July’

2025

ENVIRONMENTAL MANAGEMENT PLAN

OF

M/S. BALAJI ACTION BUILDWELL PRIVATE LIMITED

PLOT NO - 1, INDUSTRIAL PARK RAMBILLI PHASE - 1,
KRISHNAMPALEM VILLAGE, RAMBILLI MANDAL,
ANAKAPALLI, ANDHRA PRADESH - 531061

SUBMITTED BY
M/S. BALAJI ACTION BUILDWELL PRIVATE LIMITED
PLOT NO - 1, INDUSTRIAL PARK RAMBILLI PHASE - 1,
KRISHNAMPALEM VILLAGE, RAMBILLI MANDAL, ANAKAPALLI,
ANDHRA PRADESH - 531061
INTRODUCTION

M/S. BALAJI ACTION BUILDWELL PRIVATE LIMITED, having its registered office at

Delhi, established state of the art manufacturing unit in Uttarakhand for particle board, medium

density fiber (MDF) board and value added products; such as Flooring Tiles, Door-skins,

Laminated Particle Boards, Embossed MDF Boards, UV Coated Boards, Acrylic Laminated

Boards, High Density Boards, Fire Retardant Boards etc and started commercial production in

the year 2010 with installed capacity of 385 cum per day, under the brand name Action Tesa.

Within a short span, the brand has become one of the top players in the panel board industry.

With increase in the demand, the company undertook first expansion during 2012-13 by setting

up a thick MDF board manufacturing plant with capacity of 330 cum per day, which is running

at full capacity. The firm has also undertaken backward integration in the year 2013-14 by

establishing formaldehyde plant for the manufacturing of in-house glue; which is used for

manufacturing particle board/ MDF board.

The company undertook another expansion in 2016-17 by installing state of the art MDF plant

with capacity of 660 cum from Siempelkamp and commercial production started in March 2018.

Looking to the demand the company undertook another expansion of 660 CUM MDF plant from

Dieffenbacher (SWPM) company in 2022-23 and started commercial production in October 23.

Now the firm has fully integrated operations and offers wide range of add-on products like

HDHMR, BOILO BWP FR HDF, flooring tiles, door-skins, laminated particle boards, embossed

MDF boards, UV coated boards, printed boards etc.; for variety of customer segments. With the

shifting of market from plywood to panel boards which are economical and with fast conversion

to finished products as compared to plywood and hard wood.

The company is planning to set its manufacturing plant in the state of Andhra Pradesh, initially to

start with MDF board manufacturing with capacity of 710 CBM per day i.e 21300 Cum/Month.

PROJECT COST:
Total Project Cost = Rs.487.53 Crores
1. Building = Rs.115.07 Crores
2. Machinery = Rs.339.74 Crores
3. Land = Rs.32.72 Crores

SITE PARTICULARS

Name of the Industry Name M/S. Balaji Action Buildwell Private Limited

Plot No 1, Industrial Park, Rambilli Phase 1,

Site Address Krishnampalem (V), Rambilli (M), Anakapalli (Dt.),
Andhra Pradesh - 531061
Climate conditions Annual Max Temp. 420C

Annual Min Temp. 260C

Latitude & Longitude

17°30'6.31"N, 82°56'17.48"E
Own land – 42.781889 Ha.
 Built up area – 6.0 Ha.
Land acquired for the Plant
 Green Belt – 4.5 Ha.
 Open space – 32.281889 Ha.
Nearest highway MDR 123 at 0.3 km

Nearest railway station Anakapalli Railway Station at 22 km

Nearest human settlement Jaya ganesha veedhi, krishnam palem at 0.5 km

FIGURE – 1: GOOGLE IMAGE
FIGURE – 2: TOPOMAP
MEDIUM DENSITY FIBRE (MDF) BOARD MANUFACTURING PROCESS:

Medium Density Fibreboard (MDF) manufacturing plants are engineered for flexible, high -

efficiency production. These plants use Plantation Timber Line, Eucalyptus, Casuarina, Subabool

and other tress and wood waste such as sawdust and ply board residues that are unsuitable for

traditional wood processing. The end product is a high-quality, versatile panel used extensively in

furniture, interior design, construction, and packaging. MDF is known for its smooth surface,

uniform core, and excellent machining properties, making it ideal for applications requiring precision

shaping and a fine finish.

PROCESS DESCRIPTION:

1. Raw Material Handling and Preparation

 Wood Waste Yard: Designed to ensure continuous and uninterrupted supply of raw

materials such as sawmill waste, plyboard trimmings, and other residues.

 Chipping: Waste wood is chipped into uniform sizes (typically 20–25 mm) using drum

chippers. Metal detectors are installed before and after chipping to prevent metal

contamination.

 Screening: Chips are screened to eliminate fines (50 mm). Fines are utilized as boiler fuel;

oversized chips are reprocessed. Accepted chips are sent to dry chip storage silos for refining.

2. Refining

 Pre-steaming and Digestion: Chips are pre-steamed and then cooked under pressure to

soften the wood structure.

 Fiberization: Cooked chips are refined between two rotating discs to separate them into

individual fibers resembling fine human hair.

3. Glue & Wax Application

 Wax Injection: Paraffin wax is introduced into the refiner housing through heated lines to

improve board water resistance.

 Resin Addition: Urea-formaldehyde resin, diluted with water, and a hardener are added in

the blow-line downstream of the refiner. This system ensures even glue distribution while

achieving up to 15% resin savings compared to traditional blending methods.

4. Drying

 Flash Tube Drying: Resin-coated fibers are conveyed at high speed through a drying duct

exceeding 100 meters in length. Moisture is rapidly reduced through a combination of steam

and air heat exchange.

 Cyclone Separation: Dried fibers are separated from the air stream in a cyclone. A fireproof

screw conveyor collects the material, with spark detectors and automatic water sprays

installed for fire safety.

5. Mat Forming and Pre-Pressing

 Mat Forming Line: Includes metal detectors, moisture analyzers, weight-per-unit area

gauges, and automatic feeders to form a uniform fiber mat.

 Pre-pressing: The formed mat is pre-compressed to expel air and improve fiber contact,

which enhances pressing efficiency.

 Pre-heating: A preheater uses saturated steam to uniformly heat the mat, improving press

throughput and board quality.

6. Hot Pressing

 Continuous Pressing: The mat enters a continuous hot press where it is compressed and

cured under high temperature and pressure.

  Pressure Optimization: Advanced press control systems ensure even pressure distribution

and temperature, minimizing defects and resin overuse.

7. Cooling and Cutting

 Cooling Conveyor: The pressed board is transported on a cooling line to bring it to ambient

temperature before cutting.

 Edge Trimming & Cross-Cutting: Boards are trimmed to remove uneven edges and cut to

standard sizes or as per customer specifications.

8. Sanding and Finishing

 Sanding Line: Boards are sanded on both surfaces to achieve precise thickness and a

smooth finish, preparing them for lamination, painting, or further processing.

 Quality Control: Samples are taken for testing of physical and mechanical properties. Non-

conforming boards are removed or reprocessed.

9. Packaging and Dispatch

 Stacking: Finished boards are stacked in bundles, sorted by grade and thickness.

 Wrapping and Strapping: Boards are wrapped with protective film or stretch wrap and

strapped for transport safety.

 Storage: Bundles are stored in covered warehouses with controlled conditions to prevent

moisture absorption or surface damage.

 Dispatch: Boards are dispatched to customers via road or container transport based on

delivery orders.

Note: A temporary RMC plant will be constructed with 30 m3/hr capacity and 75 HP power load.
FIGURE – 3: PROCESS FLOW CHART
FIGURE – 4 : PROCESS FLOW CHART
 MATERIALS AND PRODUCTION DETAILS

LIST OF RAW MATERIAL

S. No Raw Material Description Proposed Consumption/Month

1 Glue 37,05,000 Kg
2 Formic Acid Purity 98% min. Standard 754 Kg
Packing 35 Kg
3 Di Butyl Pthalate Purity 99.2% max 774 Kg
4 Chemical Biocel WD Anti Fungal 28,925 Kg
5 Caustic Soda Purity 98 99% min 2,026 Kg
6 Wax 1,17,000 Kg
7 Green Dye 40,950 Kg
8 Black Dye 27,000 Kg
9 Red Dye 4,290 Kg
10 Ammonium Chloride 12,000 Kg
11 Agriculture Wood 17,550 Tons
12 Plantation Wood 17,550 Tons

LIST OF PRODUCTS

Sl.No. Product Quantity

1. Medium Density Fiber Board 21300 Cum/ Month
(Including Plain & Pre-laminated)

Note: A temporary RMC plant will be constructed with 30 m3/hr capacity and 75 HP power load.
FRESH WATER REQUIREMENT

Source: Fresh water requirement will be obtained from APIIC.

S.No Purpose Quantity
1. Domestic 50 KLD
2. Process 250 KLD
3. Boiler 750 KLD
4. Cooling Tower 200 KLD
Total Water Requirement 1250 KLD

Note: Proposed employment for industry is 1000 members. Per head 45 liters water will be utilized
and daily truck movement at around 100, hence 100 persons = 4 KLD. So fresh water requirement
for domestic is 50.0 KLD.

WASTE WATER GENERATION:

S.No. Purpose Quantity Mode of Disposal
1. Process water 140 KLD After treatment in ETP, will be
2. Cooling tower blow down 50 KLD dispose to onland for irrigation,

3. Boiler 28 KLD
4. Domestic 40 KLD After treatment in STP, dispose to
onland for irrigation
Total 258 KLD

Point of Disposal:
The treated effluents from the ETP and STP will be routed to an integrated water recycling system to
ensure optimal reuse within the facility where 110 KLD is used for developing green belt area and
133 KLD will be used for process, boiler ash quenching, internal road cleaning etc.,. Residual HTDS
effluent will be sent to CETP.
Total Green belt area = 4.5 Ha. i.e 11.11974 acres for which 110 KLD of recycled water is used.
As per PCB norms for 1 acre 10 KLD treated water will be utilized for greenbelt.
AIR POLLUTION CONTROL MANAGEMENT
GENERATORS:

SI.No. Details of Stack Stack1 Stack2

a Attached to Boiler DG set
b Capacity 30 TPH 1500 KVA
c Name of the Fuel Biomass HSD
d Stack height above ground 30 m 3m
e Air pollution Control Equipment Multi cyclone separator Acoustic enclosed

SOLID WASTE MANAGEMENT:

S.NO. DESCRIPTION CAPACITY DISPOSAL

1. Waste cotton 150 Kg/Month Brick manufacturers

2. ETP sludge 34 Kg/Month TSDF for land fill
3. Empty Urea Bag 5573 Agencies authorized by APPCB
Nos/Month
4. Empty barrels – 3933 Agencies authorized by APPCB
plastic Nos/Month
5. Empty barrels – steel 32 Nos/Month Agencies authorized by APPCB

HAZARDOUS WASTE MANAGEMENT:

S.NO HAZARDOUS WASTE TOTAL DISPOSAL

1 Used Oil 725 Agencies authorized by APPCB

Kg/Month
2 Chemical sludge 1124 Agencies authorized by APPCB
Kg/Month
FIGURE – 5 : SITE LAYOUT