www.polutech.com www.murugappa.

com

Business
Profile

Polutech Ltd
(a Murugappa Group Company)

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About the Murugappa Group

The making of the Murugappa Group
The Murugappa Group, headquartered in Chennai, India, is
a Rs. 15,907 Crore (USD 3.14 billion) conglomerate with
interests in Engineering, Abrasives, Finance, General
insurance, Cycles, Sugar, Farm Inputs, Fertilizers,
Plantations, bio-products and Nutraceuticals. It has 29
limited companies under its umbrella, with manufacturing
facilities spread across 13 states in India. Together, they have
over 32,000 employees. The Group, which has forged strong
joint venture alliances with leading international companies
like DBS Bank, Mitsui Sumitomo, Foskor, Cargill and
Groupe Chimique Tunisien, has consolidated its status as
one of the fastest growing diversified business houses in
India.
The management has also set in motion long-term growth
plans for all of its key businesses. Capital expenditure rose
from Rs 579 Crore against Rs 570 Crore the previous year.
Changing times, constant values
Today the Murugappa Group is firmly rooted in its
homeland, and is poised to take on the world. Building on
the same business acumen, modern and innovative outlook,
as well as vision with which the founder of the Group left
his native land to seek his fortune in Burma, the Murugappa
Group is on the threshold of the global business arena today,
backed by 100 years of experience in diverse fields, sound
traditional values and high ethical standards.

From acorn to oak
The business has its origins in 1900, when Dewan Bahadur a
M Murugappa Chettiar established a money-lending and
banking business in Burma (now Myanmar), which then
spread to Malaysia, Sri Lanka, Indonesia and Vietnam. In
these 100-plus years, it has withstood enormous vicissitudes,
including strategically moving its assets back to India and
restarting from scratch in the '30s, before the Japanese
invasion of Burma in the Second World War. Starting with a
sandpaper plant, the Group forayed into making steel safes,
and then into manufacturing. It set up an insurance
company, and bought a rubber plantation; making a small
but significant beginning. The rest is history.
Today, it is one of the country's biggest industrial houses.
Group turnover crossed the USD 1 billion mark in 2003-04,
with an impressive growth of 25 per cent over Rs 4,206 Crore
in 2002-03, and a 40 per cent jump in profit before tax over
the previous year. Consolidated Group turnover for 2004-05
crossed USD 1.44 billion, a growth of 20 per cent over the
previous year. In 2005-06, combined turnover increased by
17 per cent to USD 1630 million (Rs 7,340 Crore) and net
profit (PBT) by 45 per cent to USD 177 million (Rs 800
Crore). The Group ended the year 2006-07 with a turnover of
Rs 8,446 Crore, and profit before tax of Rs 649 Crore. The
Crore) and has the Group well on its way to achieving its
vision of becoming a USD 4 billion conglomerate by 2010.
The group is a market leader in India across a spectrum of
products like fertilisers, abrasives, automotive chains, car
door frames and steel tubes. Neemazal, a neem-based
organic pesticide, is the market leader in bio-pesticides.
Some of the country's best-known brands like BSA and
Hercules in bicycles, Parrys Spirulina and Parrys Beta
Carotene in nutraceuticals, Ballmaster and Ajax in abrasives,
Gromor and Paramfos in fertilisers, and many more come
from the Murugappa Group.
Its companies have tie-ups with Wendt GmbH of Germany,
Morgan Crucible Company plc of the UK, the China
Engineering and Exploration Bureau (CEEB), Cerdak Pty Ltd
of South Africa, Mitsui Tsumitomo Insurance Company Ltd
of Japan, DBS Bank of Singapore, Borg Warner Morsetec of
USA, Foskor Ltd of South Africa, Groupe Chimique Tunisien
of Tunisia, and Cargill International SA of Geneva. It has
registered 43 international patents for its research and
development innovations.
The group has grown consistently through its decisive and
visionary response to changing times. Its pioneering efforts,
steadfast commitment to ethical business practices and its
dogged pursuit of new areas to extend its business acumen
have brought in its wake several prestigious national and
international awards.

The Group's business philosophy can be summed up in this couplet from the ancient Indian treatise on wealth creation and
governance, the Arthashastra:
"The fundamental principle of economic activity is that no man
you transact with will lose, then you shall not."
Conducting business by a clear set of values and beliefs, the Group has observed very high standards of ethics and transparency. Its
belief in organisational renewal has allowed the Group to adapt itself to changing economic contexts and grow from strength to
strength. The Management Development Institute (IMD) of Lausanne, Switzerland, conferred the 'IMD Distinguished Family
Business Award' on the Group in 2001.

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About Polutech Ltd

POLUTECH LIMITED was incorporated in the year 1981 for the manufacture of pollution control

equipment. We are a part of the prominent MURUGAPPA GROUP - a proud conglomeration of sterling
companies such as Tube Investments, Carborundum Universal, E.I.D.Parry, Coromandel International,
Cholamandalam DBS & MS et al.

We design and manufacture water and waste water treatment & recycling systems. We build equipment
and construct turnkey plants through process engineering, fabrication, equipment supplies, testing,
erection and commissioning. We are an organization of engineers and technicians who are professionals
and specialists experienced in multi-various engineering disciplines and technologies.

POLUTECH AT A GLANCE

Single point source for water and support personnel in functions across
wastewater treatment & recycling plants the organization such as Design,

Design and manufacture water and Marketing, Procurement, Project
wastewater treatment equipments such execution & commissioning, Trouble
as High speed floating aerators, shooting, O&M, Finance & Accounts,
Clarifiers, Clariflocculator, Thickeners, Manufacturing & Production and
Slow speed aerators and Agitators to fit Administration
the needs of industries.
Strong record of supplying more than

Team of Engineers, designers and 1200 equipment to over 600 industries
drafting personal knowledgeable and and also successfully completed more
experienced in our businesses. than 50 turnkey industrial effluent and

Our team is drawn from varied sewage treatment plants with capacity
backgrounds with professional standing ranging from 20 cu.m/day to 8000
in their respective work areas. Typically cu.m/day for various industrial sectors.
our workforce consists of Chemical
Manufacturing facility at Kakkalur
Engineers, Mechanical Engineers, Industrial estate near Chennai with a
Designer Engineers, Analytical total area of 22,400 Sq.ft including the
Chemists, Electrical and covered area of 8000 Sq.ft and trained
Instrumentation Engineers as well as manpower

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POLUTECH maintains an intensive quality assurance programme through all phases of design

and manufacture of equipment it supplies.

POLUTECH is totally committed to quality and excellence and produces plants and systems

confirming to very high engineering standards. All raw materials, components, subsystems,
and systems are subjected to rigorous in-house quality control to ensure that the customer
receives only the best equipment.

Quality Control &

Testing procedures
are followed in
accordance with the
various Indian
standards as well as
international
standards such as
ASME, BS, DIN or
other standards
specified by the
customer.

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ORGANIZATION

Quality Control Department consists of a team of qualified Engineers in various disciplines

such as Mechanical, Electrical and Instrumentation and is headed by General Manager.

The functions of the Department can be broadly listed as under -

Vendor Evaluation and Development

Inspection of all items from different vendors’ right from procurement of raw material
to finished product for conformance with required standard/ specifications

Issue of Inspection Report certifying quality of the job

Liaison with the Client’s / Consultant’s Inspection Authority

VENDOR EVALUATION AND DEVELOPMENT

Adding new vendors helps to increase supply sources and to meet committed delivery
schedules. In this respect, vendor evaluation and development become a very important
function of the Quality Control Department. Capability of new vendors requesting registration
is first ascertained especially with respect to manpower quality, availability of
machines/equipment and quality monitoring facilities. Rigorous inspection is carried out
during the trial order before according final approval. All Quality Control Engineers through
Log Sheets and Weekly Reports maintain the performance record of registered vendors.

ORGANISATIONAL PHILOSOPHY

For specific projects, a team is organized under the leadership of the Project Manager. Each
department (Purchasing, Engineering, Estimating, Construction, Accounting, Process, etc)
supplies personnel to the project team as required. Dependent on the project size and
requirements, personnel are delegated to the project full time or assigned as needed. The
functional managers are responsible for supplying the proper personnel to the project them.

The project team member reports to the proper project person (project manager or engineer) for
their project execution functions. They continue to report to their functional department heads
with regard to quality, standards and methods. The Project Manager is totally concerned with

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and dedicated to the execution of the project. The department managers are responsible to
ensure that quality and method are comparable with the schedule and cost objectives
established in the project plan.

PROJECT ORGANIZATION
In accordance with the previously described procedure, a project team is formed for each
project. Overall responsibility for the project execution rests with the Project Manager. Projects
are assigned to an experienced project manager who is the principal contact with the Owner.
This organization provides single-point responsibility for the performance of the entire project
staff, both in the office and field. The Project Manager is personally responsible for conduct of
the overall project. He places special attention on front-end planning, scheduling, and cost
control. Engineering for the project is the responsibility of the Project Engineers.

PROJECT PROCEDURES

POLUTECH LIMITED uses a Project Activity Chart to define the tasks to be performed in a
project and to define the parties responsible for execution, review and approval of each task.
The personnel to be used on a project have used the Activity Chart on previous occasions and
are thoroughly familiar with the division of responsibility.

PROGRESS REVIEW

Project scheduling is a system of planning, reporting, and forecasting by which the Project
Manager and his staff control all the activities of a project with regard to time. There is a master
project schedule, which is backed up by more detailed departmental schedules. The project
schedule is generally prepared as a bar chart. However all of the input data necessary make the
bar chart can also be used for a computerized critical path schedule, should this be advisable or
desired. The project schedule is prepared in sufficient detail to identify all of the principal
activities affecting project completion. These include engineering and drafting by disciplines,
major items of equipment individually bulk materials with appropriate breakdowns, and shop
fabrication. The department head responsible for each of these activities makes his detailed
department plans and schedules consistent with the Project Schedule.

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The first issue of the Project Schedule shows the planned starting and completion dates of each
principal activity in the project. These planned dates are never changed unless the job is
rescheduled. The schedule is continually updated showing the times of actual performance in
comparison with the original plan. The updated schedule sounds the alarms for the Project
Manager and department heads to take corrective action. The updated schedule is issued
monthly for management and customer review.

DOCUMENTATION CONTROL

A code of accounts for each project is established from the general accounting code. The
accounting code is divided by material and design functions. During the estimate, each area of
the plant is referenced to the code of accounts.

COMPUTER-AIDED DESIGN AND DRAFTING (CAD)

POLUTECH LIMITED employs computers for the following design/ project activities:

1. Project

Project scheduling - bar chart and CPM.

Cash flow requirements for projects.

Progress reports.

2. CAD Drawings

Process flow diagrams

Engineering flow diagrams (P&IDS)

Equipment arrangements and layouts

Plot plans

Civil and structural

Architectural

Drums, towers, vessels and other mechanical

Piping

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 Electrical
 Instrument logic and loops
 Computer logic and ladder diagrams

RANGE OF PRODUCTS

 High Speed Floating Aerators - 1 to 40 HP

 Low Speed Floating Aerators - 1 to 40 HP
 Low Speed Fixed Surface Aerators - 3 to 50 Hp
 Clarifier Mechanism - Fixed type and Traveling type
 Clariflocculator Mechanism - Fixed and Traveling type
 Flash Mixer
 Flocculator Mechanism
 Agitators - High Speed and Low Speed
 Bar Screen - Manual & Automatic Type
 Oil skimmer - Manual
 Thickener mechanism
 Parallel Plate Clarifier / Tube Settler
 Pressure Sand Filter
 Activated Carbon Filter
 Diffused Aeration System (DAS)
 High Speed Floating Mixers

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MECHANICAL BAR SCREEN

POLUTECH’s Mechanized bar rake screen suitable for

installation in RCC channel. The screen shall be
provided with bar opening of 5mm – 20mm with bars
of SS304 construction. It shall have rake frame,
sprockets & chain, shafts, adjustable bearing blocks,
deck plates, discharge arm apron. All material in
SS304 construction.

ROTARY FINE SCREEN

POLUTECH’s Rotary fine screen of opening 2 – 3mm

in SS304 construction.

FLASH MIXER

POLUTECH’S Flash mixers are specially designed

and fabricated for the process requirement of water
and wastewater treatment. The mixer design ensures
efficient, minimum energy consumption and long
life. This equipment blends coagulants and other
chemicals with water / wastewater prior to
flocculation. The aggressive agitation results in
instantaneous and effective mixing of chemicals. This
unit is also useful for general mixing.

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FLOCCULATOR
POLUTECH’S Flocculator provides gentle agitation by
slow moving paddles. This action serves to break up the
mass rotation of liquid and promote mixing. The specially
designed flocculating paddles enhance flocculation of the
feed solids. Agglomeration of the destabilized colloids is
achieved as a result of particulate transport in the
flocculation compartment. Increased particle contact will
promote floc growth and aids faster settling.

CLARIFIER MECHANISM

POLUTECH’S Clarifiers are extensively

used for continuous mechanical removal of
settleable solids from water / wastewater.
These can be either Bridge or Center column
supported. In a center feed design the water
/ wastewater is carried to the center of the
tank, the water / wastewater enters a circular
well designed to distribute the flow equally
in all directions. The sludge removal
mechanism revolves slowly and may have
two or four arms equipped with scrapers.
The drive unit can be central or peripheral and
also manufactured with half/full scrapping
arm. They can also be equipped with scum
removal system. Besides conventional
clarifiers, high rate clarifiers with parallel plate
separators and tube settlers are also offered.
CLARIFLOCCULATOR MECHANISM

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POLUTECH Clariflocculator unit is a combination of both flocculation and clarification in a single tank.
This unit is consisting of concentric circular
compartments. The inner compartment is the flocculation
chamber and the outer compartment is the clarifier. The
chemically dosed water is uniformly distributed over the
surface of the flocculation compartment for effective
utilization of the available volume for flocculation.
The specially designed flocculating paddles enhance
flocculation of the feed solids. As heavy particles settle to

the bottom, the liquid flows radially outward and

upward and the clarified liquid is discharged over a
peripheral weir into the peripheral launder. The
deposited sludge is raked to the bottom near the central
pocket from which it can be easily discharged.
Both central driven and peripheral driven mechanisms
are available in the manufacturing range. They can also
be equipped with scum removal system. These units are
widely used in potable water treatment and industrial
wastewater treatment plants.

THICKENER MECHANISM

This unit is similar to clarifiers in construction but developed to produce a denser and thicker sludge,
which substantially reduces the plant requirement for solid
handling. High torque balanced drives and rugged structural
raking arms assure continuous operation during peak solids
loading without operator attention and maximum under-flow
concentrations for optimum solids de-watering. Both manual
lifting and automatic rake lifting devices are available in the
manufacturing range. They can also be equipped with scum
removal system and special arms are provided for dense
slurries.

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PRESSURE FILTERS
POLUTECH offers a full line of pressure filter designs to
handle a wide variety of applications. These include vertical
and horizontal single or multiple systems. Filters can be
offered with or without air-scour. Media types can be single,
dual and multiple. POLUTECH filters also feature state of the
art distribution and collecting systems for low pressure drop
operation.

FLOATING AERATOR of POLUTECH design will have the

following feature

A properly designed and balanced propeller of two
bladed designs in stainless steel.

The throat of venturi shaped is designed to provide
the most efficient fluid convergence and
divergence.

The integral ballast and large float body filled with
rigid polyurethane foam to give better stability.

SLOW SPEED FIXED SURFACE AERATORS

POLUTECH Aerators are the most efficient, economical and trouble free mechanical surface aerators
specially designed to suit all types of biological reactors. Some of the highlights of the aerator are

Low Capital cost

Low Maintenance cost

Flexibility of operation

Trouble free continuous service

Simplicity of equipment

Rugged design

The entire unit is manufactured to keep maintenance time and cost at the very minimum. The impeller is
specially designed to have self-cleaning feature, makes the equipment very robust, reliable and capable of
giving un-interrupted service over many years. These aerators provide vigorous agitation and mixing in
the wastewater to disperse the oxygen and keep the solids in suspension.

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DIFFUSED AERATION SYSTEM

The Diffuser consists of a porous Membrane made

of EPDM material. The diffuser is designed to
ensure uniform permeability and to produce a flow
of fine air bubbles. The fine uniform pore size
ensures minimal head loss across the diffuser. Since
the bubbles are of extremely small size the total
surface area that interfaces with the liquid is large.
The high contact area provided by the fine bubbles
and the high contact time provided by the slow rise
rate of the bubbles make this system very efficient
in terms of oxygen transfer efficiency.

TUBE SETTLER

POLUTECH offers lamella / tube separator, which is a versatile

clarification cum separation arrangement in which solids, oil and
grease can be removed from the feed water. The Lamella /
tube separators can be offered in steel or concrete arrangements.
An integrated flash mixer cum Flocculator is provided for
chemical treatment.

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REACTIVATOR CLARIFIER

POLUTECH Reactivator clarifier is a high rate

solids contact clarifier used for water clarification
and or softening. This unit combines flash
mixing flocculation, clarification and sludge
thickening into a single operation. It provides
selective or simultaneous removal of turbidity,
color, organic matter, odor, iron, manganese,
hardness and alkalinity

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RANGE OF SYSTEMS
OFFERED
WATER TREATMENT

Raw Water Treatment Plant

Filtration plant

Chlorination Plant

Iron Removal System

Fluoride Removal System

Desalination System

INDUSTRIAL WASTEWATER TREATMENT

Physico Chemical Treatment

Chemical Treatment

Anaerobic Reactor

Aerobic System

Biological Fixed Film submerged Aeration System

Membrane Bioreactor (MBR)

Conventional aerobic treatment

Anaerobic Treatment System

Package sewage treatment plant

TERTIARY TREATMENT & EFFLUENT RECYCLING

Recycling of Waste water

Reverse Osmosis System

Tertiary treatment system for Recycling of Sewage

Lime - Soda Softening System

Carbonation and Re-carbonation System

UF / RO / NF Systems

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ULTRA FILTRATION SYSTEM

POLUTECH offers UF System, which is a one-stop solution for

most of the pretreatment requirement for Reverse Osmosis (RO),
which ensures consistent, cost effective RO performance, by
producing water with
silt density index (SDI)
less than 1.0
UF - HF Membrane
removes the following RO fouling materials like

Particulate matter, Suspended solids, bacteria and
viruses.

Colloidal materials (non-reactive silica, iron, aluminium,
silt etc)

High molecular pollutant organic compounds. This
minimizes RO cleaning protocols and reduces
operating pressures and enhances membrane life.

REVERSE OSMOSIS

POLUTECH RO systems employ reverse osmosis

process to dematerialize water without the use of
regenerant chemicals and associated waste
disposal. POLUTECH RO units are used for
treating brackish water and seawater to produce
potable and industrial water.

Custom RO Units

POLUTECH offers custom designed large reverse

osmosis plants for meeting the requirements of pure water for industrial units. These units are designed
in multiple modules with computerized software programme for selection and optimization of
membranes. Advanced PLC controlled monitoring systems are offered for controlling the operation and
maintenance of the unit round-the-clock.

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ANAEROBIC HYBRID REACTOR

POLUTECH develops innovating technologies-

in-house. We have installed many anaerobic
reactors for Bio-degradation of wastewater.
POLUTECH LIMITED reactors are designed with
fill media.

These units are extensively used for biological

degradation of organic pollutants in waste water
generated from distilleries, sugar mills, food
processing units, tanneries, meat and fish processing units, etc.

The concept of high-rate anaerobic reactors is based on three fundamental aspects:

1. Accumulation within the reactor of biomass by means of settling and attachment to solids. Such
systems allow the retention of slowly growing microorganisms by ensuring that the mean solids
retention time becomes much longer than the mean hydraulic retention time.

2. Improved contact between biomass and wastewater. Overcoming problems of diffusion of substrates
and products from the bulk liquid to biofilms or granules.

3. Enhanced activity of the biomass due to adaption and growth.

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AHR will incorporate packed bed packed with plastic media and an unpacked zone beneath the media to
permit accumulation of granular sludge. The purpose of the media will be to retain biological solids
within the reactor either as a fixed-film attached to the media. as solids entrapped within the interstitial
voids within the media matrix or as suspended within or beneath the media as a granulated or
flocculated sludge mass. Therefore, the media acts as a gas-solids separator, helps to provide uniform
flow through the reactors improves contact between the waste constituents and the bio-mass contained
within the reactor and permit accumulation of the large amounts of bio-mass needed to produce long
solids retention times.

CD RO UNITS

POLUTECH offers CD Ro Units for wastewater with high

scaling or biofouling potentials. CD - module combine the
advantage of the open channel technique with the high
membrane packing density (density rises factor 5 against tubular
modules).

The very low

energy demand
because of the
optimized and
lower feed volume. In comparison to the other disc
modules, the CD — modules avoid the sharp 180 deg
turns, have a continuous flow velocity, don’t change the
diameter of the channel and have therefore a drastically
reduced pressure loss over the module
The new outstanding fluid form of CD – Module has the following
advantages:

Avoidance of frequent sharp reverse turns of 180° (in

conventional disc modules 2 turns per plate level)

Defined flow in the complete membrane stack,

Defined velocity without slow down or accelerating sections

Avoidance of sections with low velocity (danger of fouling),

In all parts diminished pressure losses at higher velocities.

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MEMBRANE BIOREACTOR SYSTEM (MBR)

Reinforced submerged hollow fiber membranes are employed in the filtration stage to separate purified
effluent from waste compounds, providing disinfected effluent of very high quality. The unique patented
design of these membranes incorporates braiding to significantly improve the membranes ability to
withstand the harsh operating environment of a Membrane Bioreactor and thus increases lifespan.
Special feature of the membrane design are bundles of membrane fibers that are only fixed in a single
header at their lower ends.
The upper ends of the fibers are individually sealed and free to move laterally.
MBR Tank at Sandoz Private Limited, Navi Mumbai, India
We have installed another MBR system at M/s. Silk Road Sugar Limited at Kakinada to treat the effluent
generated from their sugar refinery. By this installation we have reduced the foot print required and huge
civil cost was reduced for the similar conventional treatment plant. Here the MBR outlet water is directly

fed to the Reverse Osmosis unit, thereby removing

the filtration and Ultrafiltration system.

PACKAGE SEWAGE TREATMENT PLANT (AEROPAK)

POLUTECH manufactures and supply package sewage treatment plants
incorporating extended aeration activated sludge system.Depending upon the
quantity of waster water,the tank can be either rectangular or circular in
configuration.the clarifier compartment is located as central portion of the tank.The
waste water is aerated by means of diffused aeration in the annular portion of the

tank.POLUTECH package plants are pre-engineered to keep down the cost to the
minimum.The package plants are also supplied incorporating mechanical surface
aerators in place of compressed air system.

Aeropak installation at Mauritius

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