05/08/2022
G&B’s Expansion at Khalapur
A state-of-the- art manufacturing infrastructure, a key building block of the future readiness of Godrej that is designed to be sustainable and scalable.
by KAEZAD KARANJAWALA
Godrej Construction

Khalapur South (KS) - 2

Like Pirojshanagar at Vikhroli, the development at Khalapur has been planned to conform to the principals of sustainable development with minimal adverse environmental impact.

In the 1940s, Godrej acquired several hundred acres of land in Vikhroli for setting up an Industrial Township for manufacturing their products, expansion of their businesses and related activities. Godrej - Pirojshanagar Industrial Garden Township has been an excellent combination of man, machine and nature and has ever since demonstrated the viability of their coexistence for growth. Now, it has grown into a mixed-use occupancy with industry, commercial offices, residential complexes, schools, and the hospital. The township is a collage of various ecosystems of natural wilderness such as the mangrove forest, grasslands, modified habitats like roadside avenues, gardens, vertical and terrace gardens as well as plantations. G&B’s business ambitions have been well served for over seven decades by the Pirojshanagar industrial garden township. In the early 2010’s our businesses began experiencing capacity constraints for expansions of their activities. Also, challenges of transporting goods from Vikhroli grew considerably. These and other factors triggered the need for identifying a comparable parcel of land in the vicinity of Mumbai. The requirements as specified for the land parcel were not easy to meet. We, therefore, decided to cast our net wide and scouted for land parcels in various regions of Karnataka, Gujarat, Goa, and Maharashtra, with Maharashtra remaining a preferred destination. After a thorough survey and evaluation, Khalapur in Maharashtra was identified as the most suitable location for the planned expansion of our businesses. Khalapur as a location has many factors in its favour such as an advanced industrial development, optimal infrastructure development plans of the Government and a strong intent of the Government to support industrialization of the region under the Make-in-India policy.

Khalapur was fast emerging as one of the major industrial hubs in India. All these factors taken together helped us to zero in on Khalapur as an ideal location for G&B’s ‘Ultra Mega Industrial Project’. We have found Khalapur as a location for new industrial development has certain advantages such as being identified as an industrial zone in the proposed development plans of MSRDC which will further enhance its ecosystem for Industrialisation in the coming years. Also, the availability of water, power, gas, road connectivity to National Highways & Expressways, and other facilities around it makes Khalapur an attractive destination. Khalapur is easily accessible to Mumbai and G&B’s headquarters at Pirojshanagar, Vikhroli. Khalapur as a location has its own challenges. At present, G&B is developing about 370 acres of land parcel at Khalapur in the Village Vadval – Tambati which is split into two campuses; south & north within a kilometer from each other on either side of Pen-Khopoli highway.

Khalapur establishment is planned as state-of-the-art industrial premises with complimenting infrastructure and best-in-class facilities.

The structures are designed and constructed keeping in consideration, present and future requirements of our businesses for space, load factors, utility capacities, road network and so on.
The current plan proposes setting up of around ten manufacturing plants for Security Solutions, Interio, Material Handling, Tooling, Precision Engineering and Aerospace businesses of G&B. Also, ‘Ready Mix Concrete Plant’ is set up to aid construction. A land parcel of 290 acres in the south campus of Khalapur is being developed in two Phases, with Phase 1 comprising of five manufacturing plants, utility building, emergency response centre and an RMC plant of Godrej Construction as well as other ancillary structures that are essential for the upkeep of Green Infrastructure, spread over 165 acres. Like Pirojshanagar at Vikhroli, the development at Khalapur has been planned to conform to the principals of sustainable development with minimal adverse environmental impact. The designs of plants, other structures and the surroundings are developed to conform to the requirements of the framework for rating Green Buildings and Factories. Incorporation of Green building principles, at the design stage itself enabled us to secure ‘Pre-Certified Platinum Rating’ from the Indian Green Building Council (IGBC), even before the start of any work on ground. G&Bs strong commitment towards sustainable development is demonstrated by various Green features embedded in the project, which are:

All buildings and structures are designed for optimal human performance and all the facilities are suitable for differently abled persons as well.

Maximum use of locally sourced building materials with high recyclable content.

Insulated building roofs covered with reflective materials having high Solar Reflective Index (SRI) value for heat reduction.

Roofs and structures designed for more daylight & ventilation.

Solar PV compliant manufacturing plant roofs planned to meant hold 4 MW.

Energy efficient electrical fixtures for energy conservation

Electrical charging facilities for EVs - 2 and 4 wheelers.

Zero liquid discharge facility having capacity of 2600 cubic meters per day.

100% water recycling of wastewater assured with adequate capacity for its treatment.

Recycled water used for all flushing and landscaping requirements.

Efficient Low- flow plumbing fixtures for reducing water usage.

Built-in capacities for maximum capture and harvesting of rainwater for recharging ground water.

Use of low VOC paints, adhesives, sealants for improving indoor air quality and health of occupants.

Facility to ensure source segregation and recycling of individual and industrial wastes ensuring Zero waste to landfill.

Composting and recycling of organic and bio-degradable waste.

100% of construction waste reused and not sent to landfills.

Deployment of native and adaptive vegetation in landscapes that consumes less water and promotes enhancement of local biodiversity.

Use of digital and IT enabled monitoring systems for real-time health check of equipment to facilitate early fault detection and shorter response time for higher utilization of resources.

In addition, a comprehensive ‘Environment Management Plan’ has been prepared for both construction and operational phases. The plan is deployed on an ongoing basis for which the adequate infrastructure has been put in place.

The current plan proposes setting up of around ten manufacturing plants for Security Solutions, Interio, Material Handling, Tooling, Precision Engineering and Aerospace businesses of Godrej & Boyce.

State-Of-The-Art Facilities

The campus is planned by keeping in view the natural contouring of the land and using its characteristics optimally in the construction of various structures. Also, the structures are designed and constructed keeping in consideration, present and future requirements of our businesses for space, load factors, utility capacities, road network and so on. Contemporary construction technologies are deployed such as site assembled, pre- engineered factory manufactured buildings. This technology significantly reduces working hazards and minimizes wastage of materials.

The utilities are routed systematically through dedicated corridors for the ease of maintainability and traceability over time.

All manufacturing spaces are Wi-Fi enabled and are equipped with Building Management System. The entire electrical network of the campus is centrally monitored and controlled with the aid of Supervisory Control & Data Acquisition (SCADA) system. The network includes 100KV switchyard and plant substations. The SCADA system is implemented with robust security measures to avoid any unauthorized access. The system can be monitored remotely from Pirojshanagar. Modern fire safety measures are deployed such as Nitrogen Injection Fire Protection System (NIFPS) for the transformers at the switchyard and High Velocity Water Spray (HVWS) systems for distribution transformers. Some key firsts at Khalapur are Aluminum piping for compressed air network, Air cooled chillers, automated dosing for cooling towers and online ball type cleaning technology for cleaning of condenser tubes. Further, seamless secure wifi is installed to give the users safe access across the network. The network is resilient, responsive and scalable to the demand of users. The network can track all IoT devices across the campus.
Over 7,000 saplings of various indigenous species were planted and are being maintained by employing people from the local communities.

Community support via CSR

G&B has adopted a focused approach to ensure water sufficiency to the communities around its establishments. This has been addressed through three interventional projects in the areas of water availability, community access and quality of water. To ensure sufficiency of portable water, G&B has constructed six storage tanks and 4 check dams. These check dams ensure collection and percolation of about 135 lacs litres of rainwater to the ground. G&B has also supported the development of model school at Vavoshi, by building 4 classrooms to accommodate over 200+ children in the primary section. To maintain the continuity of schooling of remote rural underprivileged children during the pandemic, G&B converted existing community halls to learning centres in Mayani and Parkhande villages. This was done by providing solar electrical power supply, furniture like chairs and tables as well as TV screens suitable for e- learning. During the pandemic, G&B extended support to the primary health centres by providing medical equipment and supplies for COVID Care. This included hospital grade O2 concentrators, syringe machine, ECG machines, infusion pumps, hospital beds, mattresses, Foetal doppler machines, glucose drips, gloves and masks benefitting more than 5000 patients. Later, G&B supported administering of COVID Vaccination in the community. G&B has worked closely with Maharashtra Forest Department for the development of 15 acres of degraded forest land. In 2018, over 7000 saplings of various indigenous species were planted and are being maintained by employing people from the communities.
Constant monitoring and care have given a 95% survival rate for these saplings and as a result, the entire area is now green, contributing significantly to the improvement of biodiversity all around.

State-of-the-art expansion at Khalapur is a crucial building block of G&B’s future ready manufacturing capacity and capabilities.

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