1.

INTRODUCTION

Oddamavadi Plastics is a company involved in plastic recycling via extrusion process. The recycling method
adopted involves segregation of collected plastic waste according to the brand under which they were used
previously. About 1 ton plastics are being recycled daily. A site visit was carried out by the ISL consultants and
following issues have been identified.

 Odour emission in the extrusion phase.

 Noise and vibration generated by crushers.
 Waste water generated in the process of washing used plastic.
 Plastic waste generated as a byproduct of the process.

This report will elaborate on the environmental pollution factors and will discuss about possible modifications and
improvement that can be done to reduce the environmental impact while meeting CEA standards. Since this
industry is located in a populated area, these measures would ensure the wellbeing of the neighbouring
community as well.

1.1 BACKGROUND INFORMATION

Name of the Company S R plastic and Iron shop

Type of Industry Plastic Recycling Industry
Postal Address Bazar Mosque Road, Oddamavadi
Contact person Mr. Habeeb Lebbe Mohemad Rafee
Phone no 0758338020
Daily recycling capacity 1 Ton per Day
Operating hours 8.00 a.m. – 4.30 p.m
Location map Please refer to the Annexure 01
Factory layout plan Please refer to the Annexure 02
Noise Source : Plastic crushing Operations
Air Emissions : From Extrusion Process
List of Sources of Pollutants Vibrations : From crushers
Solid Waste : Plastic waste generated as a byproduct of the process
Water pollution : From process of washing used plastic
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

2. PROCESS DESCRIPTION

Plastic recycling process comprises of following units.

 Segregation unit
 Washing unit
 Crushing unit
 Extrusion unit
 Pelletizing unit
 Cooling tower

Plastic waste collected in bulk are separated according to the product being manufactured like bottles, chairs,
small plastic components in electronic circuits, pens etc. They are further segregated according to the size, brand
etc. Contaminants are removed by sending through a washing process.

Segregated garbage is then sent into the crusher through which the size reduction is accomplished. Plastic beads
thus obtained are introduced into hopper of the extrusion machine. Melting takes place once they pass through
the barrel, housing the screw due to both the heat provided externally and the shear heat produced. The melt is
then sent across a screen and a breaker plate through which the removal of contaminants and conversion of flow
from rotational to longitudinal occur. Conversion of flow pattern is important in forming extruded plastic strips.
They are sent through a water bath for cooling and then introduced into the plastic pelletizer where a cutting
process occurs producing pellets. The water used in the water bath is reused by sending through a cooling tower.
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

2.1 PROCESS FLOW DIAGRAM

Raw material receiving

Raw material Raw material storage

Water
Manual Sorting
Energy
Shredding

Washing

Solid waste
Crushing
Waste water
Extrusion

Curing

Cutting & Pelletizing

Packaging

Finished product
storage

2.2 IMPACTED AREA

S R Plastic and Iron shop is located in a residential area within the Pradeshiya Sabha Limits of Vaharai. It is
surrounded by private properties to the North, East and South East directions which are the mainly effected
areas.
Please refer Annexure 03 for details.
Please refer the Annexure 01 for the location map
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

3. RECOMMENDATIONS FOR POLLUTION MITIGATION MEASURES

3.1 ODOUR GENERATION

 It was found that the odour is generated due to extreme temperature conditions used in the recycling
process and the thickness of plastic beads. More VOCs are released as a result of above conditions. That
is, higher the temperature higher will be the degradation increasing the emission. Thus, it is recommended
to use the PLC to control the processing temperature based on the plastic being recycled. For example,
melting temperature for LDPE is lower than that of the PP. So, by altering the temperature accordingly,
over heating of LDPE can be avoided, thus eliminating any unnecessary emissions.

 Alteration of the plant layout is recommended in such a way that the odour emitting source (extruder),
Dust emitting source (Sieve separator) and sound generating source (crusher) are enclosed. Please refer
the Annexure 4 for the proposed plant layout.

 In order to reduce the emission from the source, it is recommended to cover up the extruder and send
the emission through an exhaust fan which dilutes the concentration of the emission. It has an added
advantage since cooling of the interior of the extruder enclosure occurs making it easy for the operators
to work. Refer annexure 5 for the design of exhaust system.
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

3.2 DUST GENERATION

 Dust generation from the sieve analyzer should be enclosed and cover-up. Then, it is send to the dust
collection room through the air blower. Enclosure should be large enough to do the machine operations
and other routine activities safe and quality. (Please refer annexure 4 for the plan of the enclosure)

3.3 NOISE AND VIBRATION

 Vibration can be reduced by incorporating vibration absorbers (Like rubber pads) to the base of the
crushers.

Anti-vibration rubber pads

 Cutting section is another noise and dust generating area. Cutting should be carried out in a well ventilated
enclosed area and worker should be wear dust resistant mask.
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

 In the alteration of the plant layout storage of raw material (purchase materials), Segregated and washed
materials, Crushed materials and finished goods should be placed in proper manner. Please refer
Annexure 3 for clarification. Green belt is recommended to the northen potion as a sound barrier.

3.4 WASTE WATER

Wastewater generated from the raw material washing area. Based on the effluent characteristics following
wastewater treatment method is recommended by ISL.
The treatment process consists of chemical treatment to remove BOD, COD, TSS and finally it will become suitable
discharge standards of inland surface water quality.

Plant layout diagram

Chemical
treatment unit
Dosing pumps

Sand Bed

Sludge tank

Collection sump
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

Tank Construction Details

Collection pump
150 mm thickness concrete wall and Base
10 mm reinforcement at 150 mm center to center distance

Sand Bed
9” thick brick wall with cement layor

Support structure for chemical treatment unit

4”*2” H iron structure at 1.5 m height from the ground level

Discharge Limits
Here the treated water is proposed to discharged to inland surface water, hence it should prevail those tolerance
limits;

Analysis parameters Unit Concentration

5-days Biochemical Oxygen Demand (BOD5) mg O2/l 30

Chemical Oxygen Demand (COD) mg O2/l 250

Total Suspended Solid (TSS) mg / l 50

Volatile Suspended Solid (VSS) mg / l 30

Fats, oil and grease mg/ l 10

pH - 6 – 8.5

Faecal Coliform MPN/100 ml, max 40

Disposal Of Treated Effluent

Liquid Waste

The treated effluent can be discharged into irrigation purposes such as gardening, toilet flushing etc.

Solid Waste

Solid waste collected in screening process can be properly disposed with the other solid waste generated during
the production process.
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

Scope Of Work

Scope of Work of ISL

The following services could be made available as per the need of the client;
 Design and operation management
- Design of process and sizing of tanks and piping & plumbing
- Preparation of layout drawings
- Specification for equipment and instrumentation & Plumbing.
- Commissioning after carrying out initial field testing
 Supply of electro-mechanical equipment
 Supervision during upgrading and installation
 Guarantee of the treated effluent to CEA standards
 Maintenance of the plant on prior request by the client and prior contractual arrangement.

Responsibilities of the Client

 Construction of tanks and piping and plumbing as ISL supervises.
 Separation of wastewater from storm water to meet the design demand of Wastewater to the unit.
 Supply of water and electricity during the construction and commissioning period
 Providing shelter to keep equipment and tools
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

Cost Structure

Scope of ISL

Description Unit Unit Price (LKR) Cost

No
(LKR)
Fabrication, supply and installation of agitator
1. Lot 100,000.00
(30rpm)

2. Supply and installation of dosing pump 01 40,000.00 40,000.00

Designing and commissioning fee allowed

3. 60,000.00
(Only one visit charge)

Total cost 200,000.00

Scope of Client

 Construction of tanks as per the ISL design and drawings. (Concrete tanks are preferred over brick tanks
considering the durability and water proofing quality)
 Piping materials has to be supplied by Client
 750 Litter Arpico tank has to be supplied by client
 After Completing Commissioning, Testing has to be done by client.
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

3.5 PLASTIC WASTE

 All plastic raw materials should be placed in an enclosed area and it should be clean without any
contamination of water. This location shall not be used as a breeding site of the mosquitoes. Practice of
the raw material store should be changed into enclosed area. Please refer annexure 4 for the further
clarification and raw material store location identification

Unplanned and improper raw material storage at the site

 Plastic waste generated as a byproduct of the process can again be used in the recycling process. Thus, it
will not be an issue.
Mitigation Report to address the Environmental Issues occurring due to the Plastic Recycling Process of Oddamavadi Plastics

Annexure 01

Existing plant Layout

 Washing Cooling tower
area
Office room
Extruding area

Pending raw Finished

Washed material good store
and area
Crushed material Segregated
store area Material
store Raw material store area
area (Open Area)
(Open Area)

Segregation
table
Raw material store area
(Open Area)

Raw material
store area
+ cutting area

Separator

Shop and raw

material receiving area Raw material store area
(Open Area)
Crusher 1 Crusher 2

Raw material store area

(Open Area)
 Annexure 02

Proposed Plant Layout