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Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin

Plant along with Pilot Plant for Fermentation


& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

PRE FEASIBILITY REPORT

1.0 TYPE OF THE PROJECT


The project mainly consists of installation of all the manufacturing and EMP equipment and
necessary infrastructure development required for operating Malt Spirit Plant, Cane juice Rum
Plant & Craft Gin Plant. The project proposal is for 2 KLPD Malt Spirit Plant, 2 KLPD Cane
juice based Rum Plant & 2 KLPD Craft Gin plant along with Pilot Plant for fermentation &
Bottling Plant at Plot No. 2A, Sector 4, IIE (Integrated Industrial Estate) Escort Farm, Kashipur,
District Udham Singh Nagar, Uttarakhand.
As per EIA Notification dated 14th Sep., 2006 and as amended on 13th June, 2019, the project
falls under Category “B”, Project or Activity ‘5(g)’ Distilleries (Non Molasses based distilleries ≤
200 KLPD). As per EIA Notification, 2006; as amended from time to time, “In absence of a duly
constituted SEIAA or SEAC, a Category “B” project shall be treated as Category “A” project”;
and due to absence of SEIAA or SEAC at Uttarakhand, this project will be considered as
Category “A” and will be appraised at Central level in MoEFCC, New Delhi.

1.1 NEED FOR THE PROJECT


Rum is one of the oldest spirits available, which is rich in tradition and culture of the Caribbean
and history of the British Navy. According to numerous studies, beyond being alcohol it also
provide health benefits and nutritional benefits to all age of people. Drinking rum in moderation is
beneficial for the heart. Also, it decreases cholesterol levels in the body. It is also a good drink
for peripheral artery disease prevention and is a blood thinner, which can help combat artery
blockages, prevent heart attacks and heart disease. Consuming a tablespoon or two of rum a day
can help treat the common cold. This is due to rum’s high antibacterial properties, which helps
cure colds effectively. Rum when consume moderation helps to prevent Alzheimer’s disease,
prevent kidney cancer, helps to fight sore muscles and also found useful in getting clear skin. It is
often said that drinking a tablespoon of rum daily lowers blood sugar level. Rum comprises of no
carbohydrates or fats. Moderate drinking of rum reduces anxiety, is good for the heart, and
reduces the risk of dementia; all of which increase an individual’s life span. Drinking it in
moderation can possibly extend lifespan by two to five years.
Gin serves as one of the healthiest spirits ever created, its low in calories, and the botanical
properties that survive the distillation process present plenty of health-boosting reasons. The gin
act as a natural medicine that contains some antioxidants, and anti-fungal and anti-microbial
properties that helps to fight pesky cough, prevent bloating and urinary tract infections. Gin
contain high level of antioxidant which help to “neutralize free radicals in the body” which are
some roots of cancer disease.

M/s. Himalaya Wine Company Private Limited 1 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Malt Spirits is made from fermented mash consisting primarily of malted barley or rye. Malt
spirits like others also contain many health benefits when consume moderately, much like rum
and gin, it also help in lower the risk of health problem like dementia, common cold, and
improve heart health. It contains no fat and hardly any sugar or carbohydrates. It barely alters the
level of sugar in blood. Malt spirits has many antioxidant which help in reducing the skin
problems and also helps to loose weight.
The proposed project will result in growth of the surrounding areas by increasing direct and
indirect employment opportunities in the region including ancillary development and supporting
infrastructure. Development of social amenities will be in the form of medical facilities, education
to underprivileged and creation of self-help groups. Business opportunities for local community
will be available. No adverse effect on environment is envisaged as proper mitigation measure
will be taken up for the same.

1.2 LOCATION
The project site is located at Plot No. 2A, Sector 4, IIE (Integrated Industrial Estate) Escort Farm,
Kashipur, District Udham Singh Nagar, Uttarakhand.

1.2.1 General Location Map


The map showing location of the project site is given in the figure below.

M/s. Himalaya Wine Company Private Limited 2 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Source: SOI Toposheet Figure 1.1: Location Map of the project site

M/s. Himalaya Wine Company Private Limited 3 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation & Bottling Plant
At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

1.3.2 Specific Location Map


The map showing specific location of the project site along with boundary coordinates marked on a Google image is given below:

Source: Google Earth Figure 1.2: Google image showing the specific location of the project site

M/s. Himalaya Wine Company Private Limited 4 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

1.3.3 Plant Layout


The total area for the project is 0.8533 ha. The land is already under the possession of Company.
The project site lies in IIE (Integrated Industrial Estate) Escort Farm, Kashipur.
After installation of the plant, about 33% of the total project area will be covered under greenbelt
& plantation, i.e, 0.282 Ha. Area details are given in below table.
Table - 1.1
Area break-up
S. No. Particulars Area (hectare)
1. Main plant, machinery & Utilities 0.2283
2. Raw material & product storages 0.0774
3. Road & paved areas 0.0569
4. Open area 0.03
5. Parking area 0.128
6. Admin offices & excise office 0.0507
7. Total greenbelt development and plantation 0.282
Total 0.8533 ha

Company had submitted the application for obtaining Environmental Clearance for “Proposed 10
KLPD Malt Spirit Plant along with 0.75 MW Co-generation Power Plant at Plot No. S2-09,
Escort Farm, SIIDCUL Integrated Industrial Estate, Kashipur, District Udham Singh Nagar,
Uttarakhand” to SEIAA, Uttarakhand on 16th October, 2010 and subsequently, ToR Letter was
issued by SEAC, Uttarakhand vide their letter no. 175/SEAC dated 27th August, 2020. In this
regard, due to change in Master plan because of establishment of EMC at IIE Kashipur,
management had decided to change of plot from sector 2, Plot no. 9 to Sector 4 Plot no. 2A at IIE
Escort Farm, Kashipur by approximately 0.4 km in East direction from the site proposed earlier.
Now the company herewith is proposing for “2 KLPD Malt Spirit Plant, 2 KLPD Cane juice
based Rum Plant & 2 KLPD Craft Gin plant along with Pilot Plant for fermentation & Bottling
Plant at Plot No. 2A, Sector 4, IIE-Escort Farm, Kashipur District Udham Singh Nagar,
Uttarakhand”.
Layout map showing the proposed unit indicating storage area, plant area, greenbelt area, utilities
etc. has been given in Figure below:

M/s. Himalaya Wine Company Private Limited 5 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation & Bottling Plant
At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Figure 1.3: Master Plan of IIE-Escort Farm, Kashipur

M/s. Himalaya Wine Company Private Limited 6 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation & Bottling Plant
At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Figure 1.4: Plant Layout

M/s. Himalaya Wine Company Private Limited 7 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

1.3.4 Photographs of the Proposed Project Site


The photographs showing the proposed project site are given below. It is an open and leveled
land.

1.4 SIZE OR MAGNITUDE OF THE OPERATION


Size or magnitude of operation for the proposed project is given below:
Table: 1.2
Details of the proposed project
S. No. Units Capacity Products
1. Malt Spirit Plant 2 KLPD Malt Spirits
2. Cane juice based Rum Plant 2 KLPD Rum
3. Craft Gin plant along with Pilot Plant for Gin & Fruit based
fermentation & Bottling Plant 2 KLPD distilled products

Table 1.3
Other details of the Project
A. Cost Details
1 Total Cost for the Project Rs. 30 Crores
2 Cost for Environmental Management Plan Capital Cost: Rs. 4.0 Crores
Recurring Cost: Rs. 0.65 Crores/annum
3. No. of working days 350 days/annum

1.4.1 Requirements for the project


The project requirement such as area, raw material, fuel, water, steam, power, manpower with
source of supply is described in the section below:

M/s. Himalaya Wine Company Private Limited 8 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

1.4.1.1 Raw material requirement


The basic raw material for the manufacturing of Malt spirits will be Barley/Barley (Malt). Craft
Rum will be produced from Sugar Cane & Craft gin from ENA (Extra Neutral Alcohol- Grain
Based). In the present scenario, all the raw materials are easily available in the nearby area.
Table- 1.4
Raw material requirement, source and transportation
S. Particulars Total Storage Source & mode of
No. Requirement transportation
1. Barley 4 TPD 120 T Steel Silo Barley/Malt supplier via road
2. Sugar Cane 30 TPD 10 T Cane godown Sugar cane from nearby farm via
road
3. Extra Neutral 600 BL/day 25 KL Steel tanks Grain based ENA from nearby
Alcohol distillery
4. Chemicals
CIP Chemicals 4 kg/day 60 kg In Stores Chemicals supplier via road
Caustic soda 4 kg/day 60 kg Stores/Steel Near-by Markets via road
Tanks
Enzyme 6 L/day 100 L In Stores
Yeast 40 kg/day 500 kg In Stores

1.4.1.2 Fuel Requirement


Biomass/Bagasse/Cane trash will be used for the proposed boiler of 4 TPH (2 x 2 TPH). Details
regarding fuel requirements are given below.
Table- 1.5
Fuel Requirement
S. Name of Material Requirement Source of Material
No. (TPD)
1. Biomass 25 TPD Bagasse in-house & rest from local
(Bagasse/ cane trash/ wood chips/ suppliers by road
Agro waste)

1.4.1.3 Water Requirement


The fresh water requirement for the proposed project will be 64 KLPD which will be sourced
from the Groundwater.
Status of approval: The company has obtained NOC for ground water abstraction of 64 KLPD
from CGWA vide NOC no. CGWA/NOC/IND/ORIG/2022/14749 valid from 02.03.2022 to
01.03.2025.
Break-up of the water requirement is given below:

M/s. Himalaya Wine Company Private Limited 9 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Table - 1.6
Water Requirement
S. No Process Details KLPD
1. Process Water 66
2. DM Water for Process 11
3. DM Water in Boiler 18
4. Cooling Tower Makeup water 52
5. Laboratory Water 5
6. Domestic Consumption & Others 11
Total water consumption 163
Treated water from CPU 99
Total Fresh water requirement 163- 99= 64

M/s. Himalaya Wine Company Private Limited 10 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation & Bottling Plant
At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Figure 1.5: Overall Water Balance

M/s. Himalaya Wine Company Private Limited 11 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation & Bottling Plant
At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Figure 1.6: Integrated Mass Balance for Malt Spirit/Craft Gin/Craft Rum

M/s. Himalaya Wine Company Private Limited 12 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

1.4.1.4 Steam Requirement


Steam requirement will be 3.40 TPH for plant operation which will be sourced from proposed
boiler 4 TPH (2 TPH + 2 TPH). Steam generated from the boiler will be consumed for operations
Mashing/fermentation, Pot still Distillation and Boiler De-aeration & others. The steam
requirement for the process is given below:
Table – 1.7
Steam requirement
S. No. Purpose Steam Required (TPH)
1. Mashing/Fermentation 0.5
2. Pot still Distillation 2.6
3. Boiler De-aeration & others 0.30
Total 3.40

1.4.1.4.1 Boiler details


A boiler of 4 TPH (2 x 2 TPH) capacity with Bag filter as Air Pollution Control Equipment will
be installed. Details regarding proposed boiler are mentioned in the table given below:
Table – 1.8
Proposed boiler details
S. No. Details
1. Type of Fuel Biomass
(Bagasse/ cane trash/ wood chips/ Agro waste)
2. Capacity of Boiler 2 x 2 TPH
3. Stack Height 30 meters
4. Pollution Control Equipment Measures Bag filter

1.4.1.5 Power requirement


The power requirement is 0.75 MW, which will be sourced from Uttarakhand Power Corporation
Ltd (UPCL). For the same, the company has already applied for power connection in Single
Window Clearance of Government of Uttarakhand and the same has been recommended by
UPCL.
Details regarding the D.G. Sets
D.G. set of 750 KVA will be installed for the power backup. Details regarding the D.G. Sets are
mentioned in the table given below:
Details Regarding the D.G. Sets
S. No. Details
1. Type of Fuel HSD
2. Capacity 750 KVA
3. Stack Height (above roof level) 6 meters
4. Pollution Control Equipment Measures Adequate stack height & Acoustic

M/s. Himalaya Wine Company Private Limited 13 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

1.4.1.6 Manpower requirement


There will be direct & indirect jobs and business opportunities to the local people such as daily
wage labour, transporters and raw material suppliers. The manpower required for the proposed
project will be 70 persons during operation phase (50 persons Permanent employees and 20
persons Temporary employees).
Source: Unskilled/ semi-skilled manpower from local area and skilled from outside/local.
Details regarding manpower requirement is given in the table below.
Table-1.9
Manpower Requirement
Temporary employment during construction 45
Permanent employment during construction 5
Total during construction 50
Temporary employment during operation 20
Permanent employment during operation 50
Total during operation 70

1.5 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION


The project commissioning activities will start after getting Environmental Clearance (EC) from
MoEFCC, New Delhi and relevant consents from UEPPCB. Tentative time for commissioning of
the project will be within 1 year.

M/s. Himalaya Wine Company Private Limited 14 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation & Bottling Plant
At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Activity Months

1 2 3 4 5 6 7 8 9 10 11 12

Appointment of consultant, 1
basic engineering and issue of
tender enquiries and main
machinery order placement for
units
Civil construction 2
Fabrication and mechanical 3
work
Electrical and instrumentation 3
erection
Refractory works 1
Trial runs and commissioning 2

M/s. Himalaya Wine Company Private Limited 15 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

1.6 TECHNOLOGY AND PROCESS DESCRIPTION


1) 2 KLPD Malt Spirit Plant:
 Barley Malting
 Malt storage, conveying and cleaning system.
 Malt milling system
 Mashing system
 Lauter Tun system (for wort separation), wort cooling and process water systems
 Fermenters Wash stills Spirit stills
 Spirit receivers & effluent receivers
Malt Storage, Cleaning, Conveying & Milling
This section comprises of cleaning and milling of the malt. It would comprise of equipment for
cleaning, aspiration, milling and grist storage.
Brewhouse
This section mainly comprises of the following:
 Steeles Masher
 Lauter tun
 Wort holding tank Water tanks
 Wort cooler
 Water heater
The grist is mixed with water at a recipe temperature and transferred into the lauter tun for
collection of wort. The wort collected from this is termed as first wort. With lautering in progress,
two sparging at recipe temperatures are done and the recipe amount of wort is collected. The last
wort, also termed as weak wort is collected back into one of the hot process water tanks and used
as mashing water for the next batch. The brewing process water will be stored in the tanks
dedicated for the same. The wort collected is then cooled to a recipe temperature and transferred
into the fermenters via wort cooler. A wort holding tank is provided to smoothen out the process.
The draff or spent grain disposal system mainly comprises of dump tank and spent grain silo/s.
Fermentation Section
This section comprises of fermenters required for production of wash used for distillation process.
The process is batch process. Dry yeast is used and discarded at the end of every batch. The
process is carried out at room temperature with low initial temperature.
Still House
The steps involved in the operation of still house are as follows:
a) Wash charging
b) First Distillation of wash
c) Collection of low wines

M/s. Himalaya Wine Company Private Limited 16 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

d) Charging of spirit stills


e) Second distillation (low wines + feints)
f) Spirit transfer
The description of the individual steps from (a) to (f) is given below:
a) Wash charging
The fermented wash from the fermenters is preheated and transferred into the wash stills.
b) First Distillation of wash
first distillation occurs in the Wash still where wash is distilled to give low wines. Steam is
used for this process. This distillation is carried out for a recipe defined time.
c) Collection of low wine
The alcohol vapors generated are cooled by vertical condensers using cooling water. The low
wine produced, having 15-16% alcohol produced is further cooled to the required temperature
(approx 17-18 deg C) via a sub-cooler which uses chilled water. The low wine is collected in
the low wine receiver through the spirit safe. The low wine is used as charge to second
distillation in the spirit still. The effluent i.e. potale is drained into the potale receiver and
transferred to ETP. The heat from this effluent is recovered by using it for preheating of wash
of the next batch.
d) Charging of spirit stills
The low wines and feints are preheated and charged into the spirit still/s for second
distillation.
e) Second distillation
During second distillation, spirit having about 64% alcohol will be collected and transferred
to the intermediate spirit receiver through the spirit safe. The heads and tails, also called
foreshots & feints is diverted via the spirit safe into the feint’s receiver
f) Spirit transfer
The spirit is collected in the intermediate spirit receiver and further transferred to the final
spirit receiver in the cask room.
Cleaning –In- Place
This section would typically comprise of the following:
 Rinse water tank,
 Caustic tanks
 Chemical dosing tank
 PHEs for caustic heating
Maturation / Warehouse
This section would have Mild steel racking system, generally 9 to 10 levels high to accommodate
required number of Oak wood casks matching with FMS& Craft Rum production.

M/s. Himalaya Wine Company Private Limited 17 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Figure-1.7: Malt Spirit Plant Process Flow Diagram


2) 2 KLPD Cane juice based Rum Plant:
 Sugarcane crusher, Juice preparation.
 Fermenters, Wash stills Spirit stills
 Spirit receivers & effluent receivers
Sugar cane crusher & Milling
This section comprises of cleaning and milling of the Sugar cane. It would comprise of
equipment for cleaning, milling and juice filtration.

M/s. Himalaya Wine Company Private Limited 18 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Fermentation Section
This section comprises of fermenters required for production of wash used for distillation
process. The process is batch process. Dry yeast is used and discarded at the end of every
batch. The process is carried out at room temperature with low initial temperature.
Still House /Maturation/Warehouse
The steps involved in the above operations are similar to what we do for Malt spirit
production.

Figure- 1.8: Craft Rum Plant Process Flow Diagram

M/s. Himalaya Wine Company Private Limited 19 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

3) 2 KLPD Craft Gin Plant with Fermentation & bottling:


Major equipment:
 Universal Pot still
 Maceration Tank
 Resting Tanks etc.
Grain Based ENA (Extra Neutral Alcohol) is diluted & is mixed with Botanicals in the
maceration tank for 6-10 hrs. followed by distillation in the Pot still. Distillate so produced is
kept in the resting tank followed by Dilution for final blend for Bottling.
Pilot Plant (Fermentation System)
Set of Fermenters with matching capacity of Universal Pot still (2 KLPD product). System
will be used for Pilot fermentation of different substrates i.e., Fruit juices/starchy
material/Cane juice etc. After fermentation broth will be distilled in the Universal pot still
and the effluent/washings will be sent to ETP for treatment. Distilled product will be further
processed for different products. Process Flow diagram is given below.

Figure 1.9: Craft Gin Plant Process Flow Diagram

M/s. Himalaya Wine Company Private Limited 20 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

1.6.1 Distillery Effluent treatment scheme


Effluent generation from process Capacity of ETP proposed
118 KLPD 150 KLPD

ETP for proposed unit have been designed to achieve Zero Liquid Discharge Norms. Total
effluent of said system has been divided into 2 parts:
A) Coloured effluent: Spent wash from Both Malt Plant/Rum Plant & Pilot Fermentation
system & Fermentor Washings. Solids in the coloured effluent will be concentrated to 30-40
% followed by drying in the sludge drying bed. Leachate is again recycled to the evaporator.
Latest Technology of MVR based system will be used to evaporate effluent so as to avoid
Steam / cooling water, hence reducing overall water requirement. Mechanical Vapor
Recompression (MVR) is a energy-saving low-temperature evaporative concentration
technology, which uses low-value waste steam and heat, designed on the theoretical basis of
Boyle’s law which means that during compression as the volume of gas decreases, the
pressure and the temperature increase thereby making available the energy for reuse
According to this principle, the energy normally lost in the compression is recovered, the
latent heat of steam is recycled and fresh steam consumption is avoided leading to a highly
energy saving evaporation process.
B) Non colored effluent: Spent lees/ Plant washings, Boiler blowdown/cooling water
blowdown, Evaporator condensate/Process condensate. White effluent is collected in the
equalization tank followed by pH adjustment if any. After pH adjustment it will be treated it
C.P.U. system. CPU system will comprise of Dual filtration system, RO system. ACF & UV
system to recover around 80 % of the infeed & recycled back to the process requirement.
Reject so obtained along with Reject of Water treatment plant (both with high TDS) will be
evaporated to recover more than 90 % water and reject will be used dried in sludge drying
bed.
Table – 1.10
Characteristics of untreated and treated effluent
Particulars ETP Inlet ETP Outlet
pH 4.5 – 5.5 7–8
Total Suspended Solids(mg/l) 19000 – 20000 <50
BOD (mg/l) 5000 – 6000 <30
COD (mg/l) 19000 - 20000 <250

M/s. Himalaya Wine Company Private Limited 21 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

Figure- 1.10: Effluent Treatment Plant Process Flow Diagram


1.6.2 Major equipment and machineries
Details regarding major plant equipment & machineries are given in the table below:
PLANT TYPE PARTICULARS QUANTITY
Craft Gin Plant Pilot Fermenters 7
Feed Tank 1
Maceration Tank 2
ENA Storage 1
Pot Still with Condensers 1
Gin Receivers 6
DM Water Tank 1
Chiller Unit
Cane Crushing Unit
Fermenters 5
Wash Still + Condenser 1
Spirit Still + Condenser 1
Malt Spirit Plant Malt Cleaning and Milling
1. Intake Malt Elevator 1
2. Malt Elevator-I
3. Classifier
4. Dry Destoner
5. Bucket Elevator- II

M/s. Himalaya Wine Company Private Limited 22 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

6. Magnet with Housing


7. Dry Malt Mill
Brewhouse
1. Masher 1
2. Lauter tun
3. Dump tank
4. Spent grains pneumatic conveying system
5. Spent grains main storage silo
6. Wort intermediate tank
7. Wort receiver
Fermenter 12
Wash Still + Condenser 1
Spirit Still + Condenser 1
Spirit Receiver 3
Low Wine Receiver 2
Bottling Plant Bottling System with ENA, Spirit & Blending Tanks
Miscellaneous DM Plant
Sewage Treatment Plant
Cooling Tower / Chiller Unit
Boiler Unit

1.7 DESCRIPTION OF MITIGATION MEASURES


The Company will implement mitigation measures for different environmental components (air,
water, noise, soil, waste) in order to meet environmental standards. This section will describe in
detail the mitigation measures the Company will follow in order to remain within prescribed
limits of standards.

1.7.1 Air Pollution


 Bag Filter as APCE with stack of 30 meter height will be installed with the proposed boilers
(2x2 TPH) to control the particulate and gaseous emissions due to combustion of fuel.
 DG Sets will have 6 meter stack height as per CPCB guidelines.
 Roads within the plant will be concreted to control the fugitive emissions.
 Adequate greenbelt will be developed in the plant area.
 Online Stack Monitoring system will be installed with the proposed stacks.
 The overall quality of the ambient air will be monitored and maintained within the limit
prescribed by CPCB/SPCB after the commencement of the operations of proposed project.
 Greenbelt will be developed all around the plant boundary and the same will be maintained.

1.7.2 Water Pollution


 Production facilities are designed based on achieving “Zero Effluent Discharge” norms.

M/s. Himalaya Wine Company Private Limited 23 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

 Coloured effluent i.e. spent wash & washings from Malt Spirit Plant / Craft rum plant/Pilot
Fermentation plant etc shall be concentrated into solids with Evaporator followed by drying in
the sludge drying beds.
 White effluent i.e. process Condensates, spent lees & washings etc. will be treated in C.P.U.
(Capacity 150 KLPD) & the treated water will be recycled back to process plant.
 Spent Grain / Wet cake (DWGS) (4 TPD) will be utilized as Cattle, poultry and fish feed
ingredients.
 Solids removed from Cane juice & Malt spent wash (3 TPD) shall be sold off as organic
manure.
 Sewage from domestic activity will be treated in proposed sewage treatment plant (Capacity 5
KLPD).
 Rainwater harvesting will be done within the plant premises.

1.7.3 Noise pollution


 Proper maintenance, oiling and greasing of machines at regular intervals will be done to
reduce generation of noise.
 Personal Protective Equipment like earplugs and earmuffs will be provided to the workers
exposed to high noise level.
 D.G sets will be provided with acoustic to control the noise level within the prescribed limit.
 Greenbelt inside the plant premises and at the plant boundary will be developed.
 Regular monitoring of noise level will be carried out.

1.7.4 Solid and hazardous waste pollution


 Solid waste from the operations generally comprises of fibres and proteins in the form of
DWGS (4 TPD), which will be ideally used as Cattle Feed.
 ETP sludge (0.3 TPD) will be used as manure.
 Bagasse (11 TPD) generated from cane crushing processor in Craft Rum plant will be reused
as fuel in proposed boilers
 Fly ash (4 TPD) generated from the proposed boiler will be supplied to brick manufacturers in
closed vehicles.
 Used oil & grease (0.2 KL/annum) generated from plant machinery/gear boxes as hazardous
waste will be sold out to the CPCB authorized recyclers.

1.7.5 Odour Management


 Adequate greenbelt all around the periphery of the plant will be maintained.
 Better housekeeping will maintain good hygiene condition by regular steaming of all
fermentation equipment.

M/s. Himalaya Wine Company Private Limited 24 J.M. EnviroNet Private Limited
Proposed 2 KLPD Malt Spirit Plant, 2 KLPD Cane juice based Rum Plant & 2 KLPD Craft Gin Plant along with Pilot Plant for Fermentation
& Bottling Plant At Plot No. 2A, Sector 4, IIE – Escort Farm, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre Feasibility Report

 Longer storages of any product/by-products will be avoided & use of efficient biocides to
control bacterial contamination.
 Regular use of eco-friendly disinfectants in the drains to avoid generation of putrefying
micro-organisms.

1.7.6 Greenbelt Development & Plantation


 Out of the total plant area of 8533 Sq. meter, 2815 Sq. meter i.e. 33% will be developed under
greenbelt & plantation @2500 trees/ha.
 Native plant species will be planted in consultation with local DFO.
 Greenbelt will be developed as per Central Pollution Control Board (CPCB) guidelines.
 Greenbelt development along with the road & plant boundary will attenuate noise level, arrest
dust and improve the environment in surrounding.
 Greenbelt & plantation development will begin simultaneously with the initiation of
construction activities of the proposed unit.

1.7.7 Soil Pollution mitigation measures


 No discharge of effluent or solid waste outside or inside plant premises will be done.
 Strict disposal rules will be implemented.
 Solid and hazardous waste will be handled as per applicable rules and no dumping on soil
environment.
 No construction waste will be dumped on soil and proper bins will be constructed at
designated areas where dump will be collected and disposed according to their type.
The mitigation measures which will be incorporated by the project proponent for maintaining the
prescribed standards as directed by EPA, 1986, MoEFCC guidelines and CPCB guidelines have
been given above. The Company will implement all the mitigation measures during construction
as well as operation phase compulsorily after obtaining EC.

1.8 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF


TECHNOLOGICAL FAILURE
For this proposed project, proven technologies will be selected. No new or untested technology
will be used. The process includes basic raw material requirement, sizing of equipment, utilities &
services, infrastructure facilities & sources of waste generation, their quantity, treatment & safe
disposal of the waste. Latest Technology like MVR based system will be used to evaporate
effluent so as to avoid Steam / cooling water, hence reducing overall water requirement.

M/s. Himalaya Wine Company Private Limited 25 J.M. EnviroNet Private Limited

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