Case Study:Working of the Madurai Plant for leather : Lanxess
Executive Summary of the Project
Situated 2 kms away from Madurai airport and 12 km from the main city of Madurai and spread across 25 hectares among lush greenery, the Lanxess Madurai Plant is the first facility in India to enter the Leather Chemicals, Material Protection Products and Rhein Chemie products for local consumption and exports.
The facility houses world class equipment and technology with production capacity for 12,000 MT/annum that replicates the German benchmark to meet the global competition. Out of the total production at the site, 25 to 30 percent is exported to the APAC region.
With the recently announced expansion of its Material Protection Products division to more than double of its present capacity the Madurai site is also planned for upgradation of equipment for better performance in process technologies to support new range of products.
The Rhein Chemie business unit of LANXESS manufactures rubber additives, a polymer bound product manufactured under the brand name Rhenogran.
It also has a major market share in polymer-bound chemicals catering to automotive, engineering, tyre and footwear industries.
The Material Protection Products business unit markets a range of preservatives and biocides for almost all industry sectors, including wood protection, paints & coatings, construction, health & personal care products, and beverages.
The Madurai site is the manufacturing hub for LANXESS leather business in India and the multi-purpose plant manufactures a wide variety of tanning agents, fat liquors and finishing products in close cooperation with the technical service centre in Chennai.
High-tech equipment, high-speed agitators, dispersion equipment and glass lined reactors are some of the hallmarks of the plant, besides reach trucks that are well equipped to operate in a flame-proof and explosion-proof area and can reach a height of almost six metres in the material storage facility with easy maneuverability.
For the production of lacquers and pigments for the leather finishing application, the company has unique dispersion equipment like dissolvers and turbo mills that are different from conventional size-reduction equipment.
These equipments consume less water thereby reduce the effluents.
The Madurai facility is also equipped for the production of water-based tyre mold release chemicals - Rhenodiv, an eco-friendly shift from the solvent-based release agents.
With LANXESS’ core business focused on chemical research, innovation forms an important ingredient for their future growth prospects to remain competitive in the industry.
GREEN SITE:
The LANXESS Madurai plant is certified ISO 9001 for quality and ISO 14001 for environment, thus reflects global standards in performance technology and environment protection systems for chemical manufacturing processes.
Effluents are a major concern for the water bodies in an around the production site. The Madurai site is ‘a zero discharge site’ and it does not discharge treated effluents outside the factory premises. This is accomplished by reducing, eliminating and recycling wastewater.
Manufacturing of specialty chemicals requires storage and handling of diverse hazardous and non-hazardous materials. This is systematically managed through safe design of warehouses, training of people and methodical mitigation plans.
This film was shot in their Madhurai factory and Mumbai office over several weeks by our professional crew. Drone, Gimbals, Special lenses, slow-motion cameras were used. We also engaged with professional television anchors for this project. We are making their corporate / Industrial video for the third time in a span of 10 years. LANXESS' trust in us speaks volumes about our commitment and quality we offer our clients year after year.
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