018 39

State Electricity Board

Existing D.G. Sets

500 kVA (3 Nos)

320 kVA (1No)

Proposed DG Set

No additional DG set is proposed.

Nearest Dispensary and

Govt. Hospital

Govt. Dispensary, Jattipur-632m E

Nearest Educational

facility

Govt. School Jattipur -645m E

Water demand ,supply

and Waste water

generation after

expansion with product

mix

Description Water

Consumption

KLD

Waste Water

Generation (KLD)

Effluent Treatment

& disposal facility

Domestic use

Domestic 9 6 To STP (Cap.15KLD)

Industrial Use

Process 18 16 To ETP (Cap.35KLD)

followed by ZLD

Cooling tower 43 (15 KL Fresh

make up water

+ 28 KL treated

water)

5 To ETP followed by

RO for further use in

process

Boiler 30 4

RO reject 8 4 For flushing after

treatment

4 To ETP followed by

RO for further use in

cooling tower.

Horticulture /

Green Area

Development

10 --

Fresh Water

Demand

80

Recycled water 28

Total water

consumption

108

Source: Existing bore well.






APRIL’2018 40

Nearest tourist places None within the 10 km radius of the project site

Defense installations None within the 10 km radius of the project site

Archeological Features None within the 10 km radius of the project site

Ecological sensitive

zones

None within the 10 km radius of the project site

Nearest Forests None within the 10 km radius of the project site

Nearest streams/

rivers/ water bodies

(from project

boundary) Source: All distances are taken with respect to Google Earth.

S. No. Particulars Distance (Km) Direction


1. Western Yamuna canal 3.7 W

Seismic zone As per the 2002 Bureau of Indian Standards (BIS) seismic zone map of India, the

region comes under Zone-III. This zone is called the Moderate Zone and covers

areas liable to MSK VIII.

1.3 PROPOSED PLANNING

Company : Lepro Herbals Pvt. Ltd.

Project Cost : Rs. 870.0Lacs

Production : As given below:-

PURE HERBAL PRODUCTS TO BE MANUFACTURED IN THE FACTORY

S.

No


( Herb)

Annual Quantity of Herb

used for Extraction

( Tons )

Quantity of Final

Product

(Kg/Annum )

1. Turmeric Extact Turmeric Roots 2 500

2. Pomegranate Extract Pomegranate

Peels 2 500

3. Grape Seed Extract Grape Seeds 2 400

4. Nicotine Tobacco Dust 125 1000

5. Nicotine Polacrilex 0 500

6. Pygeum Extract Prunus Africana 20 100

7. Milk Thistle Extract Cardace Seeds 10 500

8. Red Clover Extract Red Clover 2 200

9. Nicotine Di Hydrate Di

Tartrate

Tobacco Dust 0 500

10. TOTAL 163 4200






APRIL’2018 41

SEMI SYNTHETIC PRODUCTS PROPOSED TO BE MANUFACTURED IN THE FACTORY

1. Hyoscine Butyl Bromide Dubosia Leaves

In house

800

2. Hyoscine Hydrobromide 100

3. Hyoscamine Sulfate 50

4. Atropine Sulfate 700

5. Cimetropium Bromide 50

6. Met Scopolamine

Bromide 100

7. Homa Tropine Methyl

Bromide

Tropine 1

100

8. Reserpine Rauwolfia

Vomitoria 30

100

Total 31 2000

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Lepro Herbals Private Limited was incorporated on 17th November 1991 and was set up on

17.04.1992 under the Companies Act 1956 and has been synonymous to Herbal Extracts

and their Purified derivatives in India located at Village - Jattipur, GT Road, Tehsil –

Samalkha, District - Panipat, Haryana.

The proposed expansion and change in product mix is for production capacity from

9MT/day to tune of 36MT/day. The total land area acquired by the unit is 33,158Sq.m. The

conversion of land for the industrial land use (CLU) has been done from Senior Town

Planner, Rohtak vide letter no.-Memo no. STP(R)/P.R.-I(3/5823 dated 29.11.2010. Copy is

enclosed as Annexure- XIII

The existing capital investment till 31.03.2017 is 3,537.98 Lacs by Lepro Herbals Pvt. Ltd.

The proposed expansion is expected to be to the tune of 870.00 Lacs in a phased manner

over a period of 5 years. Total project cost after expansion is 4407.98Lacs.

Name and address of

the Applicant

Lepro Herbals Pvt. Ltd.

Authorized Signatory

Sunil Malik

Vice –President Supply Chain management

G.T. road, Village - Jattipur, Tehsil - Samalkha, District- Panipat, Haryana - 132 101






APRIL’2018 42

2.2 NATURE OF THE PROJECT

Lepro Herbals Private Limited, Panipat, Haryana proposes expansion and change in the

product mix for manufacturing of herbal extracts and active pharmaceuticals ingredients.

The proposed expansion with change in product mix is planned in existing plant area of 33,

254Sq.m. No additional land is required.

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION

India is a developing country with varied geographical locations resulting in climate change.

Changing climate and changing lifestyles of people globally is resulting in many varied types

of diseases and disorders which is effecting people globally. Throat infection), asthma, and

lifestyle diseases like Cholesterol, Heart diseases, constipation, diabetes etc are very

common phenomena. Few other reasons like stored water, uncovered litter, dirty places,

unhealthy living habits, unhealthy eating habits, pollution, water contamination and more

require medicines. Thus, the proposed production contributes in prevention, cure and

recovery of ailments and diseases. Drug manufacturing units produces lifesaving drugs

which helps the patients recover faster and result in no medicinal side effects. Phyto APIs

are a preferred option for varied ailments as they are plant extracts and have no Toxic effect

and are regarded SAFE.

2.4 DEMAND - SUPPLY GAP

By 2050, it is expected that India will be the most populous country with an estimated

population of 1.6 billion. By 2025, it is being viewed that 189 million Indians will be 60 or

older up from about 63 million in year 2004. This projection indicates the demand for

pharmaceutical drugs will rise in coming years.

Herbal Extract & their Purified Derivatives, Bulk Drugs & its Intermediates will be

manufactured largely comprising of anticancer, anti-parasitic, anti-inflammatory, laxatives &

pain reliever drugs. Treatment of various regular and life style diseases like chronic disease,

acute pain, congestive heart failure, type 2 diabetes, constipation, osteoarthritis, and

management of hypertension.

The industry is working in the field of Herbal Extract and their Purified Derivatives to fulfill

the ever increasing international demand of “safe“medicines.






APRIL’2018 43

2.5 IMPORTS VS. INDIGENOUS PRODUCTION

There will be Indigenous production in the entire activity. As most of the products are herbal

and majority of all the raw material demand is being met from domestic market only but few

specific herbs is being imported owing to specific geographic locations.

The pharmaceutical industry in India meets around 70% of the country's demand for bulk

drugs, drug intermediates, pharmaceutical formulations, chemicals, tablets, capsules, orals

and injectable.

2.6 EXPORT POSSIBILITY

The product is prospecting exports.

2.7 DOMESTIC/ EXPORT MARKETS

Indian drug industry is well developed for the manufacture of many bulk drugs. At present

India is self sufficient and technologically at par with the best in the world. Indian pharma

industry is unit wise small and in fact many units are in small scale sector. Almost 55% of

the domestic production is contributed by small scale units. Production during 1990-91 was

reported to be 750 tons.

2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT

2.8.1 DIRECT EMPLOYMENT

Presently the work force of this unit is 198. Highly qualified and trained manpower is

required for running operations in the plant which are already available. Regular trainings

are imparted to personnel to keep them updated with the requirements of process. An

increase of 34 manpower is proposed with the expansion in a phased manner.

2.8.2 INDIRECT EMPLOYMENT

Increase in supporting industries such as packaging, printing etc.

Increase in Supply chain

Increase in Distribution Channel both- National and International

Carrier goods

Government of India Taxes

Minor increase in telecommunication, couriers etc.






APRIL’2018 44

3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF

ANY.

No interlinked project. Proposed expansion and change of product mix is planned from

120kg/day to 141kg/Day in area of 33, 254Sq.m. Sq.m. in existing plant premises. No

additional land is required.

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT

BOUNDARY AND PROJECT SITE LAYOUT) WITH COORDINATES.

It is located at G.T. Road, Village- Jattipur, Tehsil Samalkha, District- Panipat, Haryana. The

project site falls in Survey of India Toposheet No. 53C/15, 53G/3..

The geographical location with respect to boundary pillars of the project are:-

Table 2: Geographical Position of the Boundary Pillars

NW NE


Longitude 76 059’53.70” E Longitude 76 0 59’58.49” E

SE SW


Longitude 77 00’1.34” E Longitude 76 059’44.14” E

The map showing location of the project site is enclosed as Annexure – XII.

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE

PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GIVEN

INTO SHOULD BE HIGHLIGHTED.

No alternative site was examined as the proposed expansion and change in product mix is

coming within the existing premises.

3.4 SIZE OR MAGNITUDE OF OPERATION

The size and magnitude of the project area is as given below:-

Table 3: Size or Magnitude

S. No. Particulars Details

1. Area 33,254 Sq.m.

2. Production (After expansion and

change in product mix)

The proposed production capacity is 141kg/day

3. Total Man Power (Nos.) 232Nos.( Existing -198, Proposed -34)






APRIL’2018 45

3.5 RAW MATERIAL (Quantity and Source), PRODUCT AND MODE OF TRANSPORT

RAW MATERIAL SOURCING AND STORAGE

Lepro Herbals dependence on agriculture and its produce is complete and total. All the

products of the company which command sustained high demand are produced from

agriculture and herbs. The raw materials /starting herbs used in the extraction and

production of the above listed extracts under reference and report are to be sourced

indigenously from various parts of the country as these harmonize topographically and

geographically.

The unit has 3 very large warehouses located on the premises which are used for the storage

of herbs. Being an agricultural produce with specific time of sourcing, the storage gains even

more importance for continuous supply of end product to the market.

WHO- GOOD MANUFACTURING PRACTICES and their standard protocols for WAREHOUSING

are adhered to focused heavily of safety and pest free storage.

MANUFACTURING PROCESS AND MATERIAL BALANCE OF THE COMPANYS PRODUCTS

The standardized extraction and purification process is detailed below in a flow chart with

option for minor variations which would be product specific. As it has been specified in the

point No 1.7 where all the products manufactured have been listed. The manufacturing

process and material balance with Raw Material details are appended below in detail.

A. PURE HERBAL PRODUCTS MANUFACTURED IN THE FACTORY

1. Boswellia Extract

Boswellia serrata (gum)

RRRRRRRRRRROOTroots

Extraction

Boswellia Extract

Molecular Formula: C30H46O4

Molecular Weight: 470.68

MOLECULAR WEIGHT

Boswellia Extract


Molecular Weight: 512.731 g/mol

MOLECULAR WEIGHT

https://pubchem.ncbi.nlm.nih.gov/search/#collection=compounds&query_type=mf&query=C32H48O5&sort=mw&sort_dir=asc






APRIL’2018 46

Brief description of the manufacturing process:

Boswellia extract is produced by extraction from Boswellia serrata gum. The extract has been

further purified by Phase exchange to give Boswellia extract.

List of Raw Materials:

Name of Raw Material Storage at the site

Boswellia serrata gum Warehouse

MDC Solvent Storage Tanks

Methanol Solvent Storage Tanks

Caustic potash Store

Hydro Chloric acid Solvent Storage Tanks

MATERIAL BALANCES SHEETS FOR BOSWELLIA EXTRACT

STAGE-1, STAGE-2

S. No. Raw Material Input/Kg of Product (Kg)

1 Boswellia serrata gum 800

2 Methanol 12000

Total: 12800

Sr. No. Output/Kg of product (Kg) Total

Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Methanol Concentrated syrup - - 400 0 400

2 Methanol - 60 11540 - 11600

3 Exhaust herb - - - 800 800

4 Third party mixed solvent - - - -

Total: - - - - 12800

STAGE-3 & STAGE-4

Sr. No. Raw Material Input/Kg of Product (Kg)

1 Methanol Concentrated syrup 400

2 Caustic potash 50

3 Water 1000

6 MDC 2400

Total: 3850

Sr. No. Output/Kg of product(Kg) Total

Product Liquid

effluent

Air

Emission

Recovery Solid

Waste






APRIL’2018 47

1 Aqueous layer of material - 1200 0 1200

2 MDC residue - - - 250 250

3 MDC - 50 2350 - 2400

4 Water - - - - -

5 Third party mixed solvent - - - - -

Total: - 3850

STAGE-5 & STAGE-6

Sr. No. Raw Material Input/Kg of Product(Kg)


2 HCl 75

3 MDC 2660

4 Methanol 480

Total: 4415


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Boswellia Extract - 150 0 150

2 MDC - 50 2610 - 2660

3 Methanol - 30 450 - 480

4 Exhaust aqueous layer 1125 - - - 1125


Total: - 4415






APRIL’2018 48

Figure – 1: Raw Material, Material Balance and process flow chart of Boswellia Extract






APRIL’2018 49

2. Sumbrani Extract


Sambrani extract is produced by extraction from Boswellia serrata gum. The extract has been

further purified by Phase exchange to give Sambrani extract.



1. Boswellia serrata gum Warehouse

2. MDC Solvent Storage Tanks

3. Methanol Solvent Storage Tanks

4. Caustic potash Store

5. Hydro Chloric acid Solvent Storage Tanks

MATERIAL BALANCES SHEETS FOR SAMBRANI EXTRACT:

STAGE-1, STAGE-2


1 Boswellia serrata gum 800

2 Methanol 12000

Total: 12800


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Methanol Concentrated syrup - - 400 0 400

2 Methanol - 60 11540 - 11600

Boswellia serrata (gum)

RRRRRRRRRRROOTroots

Extraction

Sambrani Extract



MOLECULAR WEIGHT

Sambrani Extract



MOLECULAR WEIGHT







APRIL’2018 50

3 Exhaust herb - - - 800 800


Total: - - - - 12800

STAGE-3 & STAGE-4



2 Caustic potash 50

3 Water 1000

6 MDC 2400

Total: 3850


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Aqueous layer of material - 1200 0 1200

2 MDC residue - - - 250 250

3 MDC - 50 2350 - 2400

4 Water - - - - -


Total: - 3850

STAGE-5 & STAGE-6



2 HCl 75

3 MDC 2660

4 Methanol 480

Total: 4415


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Sumbrani Extract - 150 0 150

2 MDC - 50 2610 - 2660

3 Methanol - 30 450 - 480







APRIL’2018 51


Total: - 4415

Figure – 2: Raw Material, Material Balance and process flow chart of Sumbrani Extract






APRIL’2018 52

3. Coleus 97%


Coleus Extract is extracted from coleus roots and is further undergo concentration, phase

exchange, lixivation, 1st Toluene lixivation , Column Purification ,2ND toluene lixivation,

Purification & lixivation and final column purification and crystallization to give coleus

extract 97%.


Name of Raw Material Source Storage at the site

6. Coleus roots Warehouse

7. Methanol B.K.Sales Solvent Storage Tanks

8. Water In House Water system

9. Methylene chloride B.K.Sales Solvent Storage Tanks

10. Hexane Pon pore Warehouse

11. Toluene Pon pore Warehouse

12. Activated alumina Real Chemsys Warehouse

13. Ethyl acetate Jubliant life sciences Warehouse

14. Chloroform B.K.Sales Solvent Storage Tanks

MATERIAL BALANCES SHEETS FOR COLEUS EXTRACT

STAGE - 1 & 2

S. No. Raw Material Input/Kg of Product(Kg)

1 Coleus roots 10000

2 Methanol 76800

COLEUS FORSKLII ROOTS Extraction

COLEUS EXTRACT AS FORSKOLIN Molecular Formula: C22H34O7







APRIL’2018 53

Total: 86800


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Coleus syrup - - 5000 - 5000

2 Exhaust Herbs - - - 10000 10000

3 Third party mixed

solvent

4800

67000

71800

Total: 86,800

STAGE - 3


1 Coleus syrup 5000

2 water 1000

3 Methylene Chloride 11704

Total: 17704


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 concentrated

syrup

- - 700 - 700

2 Aq. Layer 5300 - - 0 5300

3 Third party mixed

solvent

1064

10640

11704

Total: 17,704

STAGE - 04-06


1 concentrated syrup 700

2 Hexane 693

3 Toluene 430

Total: 1823


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Dry material - - 100 600 700

2 Hexane 64 629 0 693

3 Toluene 29 401 430






APRIL’2018 54

3 Third party mixed

solvent

0 0

0

Total: 1,823

STAGE - 07-09


1 Dry material 100

2 Activated alumina 450

2 Ethyl acetate 5400

3 Toluene 129

Total: 6079


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Dry material - - 35 65 100

2 Ethyl acetate 50 5350 0 5400

3 Toluene 13 116 129

4 Activated alumina 450 450

5 Third party mixed

solvent

0 0

0

Total: 6,079

STAGE - 10-13


1 Dry material 35

2 Activated alumina 100


4 Hexane 726

5 chloroform 1350

Total: 3471


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Dry material

(Final)

- - 25 10 35

2 Ethyl acetate 60 1200 0 1260

3 Chloroform 40 1310 1350

4 Hexane 50 676 726






APRIL’2018 55

5 Activated alumina 100 100

6 Third party mixed

solvent

0 0

0

Total: 3,471

Figure – 3: Raw Material, Material Balance and process flow chart of Coleus 97%






APRIL’2018 56

4. Selina Extract


Selina Extract is extracted from the Japanese Atractylodes roots and is further purified through

Phase Exchange, Column Chromatography and Purification.



Japanese Atractylodes Namyana Herb Warehouse

Methanol B. K. Sales corporation Solvent Storage Tanks

Hexane V.S. Interchem Pvt Ltd Solvent Storage Tanks

Ethyl acetate Jubilant life sciences Ltd Solvent Storage Tanks

Silica gel (200-400) Swambe chemicals Warehouse

MATERIAL BALANCES SHEETS FOR SELINA EXTRACT:

STAGE-1


1 Japanese Atractylodes roots 10000

2 Methanol 100000

Total: 110000


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Concentrate Syrup - - 4800 - 4800

2 Exhaust Herb - - - 10000 10000

3 Methanol - 100 95100 - 95200

Total: - 110000

Japanese Atractylodes Roots

Selina Extract Molecular Formula: C15H22O


Extraction & Purification






APRIL’2018 57

STAGE-2


1 Concentrate Syrup 4800

2 Hexane 7920

Total: 12720


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Syrup 4080 - 720 - 4800

2 Hexane - 92 7828 - 7920

Total: - 12720

STAGE-3


1 Syrup 720

2 Hexane 7920

3 Ethyl acetate 300

Total: 8940


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Syrup 510 - 210 - 720

2 Hexane - 92 7828 - 7920

3 Ethyl acetate - 50 250 - 300

Total: - 8940

STAGE-4


1 Syrup 210

2 Hexane 19800

3 Ethyl acetate 500

4 Silica Gel(200-400) 400

Total: 20910


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Syrup 150 - 60 - 210






APRIL’2018 58

2 Hexane - 100 19700 - 19800


4 Silica Gel(200-400) - - - 400 400

Total: 20910

STAGE-5


1 Syrup 60

Total: 60


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Selina Extract 28 32 - 60

Total: 28 32 - 60






APRIL’2018 59

Figure – 4: Raw Material, Material Balance and process flow chart of Selina Extract






APRIL’2018 60

5. Andographolide


Andrographolide is extracted from the leaves of Kalmegh and is further purified through

Lixiviation.



Kalmegh leaves - Warehouse

Ethyl Acetate Jubilant life sciences Ltd Solvent Storage Tanks


Denatured Spirit Ashoka distillery Solvent Storage Tanks

MATERIAL BALANCES SHEETS FOR ANDROGRAPHOLIDE:

STAGE-1 & STAGE-2


1 Kalmegh Leaves 600

2 Ethyl Acetate 5000

Total: 5600


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste


2 Exhaust Herb - - - 600 600

3 Ethyl Acetate - 60 4900 - 4960

Total: - 5600

Kalmegh leaves Extraction & Lixiviation

Andrographolide








APRIL’2018 61

STAGE-3


1 Concentrate syrup 40

2 Hexane 300

Total: 340


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Material 25 - 15 - 40

2 Hexane - 25 275 - 300

Total: - 340

STAGE-4


1 Material 15

2 Denatured Sprit 300

3 Decamax 5

Total: 320


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Andrographolide - - 13 7 20

2 Denatured Spirit - 25 275 - 300

Total: - 20 293 7 320






APRIL’2018 62

Figure – 5: Raw Material, Material Balance and process flow chart of Andographolide






APRIL’2018 63

6. Anogeissus


Anogeissus is produced by extraction from Anogeissus Leiocarpus bark. The extract has been

further purified by Column purification to give Anogeissus.



Anogeissus Leiocarpus bark Warehouse


Silica gel Store

Ethyl acetate Solvent Storage Tanks

MATERIAL BALANCES SHEETS FOR ANOGEISSUS:

STAGE-1


1 Anogeissus Leocarpus bark 800

2 Methanol 19200

Total: 20000


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Concentrated syrup - - 320 0 320

2 Methanol - 100 18780 - 18880

3

Exhaust herb - - 800 800

Anogeissus Leocarpus bark

RRRRRRRRRRROOTroots

Extraction

Anogeissus

Molecular Formula: Molecular Weight:

MOLECULAR WEIGHT






APRIL’2018 64

Total: - 20000

STAGE-2


1 Concentrated syrup 320

2 Silica gel 700

3 Methanol 4500


Total: 23520


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Anogeissuse - 64 0 64

2 Methanol - 50 4450 0 4500

3 Ethyl acetate - 100 17900 - 18000

4 Solid waste - 956 956

Total: - 23520






APRIL’2018 65

Figure – 6: Raw Material, Material Balance and process flow chart of Anogeissus

7. Passiflora Extract

Passiflora leaves Extraction

Passion Flower dry extract (Active ingredients Isobitexin) Molecular Formula: C21H20O10







APRIL’2018 66


Passion Flower dry extract is extracted from the Passiflora Leaves and is standardized with

maltodextin



Passiflora Leaves V.R Pusalkar Warehouse

Acetone V.S.Interchem pvt Ltd Solvent Storage Tanks

Hexane V.S.Interchem pvt Ltd Solvent Storage Tanks

Maltodextin Aristio chemicals Warehouse

Silicon dioxide BS Mehra & Sons Warehouse

MATERIAL BALANCES SHEETS FOR PASSION FLORA DRY EXTRACT

STAGE-1 & STAGE-2


1 Passiflora Leaves 1800

2 Methanol 20000

Total: 21800


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Concentrate syrup -- -- 300 -- 300

2 Husk -- -- -- 1800 1800

3 Acetone 100 19600 -- 19700

Total: 21800

STAGE-3 & STAGE-4



2 Hexane 600

Total: 900


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Syrup 150 -- 150 -- 300

2 Hexane -- 50 550 -- 600

Total: 900






APRIL’2018 67

STAGE-5 & STAGE-6


1 Syrup 150

2 Maltodextin 150

3 Silicon dioxide 10

Total: 310


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Passiflora flora dry extract -- 16 294 -- 310

Total: 310

Figure – 7: Raw Material, Material Balance and process flow chart of Anogeissus






APRIL’2018 68

8. Titrated Extract of Centella


Titrated extract of Centella Asiatica is extracted from the leaves of Centella Asiatica and is

further purified through Phase Exchange & Crystallization.



Centella Asiatica Leaves Warehouse


MATERIAL BALANCES SHEETS FOR TITRATED EXTRACT OF CENTELLA ASIATICA :

STAGE-1 & STAGE-2


1 Centella Asiatica leaves 3000

2 Methanol 15680

3 Water 8400

Total: 27080


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

Centella Asiatica Leaves Extraction

Titrated extract of Centella Asiatica

Asiaticoside Molecular Formula: C48H78O19


Madecassic acid



Asiatic acid



+ +






APRIL’2018 69


2 Exhaust Herb - - - 3000 3000

3 Methanol - 80 15000 - 15080

4 Water 400 - 4600 - 5000

Total: - 27080

STAGE-3



2 Chloroform 9000

Total: 13000


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Syrup - - 4000+100

=4100

- 4100

2 Chloroform - 100 8800 - 8900

Total: 13000

STAGE-4 (For Asiaticoside)


1 Syrup 4000

2 Sodium Bicarbonate 250

3 Butanol 12000

4 Water 4800

Total: 21050


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Asiaticoside Crude 3800 - 200 - 4000

2 Sodium Bicarbonate 250 - - - 250

3 Butanol - 80 11920 - 12000

4 Water 4800 - - - 4800

Total: 21050

STAGE-5 (For Asiaticoside)







APRIL’2018 70

1 Asiaticoside Crude 200

2 Methanol 400

3 Water 500

4 HCL 3

Total: 1103


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Material - 143 900+60 - 1103

2 Methanol - - - - -

3 Water - - - - -

4 HCL - - - - -

Total: - 1103

Remarks:- 900 ltr Use for hydrolysis to produce Genin.

STAGE-5


1 Material 60

2 Methanol 720

3 Activated Carbon ICP-20 3

4 Decamax 3

5 Water 100

Total: 886


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Material 20 - 40 - 60

2 Methanol - 40 680 - 720

3 Activated Carbon ICP-20 - - - 3 3

4 Decamax - - - 3 3

5 Water - 30 70 - 100

Total: 886

STAGE-6


1 Material 40

2 Methanol 500






APRIL’2018 71


4 Decamax 3

5 Water 50

Total: 596


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Asiaticoside Pure 8 - 32 - 32

2 Methanol - 20 480 - 500


4 Decamax - - - 3 3

5 Water - 15 35 - 50

Total: 596

STAGE-7(For Genin)


1 Material taken from Stage 2 100

2 Acetone 500

3 Water 150

Total: 750


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Genin Crude 50 - 50 - 100

2 Acetone 100 40 360 - 500

3 Water 75 - 75 - 150

Total: 750

STAGE-8 (For Genin)


1 Genin Crude 50

2 Chloroform 750

3 Methanol 330

4 Water 400

5 Caustic Potash 10

6 HCL 20

Total: 1560






APRIL’2018 72


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Material 20 - 30 - 50

2 Chloroform - 75 675 - 750

3 Methanol 100 30 200 - 330

4 Water 350 50 - - 400

5 Caustic Potash 10 - - - 10

6 HCL 20 - - - 20

Total: 1560

STAGE-9 (For Genin)


1 Material 30

2 Acetone 60

3 Methanol 60

Total: 150


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Material 5 - 25 - 30

2 Acetone - 30 30 - 60

3 Methanol - 30 30 - 60

Total: 150

STAGE-10 (For Genin)


1 Material 25

2 Acetone 50

3 Methanol 200


5 Decamax 5

Total: 285


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Genin Pure 10 - 15 - 25






APRIL’2018 73

2 Acetone - 20 30 - 50

3 Methanol - 20 180 - 200


5 Decamax - - - 5 5

Total: 285

Figure – 8: Raw Material, Material Balance and process flow chart of Titrated Extract of

Centella






APRIL’2018 74

9. Valerian Officinalis Extract


Valerian Dry extract is extracted from the valerian roots.



Valerian roots VNK BV Warehouse

MDC Paras Polymer Pvt Ltd Solvent Storage Tanks

Denatured spirit Ashoka distillary Solvent Storage Tanks

Maltodextrin Aristio chemicals Pvt Ltd Warehouse

Silicon Dioxide B. S. Mehra Sons Pvt Ltd Warehouse

MATERIAL BALANCES SHEETS FOR VALERIAN DRY EXTRACT:

STAGE-1 & STAGE-2


1 Valerian Roots 650

2 Ethanol 540

3 MDC 5985

Total: 7175


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Concentrate syrup - - 45 - 45

2 Exhausted Herb - - - 650 650

3 Ethanol - 56 480 - 536

4 MDC - 85.7 5858.3 - 5931.8

Total: 7175

Valerian Roots Extraction

Valerinic acid (Valerian dry Extract) Molecular Formula: C15H22O2







APRIL’2018 75

STAGE-3



2 Maltodextrin 175

3 Silicon Dioxide 11

Total: 231


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Valerian Dry Extract 26 205 - 231

2 Maltodextrin - - - - -

3 Silicon Dioxide - - - - -

Total: - - 231

Figure – 9: Raw Material, Material Balance and process flow chart of Valerian Officinalis

Extract






APRIL’2018 76

10. 18- Beta Glyhetitinic Acid


18β Glycyrrhetinic acid is a Pentacyclic triterpenoid derivative obtained from the hydrolysis of

acetyl Glycyrrhetinic acid. It is further purified by crystallization.



Acetyl Glycyrrhetinic acid In House Intermediate Storage room


Caustic Potash Aristio chemicals Warehouse

Hydrochloric acid Chaudhary chemical industries Warehouse

Water In House Water System

Toluene Pon pure chemical India Pvt Ltd Solvent Storage Tanks

Activated Carbon Jacobi Virmani brothers Warehouse

Hyflow M/S Gem Corpochem Pvt Ltd Warehouse

MATERIAL BALANCES SHEETS FOR 18Β GLYCYRRHETINIC ACID :

STAGE-1


1 Acetyl Glycyrrhetinic acid 300

2 Methanol 2400

3 Caustic Potash 120

4 Hydrochloric acid 240

5 Water 2700

Hydrolysis

18β Glycyrrhetinic acid Molecular Formula: C30H46O4


Acetyl Glycyrrhetinic acid Molecular Formula: C32H48O5 Molecular Weight: 512






APRIL’2018 77

Total: 5760


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Crude 18β Glycyrrhetinic

acid

- - 240 60 300

2 Methanol - 80 2320 - 2400

3 Water 3060 - - - 3060

Total: 5760

STAGE-2 & 3


1 Crude 18β Glycyrrhetinic acid 240

2 Methanol 2912

3 Toluene 2476.8

4 Activated Carbon 22

5 Hyflow 9

6 Water 1800

Total: 7459.8

Sr. No. Output/Kg of product (Kg)

Total Product Liquid

effluent

Air Emission Recovery Solid

Waste

1 18β Glycyrrhetinic acid - - 195 45 240

2 Methanol - 72 2840 - 2912

3 Activated carbon +

Hyflow

- - 31 31

4 Toluene - 59.6 2417.2 - 2476.8

5 Water 1800 - - 1800

Total: 1800 131.6 5452.2 76 7459.8






APRIL’2018 78

Figure – 10: Raw Material, Material Balance and process flow chart of 18- Beta Glyhetitinic

Acid






APRIL’2018 79

11. Enoxolone


Enoxolone is a Pentacyclic triterpenoid derivative obtained from the hydrolysis of acetyl

Glycyrrhetinic acid. It is further purified by crystallization.



Acetyl Glycyrrhetinic acid In House Intermediate Storage room


Caustic Potash Aristio chemicals Warehouse



Toluene Pon pure chemical India Pvt Ltd Solvent Storage Tanks

Activated Carbon Jacobi Virmani brothers Warehouse


MATERIAL BALANCES SHEETS FOR ENOXOLONE:

STAGE-1


1 Acetyl Glycyrrhetinic acid 300

2 Methanol 2400



5 Water 2700

Hydrolysis

Enoxolone Molecular Formula: C30H46O4


Acetyl Glycyrrhetinic acid Molecular Formula: C32H48O5 Molecular Weight: 512






APRIL’2018 80

Total: 5760


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Crude Enoxolone - - 240 60 300

2 Methanol - 80 2320 - 2400

3 Water 3060 - - - 3060

Total: 5760

STAGE-2 & 3


1 Crude Enoxolone 240

2 Methanol 2912

3 Toluene 2476.8


5 Hyflow 9

6 Water 1800

Total: 7459.8

Sr. No. Output/Kg of product (Kg)

Total Product Liquid

effluent


Waste

1 Enoxlone - - 195 45 240

2 Methanol - 72 2840 - 2912


Hyflow

- - 31 31

4 Toluene - 59.6 2417.2 - 2476.8

5 Water 1800 - - 1800

Total: 1800 131.6 5452.2 76 7459.8






APRIL’2018 81

Figure – 11: Raw Material, Material Balance and process flow chart of Enoxolone






APRIL’2018 82

12. De Glycrrhizinated Liquorice ( DGL)


Glycyrrhizic acid is extracted from the Glycyrrhizia Glabra and is further undergo acidification &

basification to make De Glycyrrhizinated liquorice.



Glycyrrhizia Glabra Herbs Warehouse

Water Water System

Ammonia solution Warehouse

Simethicone Warehouse

Sulphuric acid Warehouse

MATERIAL BALANCES SHEETS FOR DE GLYCYRRHIZINATED LIQUORICE

STAGE-1 & STAGE-2


1 Glycyrrhizia Glabra 2100

2 Water 21800

3 Ammonia Solution 192

4 Simethicone 9

Total: 24,101


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1. Glycyrrhizic Acid (Syrup) - - 4000 - 4000

2. Exhaust Herbs - - - 2100 2100

3. Water 601 100 17300 - 18001

4. Third party mixed solvent

Total: 24,101

STAGE- 03-04

Glycyrrhiza Glabra Extraction

De glycyrrhinated liquorice Molecular Formula: Molecular Weight:






APRIL’2018 83


1. Glycyrrhizic Acid (Syrup) 4000

2. Sulphuric acid 160

3. water 160

4. Ammonia Solution 400

Total: 4720


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 De Glycyrrhizinated

liquorice

- - 50 1200 1250

5 Sulphuric acid - - - -- -

6 Water - - - 2900 2900

7 Third party mixed

solvent

570 - - - 570

Total: 4720






APRIL’2018 84

Figure – 12: Raw Material, Material Balance and process flow chart of De Glycrrhizinated

Liquorice ( DGL )

13. Di Potassium Glycrrhizinate ( DPG )

Mono ammonium

Glycyrrhizzinate Chemical

modification






APRIL’2018 85


Dipotassium Glycyrrhizzinate is made from the Mono ammonium Glycyrrhizzinate.



Mono ammonium

Glycyrrhizzinate

In house Warehouse

Methanol B K sales Warehouse

Potassium hydroxide Aristio chemicals Warehouse

Water In House

MATERIAL BALANCES SHEETS FOR DIPOTASSIUM GLYCYRRHIZZINATE

STAGE-1 & STAGE-2


1 Mono ammonium Glycyrrhizzinate 100

2 Methanol 520

3 Water 400

3 Potassium hydroxide 15.5

4 Carbon 10.0

5 Hyflow 10.0

Total: 1055.5


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Dipotassium Glycyrrhizzinate 100 100

2 Methanol 20 500 520

3 Water 50 350 400

4 Carbon+hyflow 35.5 35.5

Total: 1055.5

Product Dipotassium Glycyrrhizzinate

Molecular Formula ‎‎:‎ C42H60K2O16

Molecular Weight‎: 899.123 g/mol






APRIL’2018 86

Figure – 13: Raw Material, Material Balance and process flow chart of Di Potassium

Glycrrhizinate ( DPG )






APRIL’2018 87

14. Ammonium Glycrrhizinate ( MAG )


Crude Glycyrrhizic Acid is produced by extraction from Glycyrrhiza Glabra herb . The extract

has been further purified by Precipitaion to give Crude Glycyrrhizic Acid and further

crystallized to give AGBP/EP.


NAME OF RAW MATERIAL SOURCE STORAGE AT THE SITE

Glycyrrhizia Glabra Herbs Karoma Investment Pvt Ltd Warehouse


Ammonia solution Flurorides & Chemicals (India) Warehouse

Simethicone Spectrum chemiclas Warehouse


Acetic acid Jubilant life sciences Ltd Warehouse

Denatured Sprit Ashoka distillery Solvent Storage Tanks

Activated Carbon Virmani brothers Warehouse



MATERIAL BALANCES SHEETS FOR

STAGE-1 & 2


1 Glycyrrhiza Glabra herb 3250

2

METHANOL 21840

3 Water 11700

Glabra herb

RRRRRRRRRRROOTroots

Extraction

1. AMMONIUM

GLYCYRRHIZINATE

Molecular Formula: Molecular Weight:

MOLECULAR WEIGHT






APRIL’2018 88

4 Sulphuric acid 178

Total: 36968


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Precipitate - 650 -- 650

2 Methanol - 100 21740 - 21840

3

Exhaust herb - 3250 3250

4

Sulphuric acid 178 - - - 178

3 WATER - 11050 11050

Total: - 36968

STAGE-3 & 4


1 Precipitate 650

2 Ammonia solution 35

3 water 650

Total: 1335


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Dry material - 385 0 385

2 Water 915 - 915

3 Ammonia - 35 - 35

Total: - - 1335

STAGE-5


1 Dry Material 385

2 Acetic acid 346.5

3 Methanol 105.6






APRIL’2018 89

Total: 837.10


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Dry Crude material 305.8 - 79.2 0 385

2 Acetic acid 346.5 - - - 346.5

3 Methanol 52.8 - 52.8 - 105.6

Total: 705.1 132 - 837.10

STAGE-6


1 Dry Crude Material 79.2

2 Ethanol 858

3 Carbon 8.8

4 Hyflow 4.4

Total: 950.4


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Final material 35.2 - 44 0 79.2

2 Ethanol - 32 826 - 858

3 Carbon - - - 8.8 8.8

4 Hyflow - - - 4.4 4.4

Total: 35.2 132 770 13.2 950.4






APRIL’2018 90

Figure – 14: Raw Material, Material Balance and process flow chart of Ammonium

Glycrrhizinate ( MAG )






APRIL’2018 91

15. Acetyl Glycrrhitinic Acid (AGA)


Glycyrrhizic acid is extracted from the Glycyrrhizia Glabra and is further undergo Hydrolysis,

Acetylation, Toluene Methanol Treatment & methanol treatment to make Acetyl Glycyrrhetinic

Acid.



Glycyrrhizia Glabra Herbs Karoma Investment Pvt Ltd Warehouse


Ammonia solution Flurorides & Chemicals (India) Warehouse

Simethicone Spectrum chemiclas Warehouse


Acetic acid Jubilant life sciences Ltd Warehouse

Sulphuric acid Chaudhary chemical industries Warehouse

Chloroform B. K. Sales corporation Solvent Storage Tanks

Toluene Pon pure chemical India Pvt Ltd Warehouse


MATERIAL BALANCES SHEETS FOR ACETYL GLYCYRRHETINIC ACID

STAGE-1 & STAGE-2


1 Glycyrrhizia Glabra 2250

2 Water 21800

3 Ammonia Solution 192

Glycyrrhiza glabra roots Extraction

ACETYL GLYCYRRHETINIC ACID Molecular Formula: C32H48O5







APRIL’2018 92

4 Simethicone 9.00

Total: 24,251


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1. Glycyrrhizic Acid (Syrup) - - 4000 - 4000

2. Exhaust Herbs - - - 2250 2250

3. Water - 17400 - 17400

4. Third party mixed solvent 601 601

Total: 601 21400 2250 24,251

STAGE- 03-04


1. Glycyrrhizic Acid (Syrup) 4000

2. Hydrochloric acid 650

3. Acetic acid 228

4. Sulphuric acid 57

5. chloroform 2595

6. Water 2600

Total: 10130


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 AGA CRUDE - - 91 109 200

2 Chloroform - 65 2530 - 2595

3 Hydrochloric acid 650 - - - 650

4 Acetic acid 228 - - - 228

5 Sulphuric acid 57 - - 57

6 Water 6400 - - - 6400


Total: 7335 65 2621 109 10130

STAGE-

05-07


1 AGA Crude 91

2 Toluene 683

3 Methanol 788






APRIL’2018 93

Total: 1562

Sr. No.

Output/Kg of product(Kg)

Total Product

Liquid

effluent

Air

Emission Recovery

Solid

Waste

1 AGA PURE - - 36.5 54.5 91

2 Toluene - 75 608 - 683

3 Methanol 106 682 788

4 Third party mixed

solvent - - - - -

Total: 181 1326.5 54.5 1562






APRIL’2018 94

Figure – 15: Raw Material, Material Balance and process flow chart of Acetyl Glycrrhitinic

Acid (AGA)






APRIL’2018 95

16. Glabradin ( 20 % )


Glabridin 40% is produced by extraction from roots of Glycyrrhiza glabra roots. The extract has

been further purified by column chromatography, lixivation to give glabridin20%..



Glycyrrhiza Glabra roots Polygon Warehouse

MDC Paras polymers Solvent Storage Tanks

Chloroform B.K.Sales Solvent Storage Tanks

Methanol B.K.Sales Solvent Storage Tanks

Denatured Spirit Ashoka Distillary Solvent Storage Tanks

Toluene Pon Pure chemicals Ware house

HP20 RESIN Chromatography world Ware house

MATERIAL BALANCES SHEETS FOR GLABRIDIN 20%:

STAGE-1, STAGE-2& STAGE-3



2 MDC 49875

Total: 52875


Product Liquid Air Recovery Solid

Glycyrrhiza glabra roots

RRRRRRRRRRROOTroots

Extraction

Glabridin 20%



MOLECULAR WEIGHT






APRIL’2018 96

effluent Emission Waste

1 MDC dry material - - 60 60

2 MDC - 90 49725 - 49815

Exhaust Herb - 3000 3000

3

4 Third party mixed

solvent

- -

Total: 52875

STAGE-4 & STAGE-5


1 MDC dry material 60

2 Methanol 3600

3 Chloroform 3000

4 Water 1470

Total: 8130


Product Liquid

effluent


Waste

1 Chloroform dry

material

- 18 18

2 Methanol 80 3520 3600

3 Chloroform - 60 2940 - 3000

4 Water 1470 - - 1470

5 Exhaust residue - 0 42 42

6 Third party mixed

solvent

Total: 8130

STAGE-06


1 After toluene dry material 18

2 After column dry material 0

3 Denatured spirit 172.8

Total: 190.8


Product Liquid effluent Air

Emission

Recovery Solid

Waste

1 Final - - 16.5 - 16.5






APRIL’2018 97

material

2 Denatured

spirit

- 46.8 126 - 172.8

3 Waste

residue

1.5 1.5

4 Third party

mixed

solvent

Total: 190.8






APRIL’2018 98

Figure – 16 Raw Material, Material Balance and process flow chart of Glabradin ( 20 % )






APRIL’2018 99




been further purified by column chromatography, lixivation to give glabridin 40%..










Hexane Real Chemsys Ware house

Ethyl acetate Jubliant lifesciences Ware house





2 MDC 119700

Total: 127100



RRRRRRRRRRROOTroots

Extraction

Glabridin 40%



MOLECULAR WEIGHT






APRIL’2018 100

Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 MDC dry

material

- - 160 160

2 MDC - 134 119406 - 119540

Exhaust

Herb

- 7400 7400

3

4 Third party

mixed

solvent

- -

Total: 127100

STAGE-4 & STAGE-5



2 Methanol 9250

3 Chloroform 7950

4 Water 3885

Total: 21245


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Chloroform

dry material

- 60 60

2 Methanol 60 9190 9250

3 Chloroform - 80 7870 - 7950

4 Water 3885 - - - 3885

5 Exhaust

residue

- 0 100 100

6 Third party

mixed

solvent

Total: 21245






APRIL’2018 101

Figure – 17: Raw Material, Material Balance and process flow chart of Glabradin ( 40 % )






APRIL’2018 102




been further purified by column chromatography, lixivation to give glabridin 60%..
















2 MDC 139650

Total: 148050



RRRRRRRRRRROOTroots

Extraction

Glabridin 60%



MOLECULAR WEIGHT






APRIL’2018 103

Product Liquid

effluent

Air

Emission

Recovery Solid

Waste


2 MDC - 80 139390 - 139470

Exhaust Herb - 8400 8400

3

4 Third party mixed

solvent

- -

Total: 148050

STAGE-4 & STAGE-5



2 Methanol 10800

3 Chloroform 9000

4 Water 4410

Total: 24390


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Chloroform dry

material

- 60 60

2 Methanol - 100 10700 - 10800

3 Chloroform - 50 8950 - 9000

4 Water 4410 - - 4410


6 Third party mixed

solvent

Total: 24390






APRIL’2018 104







APRIL’2018 105




been further purified by column chromatography, lixivation and final crystallization to give

glabridin 97%..
















2 MDC 146300

Total: 155300


RRRRRRRRRRROOTroots

Extraction

Glabridin 97%



MOLECULAR WEIGHT






APRIL’2018 106


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste


2 MDC - 411 145709 - 146120

3

Exhaust Herb - 9000

4 Third party mixed solvent - -

Total: 155300

STAGE-4 & STAGE-5



2 Methanol 10800

3 Chloroform 9000

4 Water 4410

Total: 24390


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Chloroform dry material - 60 60

2 Methanol - 80 10720 - 10800

3 Chloroform - 100 8900 - 9000

4 Water 4410 - - 4410


6 Third party mixed solvent

Total: 24390

STAGE-6


1 Chloroform dry material 60

2 Hexane 1929.6

3 Ethyl acetate 540

Total: 2529.6


Product Liquid Air Recovery Solid






APRIL’2018 107

effluent Emission Waste

1 Hexane: ethyl acetate

dry material)

- 40 - 40

2 Hexane - 68 1861.6 - 1929.6

3 Ethyl Acetate - 80 460 - 540

4 Exhaust Residue - - - 20 20

5 Third party mixed solvent - - -

Total: 2529.6

STAGE-07


1 Hexane ethyl acetate dry material 40

2 Toluene 120.4

Total: 160.4


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Dry material after Hot

toluene

- 8 - 8

2 Toluene - 20.4 100 - 120.4

3 Exhaust residue 32 32


Total: 160.4

STAGE-08


1 Hot toluene dry material 8

2 Denatured spirit 64

Total: 72


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Final material - - 5.3 - 5.3

2 Denatured spirit - 10 54 - 64

3 Waste residue 2.7 2.7


Total: 72






APRIL’2018 108







APRIL’2018 109

20. Gingerol


Gingerol is produced by extraction from ginger. The extract has been further purified by Phase

exchange to give Gingerol.



Ginger Warehouse

Hexane V.S. InterchemPvt Ltd Solvent Storage Tanks

Denatured spirit Ashoka distillery Solvent Storage Tanks

MATERIAL BALANCES SHEETS FOR GINGEROL:

STAGE-1, STAGE-2


1 Ginger 800

2 Hexane 12800

Total: 13600


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Concentrated syrup - - 100 - 100

2 Hexane - 300 12400 - 12700

3 Exhaust herb - - - 800 800

Total: - 300 12500 800 13600

STAGE-3 & STAGE-4


1 Concentrated syrup 100

2 Denatured spirit 120

Ginger Extraction

Gingerol



MOLECULAR WEIGHT






APRIL’2018 110

Total: 220


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Gingerol - 27 - 27

2 Denatured spirit - 50 70 - 120


Total: 73 50 97 - 220






APRIL’2018 111

Figure – 20: Raw Material, Material Balance and process flow chart of Gingerol






APRIL’2018 112

21. Escin


Escin is extracted from the Horse Chestnut Seed and is further purified through Carbon

treatment, Crystallization and Methanol Treatment.



Horse Chestnut Seed Hansraj Traders Warehouse


Activated carbon ICP-20 Brilex Chemicals Solvent Storage Tanks

Decamax M/S Ecokrin Hygine Pvt Ltd Warehouse


Activated carbon Global Global adsorbent warehouse

MATERIAL BALANCES SHEETS FOR VALERIAN DRY EXTRACT:

STAGE-1


1 Horse Chestnut Seed 4000

2 Methanol 48000

Total: 52000


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Concentrate syrup - - 4000 - 4000

2 Exhausted Herb - - - 4000 4000

3 Methanol - 100 43900 - 44000

Total: - 52000

STAGE-2


Horse Chestnut Seed Extraction & Purification

Escin Molecular Formula: C 55 H 86 O 24







APRIL’2018 113


2 Methanol 1440

3 Water 2000


5 Activated carbon ICP-20 30

6 Decamax 30

Total: 7560


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Crude Escin - 100 - 100

2 Methanol - 76 3764 - 3840

3 Water 1560 - 2000 - 3560


Decamax

- - - 60 60

Total: 7560

STAGE-3


1 Crude Escin 100

2 Methanol 1000

3 Global activated carbon 15

4 Decamax 3

Total: 1118


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Escin - - 80 - 80

2 Methanol - 100 900 - 1000


Decamax

- - - 38 38

Total: - 1118






APRIL’2018 114

Figure – 21: Raw Material, Material Balance and process flow chart of Escin






APRIL’2018 115

22. Horse Chest Nut Extract


Horse chestnut extract is extracted from the Horse chest nut seed and is standardized with

maltodextin.



15. Horse chest nut seed Hans raj Warehouse

16. Methanol B K sales Solvent Storage Tanks

17. Water In House

18. Maltodextrin Aristio chemicals Warehouse

19. Silicon dioxide BS Mehra & Sons Warehouse

MATERIAL BALANCES SHEETS FOR HORSE CHEST NUT DRY EXTRACT

STAGE-1 & STAGE-2


1 Horse chest nut seed 12800

2 Methanol 133120

Total: 145920


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Horse chest nut Soft mass 2300 2300

2 Exhaust herb -- 11350 11350

2 Methanol -- 150 132120 132270

Horse chest nut seed

Extraction

Horse chest nut dry extract (Active ingredients as ESCIN) Molecular Formula: C55H86O24

Molecular Weight: 1,131.27 g·mol−1






APRIL’2018 116

Total: 145920

STAGE-3 & STAGE-4


1 Horse chest nut Soft mass 2300

2 Water 1600

3 Maltodextin 54

4 Silicon dioxide 15

Total: 3959


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Horse chest nut dry extract 1505 1505

2 Methanol 50 800 -- 850

3 Water 1600 -- 1600

4 Maltodextin -- --

5 Silicon dioxide -- -- --

Total: 3959






APRIL’2018 117

Figure – 22: Raw Material, Material Balance and process flow chart of Horse Chest Nut

Extract






APRIL’2018 118

23. Nutmeglignum


Nutmeglignin Extract is extracted from the Nutmeg seeds and is further purified through Column

Chromatography and Crystallization.



20. Nut Meg seeds Namyang herb Warehouse

21. Methanol B. K. Sales corporation Solvent Storage Tanks

22. Hexane V.S. Interchem Pvt Ltd Solvent Storage Tanks

23. Ethyl acetate Jubilant life sciences Ltd Solvent Storage Tanks

24. Silica Gel(200-400) Swambe chemicals Warehouse

25. Activated Carbon Brilex Chemicals Warehouse

26. Decamex M/S Ecokrin Hygine Pvt Ltd Warehouse

MATERIAL BALANCES SHEETS FOR NUT MEG EXTRACT:

STAGE-1 & STAGE-2


1 Nutmeg seeds 775

2 Methanol 8000

Total: 8775


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste


Nutmeg seeds Extraction & Purification

Nutmeglignan Molecular formula C20H24O4 Molecular weight 328.408 g/mol







APRIL’2018 119

2 Exhaust Herb - - - 775 775

3 Methanol - 50 7750 - 7800

Total: - 8775

STAGE-3


1 Syrup 200

2 Hexane 19800

3 Ethyl acetate 500

4 Silica Gel(200-400) 600

Total: 21100


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Syrup 150 - 50 - 200

2 Hexane - 100 19700 - 19800


4 Silica Gel(200-400) - - - 600 400

Total: 21100

STAGE-4


1 Syrup 50

2 Hexane 330


4 Decamax 5

Total: 390


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 NutMeglignan 15 7 28 - 50

2 Hexane - 30 300 - 330

3 Activated Carbon - - - 5 5

4 Decamex - - - 5 5

Total: 390






APRIL’2018 120

Figure – 23: Raw Material, Material Balance and process flow chart of Nutmeglignum

24. Ruscogenin

Butcther’s Brooms Extraction

RUSCOGENINS AS NEORUSCOGENIN


Molecular Weight: 428.604 RUSCOGENIN








APRIL’2018 121


Ruscogenin is extracted from the leaves of Butcther’s Brooms and is further purified through

Phase Exchange,Column Purification & Crystallization.



Butcther’s Brooms Roots Enco Meyve Ticaret ltd Warehouse

Methanol B.K Sales Solvent Storage Tanks

N-Butanol Radient polycan Warehouse

MDC B. K. Sales corporation Solvent Storage Tanks


Potassium Hydroxide Aristio chemicals Warehouse

Activated carbon Virmani brothers Warehouse

Silica gel REAL CHEMSYS Warehouse

Sodium Hydroxide Aristio chemicals Warehouse

MATERIAL BALANCES SHEETS FOR RUSCOGENIN:

STAGE-1 & STAGE-2


1 Butcther’s Brooms 500

2 Methanol 6400

3 Water 1600


Total: 8700


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste


2 Exhaust Herb - - - 500 500

3 Methanol - 50 6350 - 6400

4 Water 200 800 - 1000

Total: - 8700

STAGE-3



2 Butanol 3000






APRIL’2018 122

3 HCL 250

Total: 4050


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Material 950 - 100 - 1050

2 Butanol 100 50 2850 - 3000

Total: - 4050

STAGE-4


1 Material 100

2 HCL 100

3 Butanol 1000

4 Caustic Potash 50

5 Water 100

Total: 1350


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Material 340 - 60 - 400

2 Butanol - 50 900 - 950

Total: 340 50 960 - 1350

STAGE-5


1 Material 60

2 Methanol 300

3 Water 700

4 MDC 1300

Total: 2360


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Material 1010 - 50 - 1060

2 Methanol - - - - -

3 Water 100 1200 - 1300






APRIL’2018 123

4 HCL - - - - -

Total: - 2360

STAGE-6


1 Material 50

2 MDC 1500

3 Methanol 50

4 Silica Gel(200-400) 150

Total: 1600


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Material - - 5 - 5

2 MDC - 100 1400 - 1500

3 Methanol - 10 40 - 50

4 Silica Gel(200-400) - - - 195 195

Total: - 1750

STAGE-6


1 Material 5

2 Methanol 40

3 Activated Carbon ICP-20 .250

4 Decamax .250

5 Water 10

Total: 55.5


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Ruscogenin 2 - 3 - 5

2 Methanol - 10 30 - 40

3 Activated Carbon ICP-20 - - - .250 .250

4 Decamax - - - .250 .250

5 Water 2 8 - 10

Total: 55.5






APRIL’2018 124

Figure – 24: Raw Material, Material Balance and process flow chart of Ruscogenin






APRIL’2018 125

25. Euphorbia Prostrata Ethanolic dry Extract


Euphorbia Prostrata Ethanolic Liquid Extract is extracted from the Euphorbia Prostrata leaves

and is further purified through Phase Exchange.

List of Raw Materials


Euphorbia Prostrata leaves Panacea Biotec limited Warehouse

Denatured Spirit Ashoka distillary Solvent Storage Tanks



MATERIAL BALANCES SHEETS

STAGE-1 & STAGE-2


1 Euphorbia Prostrata leaves 600

2 Denatured Spirit 12000

Total: 12600


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste


2 Exhaust Herb - - - 600 600

3 Denatured Spirit - 100 11300 - 11400

Total: - 100 11900 600 12600

Euphorbia Prostrata

leaves

Extraction

Euphorbia Prostrata Dry Extract

(Apigenin 7-O-glucoside)

Molecular formula: C21H20O10 Molecular weight: 432.38

Euphorbia Prostrata Dry Extract (Gallic acid)

Molecular formula: C7H6O5 Molecular weight: 170.12







APRIL’2018 126

STAGE-3



2 Hexane 2400

3 Ethyl Acetate 10000

Total: 13000


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Euphorbia Prostrata Dry

Extract

580 - 20 - 600

2 Hexane - 50 2350 - 2400

3 Ethyl Acetate - 50 9950 - 10000

Total: - 13000

Figure – 25: Raw Material, Material Balance and process of flow chart f Euphorbia

Prostrata Ethanolic dry Extract






APRIL’2018 127

26. Humulus Lupulus


Humulus lupulus dry extractis extracted from the Humulus Lupulusand is standardized with

Lactose.



Humulus lupulus Warehouse

Ethanol Ashoka Distillery Solvent Storage Tanks

Water In House

Lactose Alchem Solvent Storage Tanks

Silicon dioxide BS Mehra & Sons Warehouse

MATERIAL BALANCES SHEETS FOR HUMULUS LUPLUS DRY EXTRACT

STAGE-1 & STAGE-2


1 Humulus Lupulus 100

2 Ethanol 1025

3 Water 1800

Total: 2925


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Humulus lupulus soft mass 25 25

2 Exhaust herb 100 100

Humulus lupulus Extraction

Humulus lupulus dry extract (Active ingredient is Rutoside) Molecular Formula: C27H30O16

Molecular Weight: 610.52 g·mol−1






APRIL’2018 128

3 Ethanol 50 950 1000

4 Water 200 1600 1800

Total: 2925

STAGE-3& STAGE-4


1 Humulus lupulus soft mass 25

2 Methyline chloride 40

Total: 65


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Humulus lupulus dry residue 17 -- 17

2 Methyline chloride 8 40 48

Total: 65

STAGE-5& STAGE-6


1 Humulus lupulus dry residue 17

2 Lactose 5

3 Silicon dioxide 0.5

Total: 22.5


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Humulus lupulus dry extract 0.5 22.0 22.5

Total:






APRIL’2018 129

Figure – 26: Raw Material, Material Balance and process of Humulus Lupulus






APRIL’2018 130

27. Hydro tyrasol


Oleuropein is extracted from the olives leaves and is further undergoing concentration, phase

exchange, Hydrolysis, column purification to make hydroxytyrosol.


NAME OF RAW MATERIAL STORAGE AT THE SITE

Olives leaves Warehouse

Water Water System


Methylene Chloride Solvent Storage Tanks

Hydrochloric acid Warehouse

Sodium Hydroxide Warehouse

Ethyl Acetate Warehouse

Hexane Warehouse

Silica Gel Warehouse

MATERIAL BALANCES SHEETS FOR HYDROXYTYROSOL

STAGE-1 & 2


1 Olives leaves 4500

2 Water 6750

3 Methanol 48600

Total: 59,850


Olive leaves

Extraction & Purification

Hydroxytyrosol Molecular Formula: C8H10O3







APRIL’2018 131

Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Concentrated Syrup - - 6500 - 6500

2 Exhaust Herbs - - - 4500 4500

3 Third party mixed

solvent 0 100 48750 - 48850

Total:

59,850

STAGE-3 & 4


1. Concentrated syrup 6500

2. Methylene chloride 12970

3. Hydrochloric acid 780

4. Sodium hydroxide 500

5. Ethyl acetate 16200

6. Water 500

Total: 37,450


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Crude Hydroxytyrosol 6250 - 250 0 6500

2 Methylene chloride - 70 12900 0 12970

3 Hydrochloric acid 780 0 0 0 780

4 Sodium hydroxide 500 0 0 0 500

5 Ethyl acetate 0 50 16150 0 16200

6 Water 500 0 0 0 500

7 Third party mixed

solvent

0 0 0 0 0

Total: 37,450

STAGE-5


1 Crude hydroxytyrosol 250

2 Methanol 250

3 Silica gel 1000






APRIL’2018 132

4 Hexane 9900


Total: 42,900


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Hydroxytyrosol 0 - 70 180 250

2 Methanol - 20 230 0 250

3 Hexane 0 75 9825 0 9900

4 Silica gel 0 0 0 1000 1000

5 Ethyl acetate 0 75 31425 0 31500

6 Third party mixed

solvent

0 0 0 0 0

Total: 42,900






APRIL’2018 133

Figure – 27: Raw Material, Material Balance and process of Hydro tyrasol






APRIL’2018 134

Sugar can wax(Mud)

r RRRRRRRRRRROOTroots

Extraction

Policosanol

Molecular Formula: ‎C28H58O


MOLECULAR WEIGHT

28. Policosanol


Tobacco absolute is produced by extraction from

sugarcane mud.



sugarcane mud Warehouse

1. MEK(Methyl Ethyl ketone) Solvent Storage Tanks

2. Decamex store

3. Methanol Solvent Storage Tanks

MATERIAL BALANCES SHEETS FOR BOSWELLIA DRY EXTRACT

STAGE-1


1 Sugarcane mud 20

2 MEK 240

Total: 260


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 1st crystallized material - - 6 0 6

2 MEK - 40 200 - 240

03 Exhaust residue - - 14 14

Total: - 40 206 14 260

STAGE-2


1 1st crystallized material 6

2 Methanol 240

3 Decamex 3

Total: 249






APRIL’2018 135


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Methanol treated dry material - - 4 0 4

2 methanol - 5 235 - 240

03 Exhaust residue - - 5 5

Total: - 5 239 5 249

STAGE-3 & stage -04


1 Methanol treated dry material 6

2 MEK 80

Total: 86


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Methanol treated dry material - - 2.5 0 2.5

2 methanol - 10 70 - 80

03 Exhaust residue - - 3.5 3.5

Total: - 10 72.5 3.5 86






APRIL’2018 136

Figure – 28: Raw Material, Material Balance and process of Policosanol

29. Tobacco Absolute

Tobacco absolute crude

r RRRRRRRRRRROOTroots Extraction

Tobacco absolute Molecular Formula: Molecular Weight:

MOLECULAR WEIGHT






APRIL’2018 137


Tobacco absolute is produced by extraction from Tobacco absolute crude .



Tobacco absolute crude Warehouse

4. Propylene Glycol Solvent Storage Tanks

5. Decamex store

MATERIAL BALANCES SHEETS FOR TOBACCO ABSOLUTE:

STAGE-1, STAGE-2


1 Tobacco absolute crude 18

2 Decamex 6

3 Propylene Glycol 540

Total: 564


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Tobacco absolute light - - 18 0 18

2 Propylene Glycol - 30 510 - 540

03 Decamex - - 6 6

Total: - 564






APRIL’2018 138

Figure – 29: Raw Material, Material Balance and process of Tobacco Absolute

B. PURE HERBAL PRODUCTS PROPOSED TO BE MANUFACTURED IN THE FACTORY

1. Turmeric Extract


Turmeric extract is obtained after extracting ground raw Turmeric, filtered and concentrated to

desired softmass.


NAME OF RAW MATERIAL SOURCE STORAGE AT THE

SITE

Raw Turmeric Darshan Drug House. Delhi Warehouse






APRIL’2018 139

Rice Husk Mahabir Warehouse

Reverse Osmosis Water(R. O. Water) In-house Water System

Ethanol DCM Shriram, Storage Tank

MATERIAL BALANCES SHEETS FOR TURMERIC EXTRACT:

STAGE-1: Extraction


1 Raw Turmeric 5

2 Water 5

3 Rice Husk 1

4 Ethanol 95

Total: 106


Product Liquid effluent Air Emission Recovery Solid Waste

1 Raw Turmeric - - - 5 5

2 Water - - - - 0

3 Rice Husk - - - 1.0 1

4 Ethanol - 4.0 91 - 95

Total: 0 4.0 91 6.0 101






APRIL’2018 140

Figure – 30: Raw Material, Material Balance and process of Turmeric Extract

2. Pomegranate Extract


Pomegranate extract is obtained after extracting ground Pomegranate peels, filtered,

concentrated and dried. The dried powder is milled & sifted.



Pomegranate Peels Darshan Drug House. Warehouse


Reverse Osmosis Water(R. O. Water) In-house Water System

Ethanol - Storage Tank

MATERIAL BALANCES SHEETS FOR POMEGRANATE EXTRACT:

STAGE-1:






APRIL’2018 141


1 Pomegranate Peel 5

2 Water 10

3 Rice Husk 1

4 Ethanol 90

Total: 106


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Pomegranate Peel - - - 5 5

2 Water 10 - - - 10

3 Rice Husk - - - 1.0 1

4 Ethanol - 4.0 86 - 90

Total 0 4.0 86 6.0 106

Figure – 31: Raw Material, Material Balance and process of Pomegranate Extract






APRIL’2018 142

3. Grape Seed Extract


Grape Seed Phytozome is made from the Grape Seed extract & Lecimulthin dissolution & drying.



Grape Seed extract In House Warehouse

Lecimulthin Warehouse

Denatured sprit Ashoka distillery Solvent Storage Tanks


MATERIAL BALANCES SHEETS FOR GRAPE SEED EXTRACT


1 Grape Seed extract 25

2 Lecimulthin 50

3 Ethyl Acetate 225

4 Denatured Sprit 40

Total: 340


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Grape Seed Phytozome - - 70 5 75


3 Denatured Sprit 20 20 40

Total: - 30 305 5 340

Grape Seed Extract Dissolution & drying

Grape Seed Phytozome






APRIL’2018 143

Figure – 32: Raw Material, Material Balance and process of Grape Seed Extract

4. Nicotine Ditartrate Dihydrate.


Nicotine API which is manufactured in-house as described earlier is treated with L(+)-

Tartaric Acid & Tartaric Acid. This resulting reaction mass is filtered, and then concentrated.

The concentrated syrup is dissolved in R.O. water and crystallized in Ethanol. The crystallized

material is centrifuged and dried to form Nicotine Ditartrate Dihydrate.

Nicotine Ditartrate Dihydrate Molecular Formula: C180H26N2O12.2H2O Molecular Weight: 498.4






APRIL’2018 144



Nicotine In-house Warehouse

Absolute Alcohol (Ethanol) Daurala Sugar Solvent Storage Tanks

Methanol B. K. Sales Solvent Storage Tanks

Reverse Osmosis Water In-house Water System

Tartaric Acid Aristo Chemicals Warehouse

MATERIAL BALANCES SHEETS FOR NICOTINE DITARTRATE DIHYDRATE:


1 Nicotine Final 7

2 Methanol 70

3 Tartaric Acid 12

4 Ethanol 60

5 Water 15

Total: 164

S. No Output/Kg of product(Kg) Total

Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Nicotine Ditartrate Dihydrate - - 18 - 18

2 Methanol 20 5 45 - 70

3 Tartaric Acid - - - - -

4 Ethanol 10 10 - - 20

5 RO Water 15 - - - 15

6 Mixed Solvent - - 41 - 41

Total: 45 15 104 164






APRIL’2018 145

Figure – 33: Raw Material, Material Balance and process of Nicotine Ditartrate Dihydrate.

5. Nicotine Polacrilex


Nicotine API which is manufactured in-house as described in the earlier section is treated

with Amberlite IRP-64 Resin. This nicotine-resin complex is further washed with acetone and

treated with ethanol & glycerol to form Nicotine Polacrilex, also known as Nicotine Resinate.

Nicotine Polacrilex/Resinate Molecular Formula: C10H14N2 x (C10H10C4H6O2)Y






APRIL’2018 146




Acetone Pon Pure Chemical Solvent Storage Tanks

Amberlite IRP-64 Resin Virmani Brothers Warehouse


Glycerol Real Chemsys Warehouse


MATERIAL BALANCES SHEETS FOR NICOTINE POLACRILEX


1 Nicotine Final 10

2 Acetone 600

3 Amberlite Resin 50

4 Ethanol 500

5 Water 2000

6 Glycerol 30

Total: 3190


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Nicotine Polacrilex - - 60 - 60

2 Acetone 15 10 575 - 600

3 Amberlite Resin - - - - -

4 Ethanol 10 10 480 - 500

5 Glycerol - - - 20 20

6 RO Water 1950 50 - - 2000

7 Mixed solvent - - 10 - 10

Total 1975 70 1125 20 3190






APRIL’2018 147

Figure – 34: Raw Material, Material Balance and process of Nicotine Polacrilex

6. Pygeum Extract


Pygeum Extract is manufactured by extraction of Pygeum bark using Methylene Chloride.



1. Pygeum Bark World Botanical Warehouse

2. Methylene chloride B. K. Sales Solvent Storage Tanks

MATERIAL BALANCES SHEETS FOR PYGEUM EXTRACT


1 Pygeum Africana Bark 2,000

2 Methylene Di Chloride 20000

Total: 22000



Emission

Recovery Solid

Waste






APRIL’2018 148

1 Pygeum Extract - - 10 - 10

2 Pygeum Africana Bark - - - 1990 1990

3 Methylene Di Chloride 40 50 19910 - 20000

Total: 40 50 19920 1990 22000

Figure – 35: Raw Material, Material Balance and process of Pygeum Extract

7. Milk Thistle Extract

IUPAC Name:

(2S,3R)-3,5,7-trihydroxy-2-[(2S,3S)-3-(4-

hydroxy-3-methoxyphenyl)-2-(hydroxymethyl)-

2,3-dihydro-1,4-benzodioxin-6-yl]-2,3-

dihydrochromen-4-one.


CAS Registry Number: 22888-70-6







APRIL’2018 149

Briefdescription of the manufacturing process:

Silymarin is extracted from the Cardus marianum seeds and is further purified through Column

Phase exchange, Concentration, filtration and thermo vacuum drying.



Cardus marianumSeeds

Herbar SP.Z.O, Poland.

PharmekoLettland, Madona

Latvia

Warehouse

Rice Husk Mahabir, Sai Traders Warehouse

Reverse Osmosis Water(R. O.

Water)

In-house Water System

Acetone B K Sales, Real Chemsys, Ghaziabad Storage Tank

Hexane Real Chemsys, Ghaziabad Storage Tank

1. Ethanol DCM Shriram, Storage Tank

MATERIAL BALANCES SHEETS FOR SILYMARIN/MILK THISTLE DRY EXTRACT:

STAGE-1: Extraction & Purification


1. Cardus marianum seeds 20

2. RO Water 8

3. Rice Husk 5

4. Acetone 300

5. Hexane 10

6. Ethanol 20

Total: 363


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Cardus marianum seeds - - - 20 20

2 RO Water - - 8 - 8

3 Rice Husk 5 5

4 Acetone 45 255 300

5 Hexane 1 9 10

6 Ethanol 2 18 20

Total: 363






APRIL’2018 150

Figure – 36: Raw Material, Material Balance and process of Milk Thistle Extract

8. Red Clover Extract






APRIL’2018 151


Red clover is extracted from Red clover herb and purified via solvent washing,



Red Clover Herb Darshan Drug House Warehouse


Reverse Osmosis Water(R. O.

Water)


Methanol B K Sales Storage Tank

Hydrochloric Acid Ganpati Chemicals, Karni Chemicals Warehouse

Ammonia Solution Ganpati Chemicals, Karni Chemicals Warehouse

Calcium Chloride Adhunik Warehouse

MATERIAL BALANCES SHEETS FOR RED CLOVER EXTRACT

STAGE: Extraction


1 Red Clover Herb 20

2 Rice Husk 5

3 Ethanol 140

4 Water 60

Total: 225


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Red Clover Herb - - - 20 20

2 Rice Husk - - - 5 5

3 Ethanol - 4 136 - 136

4 Water 15 - 45 - 60

Total: 15 4 181 25 225

STAGE: Purification up to Drying


1 Hexane 10

Total: 10


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste






APRIL’2018 152

1 Hexane - 1 9.0 - 10

Total: 0 1 9.0 - 10

Figure – 37: Raw Material, Material Balance and process of Red clover






APRIL’2018 153

9. Nicotine Di Hydrate Di Tartrate


Nicotine API which is manufactured in-house as described earlier is treated with L(+)- Tartaric

Acid & Tartaric Acid. This resulting reaction mass is filtered, and then concentrated. The

concentrated syrup is dissolved in R.O. water and crystallized in Ethanol. The crystallized

material is centrifuged and dried to form Nicotine Ditartrate Dihydrate.







Tartaric Acid Aristo Chemicals Warehouse

MATERIAL BALANCES SHEETS FOR NICOTINE DITARTRATE DIHYDRATE:


1 Nicotine Final 7

2 Methanol 70

3 Tartaric Acid 12

4 Ethanol 60

5 Water 15

Total: 164


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Nicotine Ditartrate Dihydrate - - 18 - 18

2 Methanol 20 5 45 - 70

3 Tartaric Acid - - - - -

Nicotine Ditartrate Dihydrate Molecular Formula: C180H26N2O12.2H2O Molecular Weight: 498.4






APRIL’2018 154

4 Ethanol 10 10 - - 20

5 RO Water 15 - - - 15

6 Mixed Solvent - - 41 - 41

Total: 45 15 104 164

Figure – 38: Raw Material, Material Balance and process of Nicotine Di Hydrate Di Tartrate






APRIL’2018 155

C. SEMI SYNTHETIC PRODUCTS PROPOSED TO BE MANUFACTURED IN THE FACTORY

1. Hyoscine Butyl Bromide

Brief description of the manufacturing process

Duboisia leaves are extracted with mixture of Chloroform and Methanol to produce Hyoscine

Syrup which is reacted with Hydrobromic Acid to produce Hyoscine Hydrobromide. Hyoscine

DuboisiaLeaves

Hyoscine Butylbromide Molecular Formula: C21H30BrNO4 Molecular Weight: 440.4

n-Butylbromide

reaction

Hyoscine Molecular Formula: C17H21NO4







APRIL’2018 156

Hydrobromide is basified to form pure Hyoscine syrup, which is treated with n-butylbromide to

make Hyoscine butylbromide. It is further purified by crystallization and washing to produce

Hyoscine Butylbromide API.



DuboisiaLeaves Twin Multiflora Warehouse

Acetonitrile Bharat Jyoti Solvent Storage Tanks

Activated Carbon Brilex Chemicals Warehouse

Ammonia Solution Karni Chemicals, Ganpati Warehouse

n-Butylbromide Neogen Chemicals Limited Warehouse

Hydrobromic Acid Neogen Chemicals Limited Warehouse

HyfloSupercel (Filter aid) Gem Corporation Warehouse


Methylene Chloride B. K. Sales Solvent Storage Tanks

Purified Water in bulk In-house Water System

Reverse Osmosis Water

(R. O. Water)


MATERIAL BALANCE SHEETS FOR HYOSCINE BUTYLBROMIDE:

Stage-1: Extraction


1 Duboisia Leaves 40.00 kg

2 Rice Husk 10.00 kg

3 Methanol 54 liters

4 Chloroform 540 liters

5 Soda ash 0.80 kg

6 R.O. water 2 liters

Total:


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Duboisia Leaves - - - 45 45.0

2 Rice Husk - - - 12.0 12.0

3 Methanol - 2.0 58.0 - 60.0

4 Chloroform - 30.0 570.0 - 600.0

5 Soda ash - - - 0.9 0.9






APRIL’2018 157

6 R.O. water 2.0 - - - 2.0

Total: 2.0 32.0 628.0 57.9 719.9

STAGE-2: HHBr crude



2 Hydrochloric Acid 1.5 liters

3 Methylene Chloride 150 liters

4 Ammonia Solution 1.1 liters

5 Hydrobromic Acid 0.500 liters


Total: 248.1


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 R.O. water 75.0 - - - 75.0

2 Hydrochloric Acid 1.5 - - - 1.5

3 Methylene Chloride - 8.0 142.0 - 150.0

4 Ammonia Solution 1.1 - - - 1.1

5 Hydrobromic Acid 1.1 - - - -

6 Methanol - 2.0 18.0 - 20.0

Total: 77.6 10.0 160.0 0 248.1

Stage-3: Hyoscine Syrup Formation


1 Hyoscine Hydrobromide crude 1.4

2 Liquid Ammonia 0.6

3 MDC 5.0

4 Water 4.0

Total: 11.0


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Hyoscine Hydrobromide crude - - - - 1.4

2 MDC - 0.5 4.5 - 5.0

4 Water 4.0 - - - 4.0

5 Liquid Ammonia 0.6 - - - 0.6

Total: 4.6 0.5 4.5 0 11.0






APRIL’2018 158

Stage-4: HBBr crude Formation


1 Hyoscine Syrup 1.1

2 Acetonitrile 1.1

3 Butyl bromide 1.1

4 Methanol 4.0

Total: 7.3


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Hyoscine Syrup - - - - 1.1

2 Acetonitrile - - - - 0

3 Butyl bromide - - - - 0

4 Methanol - - - - 0

5 Third party mixed solvent 6.2 - - - 6.2

Total: 6.2 0 0 0 7.3

Stage-5: Final HBBr API


1 Hyoscine butyl bromide(crude) 1.1

2 Methanol 8.0

3 Carbon 0.1

Total: 9.2


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Hyoscine Butyl bromide(API) - - - - -

2 Methanol - 0.5 7.5 - 8.0

3 Carbon - - - 0.1 0.1

Total: 0 0.5 7.5 0.1 8.1






APRIL’2018 159

Figure – 39: Raw Material, Material Balance and process of Hyoscine Butyl Bromide






APRIL’2018 160

Hyoscine Molecular Formula: C17H21NO4

Molecular Weight: 303.35 Hyoscine Molecular Formula: C17H21NO4


Hyoscine Hydrobromide Molecular Formula: C17H21NO4. HBr Molecular Weight: 384.4 Hyoscine Hydrobromide Molecular Formula: C17H21NO4. HBr Molecular Weight: 384.4

ExtractionE

xtraction

Hydrobromic Acid

ReactionHydrobrom

ic Acid Reaction

2. Hyoscine Hydrobromide

Brief description of the manufacturing process

Hyoscine Hydrobromide is basified to form pure Hyoscine syrup, which is treated with n-

butylbromide to make Hyoscine butylbromide. It is further purified by crystallization and

washing to produce Hyoscine Butylbromide API.



1. DuboisiaLeaves Twin Multiflora Warehouse

2. Acetonitrile Bharat Jyoti Solvent Storage Tanks

3. Activated Carbon Brilex Chemicals Warehouse

4. Ammonia Solution Karni Chemicals, Ganpati Warehouse

5. n-Butylbromide Neogen Chemicals Limited Warehouse

6. Hydrobromic Acid Neogen Chemicals Limited Warehouse

7. HyfloSupercel (Filter aid) Gem Corporation Warehouse

8. Methanol B. K. Sales Solvent Storage Tanks

9. Methylene Chloride B. K. Sales Solvent Storage Tanks

10. Purified Water in bulk In-house Water System

11. Reverse Osmosis Water

(R. O. Water)


Stage-1: Hyoscine Syrup Formation






APRIL’2018 161


1 Hyoscine Hydrobromide crude 1.4

2 Liquid Ammonia 0.6

3 MDC 5.0

4 Water 4.0

Total: 11.0


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Hyoscine Hydrobromide crude - - - - 1.4

2 MDC - 0.5 4.5 - 5.0

4 Water 4.0 - - - 4.0

5 Liquid Ammonia 0.6 - - - 0.6

Total: 4.6 0.5 4.5 0 11.0

Stage-2: HBBr crude Formation


1 Hyoscine Syrup 1.1

2 Acetonitrile 1.1

3 Butyl bromide 1.1

4 Methanol 4.0

Total: 7.3


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Hyoscine Syrup - - - - 1.1

2 Acetonitrile - - - - 0

3 Butyl bromide - - - - 0

4 Methanol - - - - 0

5 Third party mixed solvent 6.2 - - - 6.2

Total: 6.2 0 0 0 7.3

Stage-3: Final HBBr API


1 Hyoscine butyl bromide(crude) 1.1

2 Methanol 8.0

3 Carbon 0.1






APRIL’2018 162

Total: 9.2


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Hyoscine Butyl bromide(API) - - - - -

2 Methanol - 0.5 7.5 - 8.0

3 Carbon - - - 0.1 0.1

Total: 0 0.5 7.5 0.1 8.1






APRIL’2018 163






APRIL’2018 164

Figure – 40.: Raw Material, Material Balance and process of Hyoscine Hydrobromide

3. Hyoscamine Sulfate

Hyoscyamine Hyoscyaminesulphate



Hyoscamine Crude In-house Warehouse

Sulfuric Acid Choudhary Chemicals Warehouse

Acetone V.S. Interchem Private Limited Solvent Storage Tanks

Distilled Water In-house Water System

Sulphuric Acid Super Acid Warehouse

MATERIAL BALANCE FOR HYOSCAMINE SULPHATE:


1 Hyoscamine Crude 6

2 Sulfuric acid 1.3

3 Water 11.7

3 Acetone 142

Total: 161

Sr. No. Output/MT of product Total

Product Liquid

effluent

Air

Emission

Recovery Solid Waste

1 Hyoscamine

Sulfate

1.2 0.2 6 - 7.4

2 Sulfuric acid 0.3 - - - 0.3

3 Water 11.3 - - - 11.3

4 Acetone 20 2.0 120 - 142






APRIL’2018 165

Total: 34.8 0.2 126 - 161

Figure – 41.: Raw Material, Material Balance and process of Hyoscamine Sulfate

4. Atropine Sulfate






APRIL’2018 166


Hyoscyamine is extracted from Duboisia Leaves. It is further purified through phase exchange,

concentration, crystallization, column chromatography, concentration, re-crystallization,

filtration & vacuum drying. The pure Hyoscyamine is racemized into Atropine and further

purified, crystallized & dried. The dry atropine is reacted with Sulfuric acid, purified crystallized,

filtered & dry to get Atropine Sulfate.


NAME OF RAW MATERIAL SOURCE STORAGE AT THE

SITE

Duboisia Leaves Queensland Botanicals Pty Ltd., Warehouse

Rice Husk Sai Traders,Mahavir Trading Company, ARS

Paddy Husk (P) Ltd Warehouse

Methanol B. K. Sales corporation, Warehouse

Chloroform Ganpati Chemical Co. Storage Tank

Soda ash M/S Syndic India, Warehouse

Reverse Osmosis Water (R. O.

Water)

In House Water System

Hydrochloric Acid

Ganpati chemicals, A.G Gasochem Pvt.

Ltd, Ganpati chemicals Company, Sunil Kumar &

Brother, Shri karni Chemicals,

Warehouse

Methylene Chloride V.S. InterchemPvt Ltd, B. K. Sales corporation,

Paras Polymer Pvt. Ltd. Storage Tank

Ammonia Solution Ganpati chemicals Corporation, Shri kArni

Chemicals Warehouse

Toluene V.S. InterchemPvt Ltd, B. K. Sales corporation,

Paras Polymer Pvt. Ltd. Warehouse

Hexane V.S. InterchemPvt Ltd, B. K. Sales corporation,


Alumina Oxide Dessica Chemicals, Real Chemsys. Warehouse

Acetone V.S. InterchemPvt Ltd, B. K. Sales corporation,


Hiflo Gem Corporation Warehouse

Sulfuric Acid Karni Chemicals, Ganpati Chemicals Warehouse






APRIL’2018 167

MATERIAL BALANCES SHEETS FOR HYOSCYAMINE:

STAGE-1: Extraction


1 Duboisia Leaves 2500 kg

2 Rice Husk 625 kg

3 Methanol 3000 L

4 Chloroform 30000 L

5 Soda ash 45 kg

6 R.O. water 500L

Total: 36670


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Duboisia Leaves - - - 2500 2500

2 Rice Husk - - - 625 625

3 Methanol - 50 2950 - 3000

4 Chloroform - 500 29500 - 30000

5 Soda ash 20 - - 25 45

6 R.O. water 500 - - - 500

Total: 520 550 32450 3150 36670

STAGE-2 Semi Purification



2 Hydrochloric Acid 75 liters

3 Methylene Chloride 2000 liters

4 Ammonia Solution 150 liters


6 Toluene 120 liters

7 Hexane 2 liters

Total: 6147


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 R.O. water 3000 - - - 3000

2 Hydrochloric Acid 75 - - - 75






APRIL’2018 168

3 Methylene Chloride - 100 1900 - 2000

4 Ammonia Solution 150 - - - 150

5 Methanol - 40 760 - 800

6 Toluene - 3 117 - 120

7 Hexane - 0.2 1.8 - 2.0

Total: 3225 143.2 2778.8 0 6147

STAGE-3: Final Purification


Hyoscyamine 1.0

Methylene Chloride 100 liters

1. Alumina 30 kg

Toluene 30liters

Acetone 30 liters

Hiflo Supercell 0.4 kg

Triethyl amine 1.2 liters

Chloroform 3.0 liters

R O Water 3.0 liters

Activated Carbon 0.1

Total: 198.6


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Hyoscyamine - 5 95 - 100

2 Methylene Chloride - - - 30 30

3 Alumina - 1 29 - 30

4 Toluene - 1 14 - 15

5 Acetone 1.5 28.5 30

6 Hiflo Supercell 0.4 0.4

7 Triethyl amine - 0.2 1.0 1.2

8 Chloroform 0.2 2.8 3.0

9 R O Water 3.0 3.0

10 Activated Carbon 0.1 0.1

Total: 3 8.9 170.3 30.5 198.6






APRIL’2018 169

Figure – 42.: Raw Material, Material Balance and process of Atropine Sulfate

5. Cimetropium Bromide

Hyoscine Cimetropium Bromide



Hyoscine Syrup In-house Warehouse

Cyclopropyle methyl bromide Unisynaxis Laboratories

Private Limited,

Warehouse

Acetonitrile V.S. Interchem Private

Limited

Solvent Storage Tanks






APRIL’2018 170

Methylene Di Chloride V.S. Interchem Private

Limited

Solvent Storage Tanks

Ethyl Alcohol DCM, Daurala Solvent Storage Tanks



MATERIALS BALANCE FOR CIMETROPIUM BROMIDE:


1 Hyoscine syrup 021

2 Cyclopropyle methyl bromide 046

3 MDC 452

4 Acetonitrile 110

5 Methyl alcohol 115

6 Ethyl alcohol 032

776

Total:

Sr. No. Output/MT of product Remark


Emission

Recovery Solid

Waste

1 Cimetropium Methyl

Bromide

15 - 16 - 31

2 MDC 02+6 20 430 - 458

3 Acetonitrile 5+10 5 100 - 120

4 Ethanol - 5 - - 5

5 Third party mixed solvent - - - - 162

Total: 38+162 30 546 776






APRIL’2018 171

Figure – 43: Raw Material, Material Balance and process of Cimetropium Bromide

6. Methscopolamine Bromide

Hyoscine Hydrobromide Methscopolamine Bromide

(Natural origin) Quarternary salt formation on nitrogen. Minor change






APRIL’2018 172

List of raw materials:


Hyoscine Hydrobromide Crude In-house Warehouse

Methyl Bromide Unisynaxis Laboratories Private

Limited,

Warehouse

Acetonitrile V.S. Interchem Private Limited Solvent Storage Tanks

Ethanol DCM, Daurala Warehouse

Methylene Chloride B. K. Sales Solvent Storage Tanks


MATERIAL BALANCE FORMETHESCOPLAMINE BROMIDE


1 Hyosine Hydro Bromide (crude) 12

2 Methyl Bromide 30

3 Acetonitrile (ACN) 23.6

4 Ethanol 65.1

5 Water 107.5

6 MDC 399

Total: 637.2

Sr. No. Output/ Kg of product(Kg) Total

Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Methescoplamine Bromide 3.7 - 7.2 - 10.9

2 Ethanol - 5 - - 5

3 Water 107.5+2.5 - - - 110

4 MDC - 19 380 - 399

5 Third party mixed solvent - - - - 112.3

Total: 113.7 14 387.2 - 637.2






APRIL’2018 173

Figure – 44: Raw Material, Material Balance and process of Methscopolamine Bromide

7. Homa Tropine Methyl Bromide

Homatropine HomatropineMethylbromide

(Natural origin) Quarternary salt formation on nitrogen. Minor change



Mandelic Acid Warehouse






APRIL’2018 174

Acetyl Chloride Warehouse

Acetone V.S. Interchem Private Limited Solvent Storage Tanks

Thionyl Chloride Warehouse

Tropine In House Warehouse


Ethanol DCM, Daurala Solvent Storage Tanks

Ethyl Alcohol B. K. Sales Solvent Storage Tanks


MATERIALS BALANCE FOR HOMATROPINE METHYL BROMIDE

Sr.

No.

Raw Material Input/Kg of Product(Kg)

1 Mandelic acid 5

2 Acetyl chloride 7.7

3 Thionyl chloride 11.5

4 Tropine 4.2

5 MDC 320

6 Water 56

7 Acetone 88.6

8 Methyl Bromide 26

9 Ethanol 23.7

- - -

Total: 542.7

Sr.

No.

Output/MT of product Remark


Emission

Recovery Solid

Waste

1 Homatropine Methyl

Bromide (Pure)

3.2+1.8 - 6 - 11

2 MDC - 15 300 - 315

3 Water 56+15 - - - 71

4 Acetone - 3.6 80 - 83.6

5 Third party mixed solvent 62.1 - 62.1

Total: 138.1 18.6 386 - 542.7






APRIL’2018 175

Figure – 45: Raw Material, Material Balance and process of Homa Tropine Methyl Bromide

8. Reserpine


Reserpine is extracted through Rauwolfia Vomitoria roots through Methanolic Extraction.

The extract is further purified via Phase Exchange, Crystallization and Column

Chromatography to produce Reserpine API.

Rauwolfia

Vomitoria roots

Extraction &

Purification

Reserpine Molecular Formula: C33H40N2O9







APRIL’2018 176



Rauwolfia Vomitoria World Botanical Warehouse


Alumina oxide neutral Real Chemsys Warehouse

Ammonia Solution Fluorides Warehouse

n-Butanol Radiant Warehouse


Methylene chloride B. K. Sales Solvent Storage Tanks

Reverse Osmosis Water

(R. O. Water)


Silica Gel (60-120 Mesh) Real Chemsys Warehouse

Toluene V. S. Interchem Private Limited Solvent Storage Tanks

MATERIAL BALANCE SHEETS FOR RESERPINE:

STAGE-01


1 Rauwolfia powder 4000

2 Husk 400

3 Methanol 31680

4 Toluene 6069

Total 42149


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Syrup - - 350 - 350

2 Exhausted powder with husk - - - 4400 4400

3 Methanol 1580 1600 28500 - 31680

4 Toluene 309 260 5150 - 5719

Total 1889 1860 34000 4400 42149

STAGE-02


1 Syrup 350

2 Ethanol 572

Total 922






APRIL’2018 177


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Reserpine(crude) - - 35 - 31

2 Ethanol 50 52 470 - 572

3 Toluene 39 280 - 319

Total 50 91 781 - 922

STAGE-03


1 Reserpine(crude) 35

2 MDC 2190

3 Ethanol 280

4 Butanol 195

5 Water 210

Total 2910


Product Liquid

effluent

Air

Emission

Recovery Solid

Waste

1 Reserpine 8 - 27 - 35

2 MDC - 220 1970 - 2190

3 Ethanol 60 20 200 - 280

4 Butanol 60 15 120 - 195

5 Water 210 - - - 210

Total 338 255 2317 - 2910






APRIL’2018 178

Figure – 46: Raw Material, Material Balance and process of Reserpine






APRIL’2018 179

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR

THEIR MANAGEMENT/ DISPOSAL.

3.9.1 SOLID

Solid Waste Generation

Hazardous waste generation

S

No.

Hazardous

waste

description

Category

as per

HWMR

Rules

Existing

Quantity

per annum

proposed

Quantity

per annum

Total

per

annum

Unit Method of

Disposal

1 ETP Sludge 34.3 2400 600 3000 Kg

It will be sent to

GEPIL site at

Faridabad for

treatment and

disposal

2 Used Oils and

Spent Oil

5.1 & 5.2 1000 - 1000 Lit

3 Process residue

and waste

process oil

28.1 20000 10000 30000 Kg

4 Off

Specification

product

28.3 100 100 200 Kg

5 Expiry Drugs/

Medicines

28.4 100 100 200 Kg

6 Spent Solvent 28.6 12000 6000 18000 LTR

7 Spent Carbon 28.3 450 250 700 Kg

8 Empty Barrels

and Containers

33.1 300 150 450 Nos

Particulars Existing Proposed

Total

Treatment/ disposal

Herbal extract left over

(TPA)

1650 150 1800 100% used in Husk fired boiler

Municipal Solid Waste

(Kg/ day)

99 17 116 It is being sent to Sent to Municipal corporation,

Panipat. For proposed capacity the same practice

will be follow.

Husk Ash 500 -- 500






APRIL’2018 180

3.9.2 WATER REQUIREMENT AND WASTE WATER GENERATION

The present water requirements for the existing facility are 74 KLD. As there is an increase in

the production capacity post this expansion the total water requirement as detailed earlier

also would increase to 100 KLD after the installation of the ZLD system.

Existing Water consumption & Waste water generation details

Description Water Consumption

KLD

Waste Water

Generation

(KLD)

Effluent

Treatment &

disposal facility

Domestic use

Domestic 5 2 To STP (10KLD)

Industrial Use

a) Process 13 11 To ETP (25KLD)

b) Cooling tower 24 4

To ETP(25KLD)

c) Boiler/RO 25 3

d) Floor washing and

equipment washing

7 7

Fresh water

consumption

74 27

* Source: Existing bore well.

After expansion with change in water mix one-time water requirement is 120 KLD. Daily fresh

water requirement is 100 KLD and 20 KLD water will be recycled.

Proposed Water Demand and Waste Water generation

The water demand for proposed expansion and change in product mix is given in the flow chart

below:

Description Water Consumption

KLD

Waste Water

Generation (KLD)

Effluent

Treatment

& disposal

facility

Domestic use

Domestic 9 6 To STP (Cap.15KLD)

Industrial Use

Process 18 16 To ETP (Cap.35KLD)

followed by ZLD






APRIL’2018 181

Cooling tower 43 (15 KL Fresh

make up water + 28

KL treated water)

5 To ETP followed by RO

for further use in process

Boiler 30 4

RO reject 8 4 For flushing after

treatment

4 To ETP followed by RO

for further use in cooling

tower.

Horticulture / Green Area

Development

10 --

Fresh Water Demand 80

Recycled water 28

Total water consumption 108






APRIL’2018 182

Waste Water16 KL

2 KL

Process

Loss

RO Reject

The one time water demand will be 108 KLD. Daily fresh water demand - 80 KLD and the recycled water - 28 KLD

R.O. / DM Plant 80 KL

Boiler 51 KL (30 KL Fresh make up water + 21 KL Condensate Recovery

water)

Cooling Tower 43 KL (15 KL Fresh make up water + 28

KL treated water)

Domestic 9 KL

70 % Condensate

Recovery (21 KL)

Process 18 KL

R.O. Reject 8 KL

Reused in Horticulture (Green Area 6700 m2 area)

10 KL To be reused for

CT 23 KL

MEE 06 KL

R.O. Plant 29 KL

R.O. Permeate23K

L

5KL To be

reused for CT

Blow Down 4 KL

Blow Down 5 KL

Evaporation loss 38 KL

ETP 16+4+4+5= 29 KL

Floor Washing 4

KL

Consumption 3 KL

STP 4 + 6 = 10 KL

Dry Sludge 10 Kg

For Flushing

4 KL

10.0 Kg Solid

Waste – Use as

Manure

Sent GEPIL-Faridabad

for Disposal






APRIL’2018 183

A. ETP

The discharge design of the effluent is based on a capacity of 35 KLPD.

Table : Influent characteristics

S. No. Parameters Value Unit

1 COD 5000- 8000 mg/l

2 BOD 300- 350 mg/l

3 TSS 125- 180 mg/l

4 pH 6.0- 9.0

5 OIL & GREASE 5- 10 mg/l

Table: Treated Effluent Characteristics

S. No. Parameters Value Unit

1 COD <250 mg/l

2 BOD <100 mg/l

3 TSS <100 mg/l

4 pH 5.5 to 9.0

The detailed design of the ETP is as under

ETP DESIGN

The details of ETP operations

1. Equalization Tank (ET)

Receive the various liquid effluents generated by the process into ET via bar screen

chamber and oil & grease trap.

Start the aerator in effluent continuously.

Pump the collected and equalized effluent to the next stage of Flocculation System No-

1. (FSN-1) in regulated fashion.

Draw a sample of effluent each day.

Ensure that water level indication mark above the fourth level from the top is always

visible. Adjust the outflow from tank accordingly.

When level goes below fourth level from top, stop pumping. Resume when the level

touches the fourth level mark from top.

Allow boiler blow down water in Equalization tank to keep the water warm.

2 Flocculation Systems No. 1-1 (FSN-1):-

Prepare chemical solutions in dosing tanks.






APRIL’2018 184

Start the dosing of coagulant & flocculants in flocculation system no. 1.

Allow the effluent freely flow from the primary settling tank.

Add 50-200 PPM Microflock-90 solution to FSN-1 (1.0 liter Micro flock added to 200

liter water) continuously as a trickle over 12 Hrs. Maintain continuous additions round

the clock.

Add 10-30 PPM ferric chloride to FSN-1 (0.5 Kg ferric chloride in 200 liter water)

continuously as a trickle over 12 Hrs. Maintain continuous additions round the clock.

Let the tank over flow by gravity to the next stage of Primary Settling Tank (PST).

Start the sludge pump of primary settling tank.

Store the primary treated effluent in intermediate storage tank.

Start to pump the effluent in USAB for biological treatment.

3 Up-Flow Anaerobic Sludge Blanket (UASB)

Allow the effluent in USAB for biological treatment.

Prepare nutrient solution in dosing drum & start the dosing of DAP in intermediate

storage tank.

Maintain D.O. level less than 0.2 mg/l, alkalinity 1000-5000mg/l &COD:N:P::250 :5 : 1 .

Feed effluent from UASB to first stage aeration tank.

Monitor the temperature in the outflow effluent. It should not exceed 37 0C. Preferably

33-370C.

Collect sample from UASB outlets daily.

4. Filter Press No-1 (FP-1) 5. Aeration Tank No-1 (AT-1)

Receive effluent on a continuous basis.

Run the air blower to continuously purge air in the effluent.

Dose Micro flock-90 (1 liter micro flock-90 in 100 liter water) at a trickle over 12 hours

at the AT-1 over flow line Maintain continuous additions round the clock if required.

Draw a sample of slurry periodically.

Add 500 gmsgud in the tank as & when required to maintain MLSS

Modify sludge wasting frequency so as to have mixed liquor suspended solids (MLSS)

at 2500 to 5000 PPM.

6. Clarifier No-1 (CF-1)

Receive the effluent in the drum located in the center of CF-1.






APRIL’2018 185

Run the scrapper on a continuous basis. The sludge is pumped for recirculation from

CF-1 to AT-1 continuously.

Allow the clarified effluent to overflow into outlet launder for onward flow to Aeration

Tank No-2 (AT-2).

Periodically clean the outlet launder for foam and floating mass.

At every 6 hrs interval waste 0.55 kl of settled sludge from the clarifier bottom is

pumped to the sludge sump in PST. Before wasting stop recirculation from CF-1 to AT-

1 for about 15 minutes.

Draw a sample of clarified over flowing effluent daily.

7. Aeration Tank No-2 (AT-2)

Receive effluent on a continuous basis.

Run the air blower to continuously purge air into the effluent through fine bubble air

diffusers.

If required, spray the effluent over the liquid surface to arrest foaming.

Dose Micro flock (1 liter in 100 liter water) as a trickle over 12 hours at the AT-2

overflow launders. Maintain continuous additions round the clock.

Draw sample of the effluent slurry periodically.

Modify sludge wasting frequency so as to maintain mixed liquor suspended solids

(MLSS) at 2500 to 5000 PPM.

8. Clarifier No-2 (CF-2)

Receive the effluent slurry into the drum located in the center of CF-2.

Run the scrapper on a continuous basis. Run recirculation from CF-2 to AT-2 on a

continuous basis.

Periodically clean the outlet launder of CF-2.

At every 6hr. interval waste 0.55 kl of settled sludge from the clarifier bottom with the

aid of pump and transfer it to the sludge sump below TS. Before wasting stop

recirculation from CF-2 to AT-2 for about 15 minutes.

Draw a sample of clarified liquid overflow daily.

9 Holding Tank (HT)

Receive the effluent continuously.






APRIL’2018 186

Add 25-75kg of activated carbon daily @ 1-3 kg at the interval of one hour round the

clock.

Dose micro flock-90 (1 liter in 100 liter water) as a trickle over 12 hours at the AT-2

overflow launders. Maintain continuous additions round the clock.

Dose ferric chloride (0.3 kg in 200 liter water) as a trickle over 12 hours in holding

tank. Maintain batch additions as & when required.

Run the aerator for proper mixing in holding tank continuously for 5-10 minutes.

Stop the aerator for settling the flocks.

Start the pump to pass supernatant thru activated carbon filter.

Discharge the treated water in lawns.

Start the pump to feed sludge from holding tank to filter press.

DOMESTIC WASTE WATER

The total domestic waste water generated is 10.0 KLD. This quantity of waste water is treated

in properly designed Sewage treatment plant. The details and the schematic flow is appended

below.

SEWAGE TREATMENT PLANT

Process Scheme of Sewage Treatment Plant

Equalization Tank

The raw sewage collected in worker toilet sump thru bar and screen chamber for removal of

coarse and floating matters by trapping them in mesh. The screened sewage is passed through

the equalization tank to homogenize the characteristics by means of air agitation which help in

avoiding shock loading to the downstream process.

Aeration Tank

This homogenized sewage is pumped to aeration tank with the help of sewage transfer pump.

The aeration tank is designed on extended aeration activated sludge process to degrade the

organic matters by means of biological activity. The aeration tank is equipped with membrane

diffusers and blower assembly to provide atmospheric oxygen in to the sewage. The air

blowers are common for aeration process and equalization process.

Clarifier

The treated sewage from the aeration tank is taken in to the clarifier where the biomass is

settled with the help of polymer. The sludge settled in the clarifier is recycled back to the

aeration tank to maintain the desired level of mixed liquor suspended solids in with the help of

the pump.

Sludge Drying Beds






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Excess sludge is disposed of in the sludge drying bed for dewatering of sludge.

Chlorination Tank

The clear supernatant from clarifier is then transferred in to the chlorination tank for

disinfection by sodium hypochlorite added in tank by dosing pump.

Sand Filter

From Chlorination tank the treated effluent is pumped for filtration to the multi-grade filter.

Activated Carbon Filter

The effluent is further passed through the activated carbon polishing unit.

Treated Water Storage Tank

The finally treated water is stored in collection tank and pumped directly to the garden for

irrigation purposes.

Figure – 1: Schematic Flow Diagram of Sewage Treatment Plant






APRIL’2018 188

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE

INFORMATION OF EIA PURPOSE

Project Concept

Form 1, Pre-feasibility Project Report with Proposed TOR to SEAC

Scoping by EAC (Site visit by sub group of EAC, if necessary)

TOR approved by SEAC EC - rejected by SEIAA on recommendation of SEAC

Draft EIA Report to SPCB

by Project Proponent

Public Consultation process by SPCB

Summary EIA and Form 1 – display

on the Website by SPCB

Proceedings of Public Consultation

Appraisal and Recommendation by SEAC

Display on MoEF&CCWebsite

Display at Panchayat, ZP, DM/DC/

Dy. Com & on the SPCB website

To Proponent for Submission of Final EIA

Report/Supplementary Report to Draft EIA

Approval by SEIAA

Rejected Approved Display on SEIAA Website& Project Proponent Website

Post EC

Monitoring

Submission of half yearly Compliance

Report to MoEF&CC/ RO-MoEF&CC

Display of Compliance Report

on MoEF&CCWebsite






APRIL’2018 189

4.0 SITE ANALYSIS

4.1 CONNECTIVITY

The site is located in the RIICO industrial area. All the amenities that are required for a stable

industry are available there.

Table 4: Connectivity

Particulars Name Distance, Direction


National Highway NH-1 20m,W

State Highway SH-16 7.15 Km, NW

Railway Station Diwana 2.59 Km, NNW

Airport Delhi International Airport 81.50 Km, S

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

4.2.1 LANDFORM

The unit is situated in the non -notified Industrial area. The proposes expansion and change

in product mix is coming within the existing premises. No additional land is required for the

expansion and change in product mix.

4.2.2 LAND USE

The proposed land use of the project is as under.

S.No Particulars Exiting

Area (SQM)

Proposed

Area

(SQM)

Total Area

(SQM)

Percentage

(%)

1 Buildings / Office / Warehouses

/QC/R&D / Workshop/ DG Room

/Manufacturing plants/ETP/RO

Plant/Boiler

18,163 1,400 19,563 58.83

2 Paved area/


4,569 301 4,870 14.64

3 Green belt 6,700 -- 6,700 20.15

4 Open area 3,822 -1,701 2,121 6.38

TOTAL 33,254 -- 33,254 100%

4.2.3 LAND OWNERSHIP

The project is situated in non industrial area and duly converted for industrial use.






APRIL’2018 190

4.3 TOPOGRAPHY (ALONG WITH MAP)

The topography of the district is flat surfaces with slight slopes running from North East

towards South and South West. It mostly has alluvial deposits which resulted from tectonic

changes effected due to Himalayan ranges. These deposits are composed of layers

originating from alluvial silt and sand. The Western Yamuna canal is exists at 3.72 km in

West direction of the proposed plant. There is no River in the near vicinity of 10 Km.

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER

BODIES (INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE

PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL PARK,

WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE

HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE

GAZETTE NOTIFICATION SHOULD BE GIVEN.

The existing land use pattern is given in point no. 1.2.

4.5 EXISTING INFRASTRUCTURE

The existing project is a Lepro Herbals Private Limited, situated at G.T. Road Village-

Jattipur, Tehsil –Samalkha, Tehsil – Panipat, Haryana.

The land is duly converted (CLU) for Industrial use

Power is supplied almost uninterrupted from HSEB through an independent feeder.

There is availability of semi- skilled/skilled work force from the vicinity.

A. Physical Infrastructure

Physical Infrastructure is an important aspect of a city. It determines the quality of life to a

large extent. Physical Infrastructure deals with.

Water Supply

Electricity

Solid Waste disposal

B. Water supply

The water requirement is being met from existing bore well.

C. Solid Waste & Sanitation

All solid waste will be disposed of to the GEPIL site of Faridabad.






APRIL’2018 191

D. Electricity

The Unit is being fed through an independent feeder from the nearest Haryana State

Electricity Board. The unit has a total connected load of 810 kVA which is being supplied

Haryana State Electricity Board. There is no increase of electricity load envisaged after

expansion and change in product mix.

4.5.1 BASIC AMENITIES

The social infrastructure viz. hospitals, schools, places of worship, community facilities are

available in the study area. Habitation of Jattipur -500m,E is the nearest habitation. The

Location of the project is remote from the urban part of Panipat district but is an urbanizing

developing area.

4.6 SOIL CLASSIFICATION

The district has two types of soils viz-tropical arid brown and arid brown soils (solemnized).

The arid brown soils are found in major parts of the district whereas tropical arid brown

soils are found in north eastern part of the district especially in parts of Bapoli and Panipat

blocks.

4.7 CLIMATE

The climate of the district can be classified as sub tropical and semi arid. The area receives

normal annual rainfall is about 680 mm which is spread over 31 rainy days. 77% of rainfall

occurs during south-west monsoon. The normal annual rainfall of district based on average

of 5 years (2006-2010) has been computed as 591 mm.

4.8 SOCIAL INFRASTRUCTURE AVAILABLE

The well-established social infrastructure like hospitals, temple, community centre, roads,

bridges, telecommunication and others similar are available/ existing within 15 km radius..

5.0 PLANNING BRIEF

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND TRANSPORTATIONETC.)

TOWN AND COUNTRY PLANNING/ DEVELOPMENT AUTHORITY CLASSIFICATION.

The Bulk Drugs and Chemical industry is aptly described as the “Life Saving Industry”

signifying the crucial role its products play in alleviating human suffering from diseases and

controlling the various epidemics with pose and endemic danger to human civilization.






APRIL’2018 192

Keeping in view the apparent consumption for pharmaceutical formulations and existing

production capacities in the state and adjoining areas.

5.2 POPULATION PROJECTION

There will be recruitment of additional 34 workers as per requirement in operational phase.

The existing project has employed a work force of 198 workers. Hence the projected

population shall marginally augment by 34 workers only and shall not contribute major

increase in local area population.

5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC.)

S.

No

Particulars Exiting

Area (SQM)

Proposed

Area

(SQM)

Total Area

(SQM)

Percentage

(%)

1 Buildings / Office / Warehouses

/QC/R&D / Workshop/ DG Room

/Manufacturing plants/ETP/RO

Plant/Boiler

18,163 1,400 19,563 58.83

2 Paved area/


4,569 301 4,870 14.64

3 Green belt 6,700 -- 6,700 20.15

4 Open area 3,822 -1,701 2,121 6.38

TOTAL 33,254 -- 33,254 100%

The existing unit has approximately 20.15% total land area in green belt and plantation. The

remaining greenbelt will be done outside the plant premises boundary in school, panchayt ,

along the road side. The main aim of the green belt development is to improve the ecosystem

to a maximum possible extent by designing the green cover with the same native species.

However, in order to compensate the loss of vegetation, it is suggested to carry out extensive

afforestation program mainly in and around the project area. Appropriate plant species of

different life forms have been suggested in the following table to grow and to re-establish the

vegetation cover and thereby provide habitat for the faunal species. The list of plant species

suggested includes the following criteria:-

Tree species which are well adapted to local environmental setting, tall, bearing larger

canopy cover and leaf area.

Tree species of different size classes (small, medium and larger) were suggested to

maintain the different canopy levels at vertical profile.






APRIL’2018 193

Fruit trees in the selection list would help to attract birds and fruit eating bats which

are locally available.

Wild species were suggested to provide habitat for faunal species, increase the faunal

species diversity and maintain the naturalness.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL)

On the basis of the preliminary site visit, the infrastructure demand in the villages assessed on

the basis of need and priority. The health infrastructure of the study area requires

improvement. The assessment will be identified in the socio economic survey, after the grant

of TOR and will be submitted at the time of final presentation regarding EC.

5.5 AMENITIES/ FACILITIES

As there is no major construction activities to be proposed. However necessary amenities will

be provided if required.

6.0 PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The area is very well connected by road network to the site, district headquarter etc. The area

is self sufficient to cater the needs of the project. Hence, no infrastructure is proposed.

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

No housing facility has been proposed.

6.3 GREEN BELT

The same has been given in point 5.2.

6.4 SOCIAL INFRASTRUCTURE

The existing project is situated at Tehsil –Samalkha, District – Panipat (Haryana). Local

population is employed by the company in the project. Further, indirect means of earnings

have been created in the area of contractual jobs, vehicle driving, shops, construction etc.

Therefore, this project brought a positive impact on the adjoining society. The proponent is

being spent 1% of profit for the development of the area i.e. medical facilities, schools, temples

and other social work. There is well developed social infrastructure in the area; detail has

been tabulated in section – III of Form – 1.






APRIL’2018 194

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/ METRO/WATER WAYS

ETC.)

Given in point no. 4.0.

6.6 DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OF WATER)

Given in point no. 3.8.1.

6.7 SEWERAGE SYSTEM

For the treatment of domestic sewage, STP (10 KLD) has already provided with adequate

capacity in existing plant.

6.8 INDUSTRIAL WASTE MANAGEMENT

The company has already provided ETP (25KLD) for treatment of industrial waste water.

The up gradation of the ETP (35KLD) and the scheme for ZLD is proposed in order to comply

the norms .

6.9 SOLID WASTE MANAGEMENT

The same has been given in point no. 3.9.1.

6.10 POWER REQUIREMENT AND SUPPLY/ SOURCE

The same has been given in point no. 4.5.

7.0 REHABILITATION AND RESETTLEMENT (R & R PLAN) : Not applicable

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED

PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOUR (A

BRIEF OUTLINE TO BE GIVEN)

Since, it is an existing project and there is no habitation in the unit area, therefore

rehabilitation & resettlement plan is not required/ applicable.






APRIL’2018 195

8.0 PROJECT SCHEDULE AND COST ESTIMATES: Rs. 51.11Cr.

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION (TIME

SCHEDULE FOR THE PROJECT WILL BE GIVEN).

The construction phase in this project is likely to commence in after the obtaining statutory

approval from the concerned departments. In the meanwhile, the changes in the product mix

can be initiated.

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC

VIABILITY OF THE PROJECT.

The expected capital investment for the Proposed expansion with change in product mix

cost is Rs 870Lacs.

9.0 ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFITS TO

THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA.

There have been many social benefits from the existing manufacturing operations. The

underlying financial and social benefits envisaged through the existing plant have been

listed as follows:-

Table 10: Financial & Social Benefits

S. No. Activities

1. It aims to provide few additional employments to the local population of the proposed study

area.

Existing Direct employment provided: -198 Approx.

Indirect Employment to locals :- 25 + 25 Approx.

The proposed expansion with change in product mix aims to continue the sustainable social

development. The Project authorities are committed towards fulfilling social responsibility.

As per the Companies Act 2013 , The CSR would be applicable for every company having net

worth of Rs. 500 crore or more, or turnover of Rs. 1000 crore or more or a net profit of Rs. 5

crore or more during a year, such Companies shall be required to ensure that every year at

least 2% of its average net profits during the three immediately preceding financial years is

spent on CSR activities as may be approved and specified by the company. Lepro Herbals

Pvt. Ltd. is not under the threshold limit applicable for mandatory CSR. However, The project

understands its responsibility towards the society and therefore has been undertaking many

projects for sustainable development (few of which are given below).






APRIL’2018 196

After the analysis of the baseline data generation, socio – economic survey, and the public

hearing, the appropriate sustainable development plan will be contributed on the basis of

need based analysis, projected by the corporation.

The appropriate amount of CSR will be proposed by the Lepro Herbals Private Limited with

its applicability as per the Companies Act, 2013 with an appropriate 2% of the next three

years average annual net profits of the coming years.

10.0 CONCLUSION

Lepro Herbals Pvt. Ltd. proposes expansion with change in the product mix for

manufacturing of herbal extracts and active pharmaceuticals ingredients in existing plant

area of 33,254Sq.m. No additional land is required. The total capital investment till

31.03.2017 of Lepro Herbals Pvt. Ltd. plant of Herbal Extract & Its Purified Products is

3,537.98Lacs. The project is not only contributing to the growth of Indian economy but also

strengthen the socio-economic values/ status in the area. All the latest and environment

friendly technology is adopted. The unit is already adopting all measures like; pollution

control equipments, effective EMP & DMP to prevent harm/ damage to the environment.

Green belt development in & around the area is increase aesthetic value, as tool for effective

pollution mitigate measure, and are also serve as biological indicators for that particular site.

*****************

pre feasibility report -...

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