Iffco Project

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT
HISTORY & DEVELOPMENT
Production facilities of its own and hence dependent on public/private Sectors for supplies. To overcome this lacuna and to bridge the demand supply gap in the country, a new cooperative society was conceived to specifically cater to the requirements of farmers. It was a unique venture in which the farmers of the country through their own Co-operative Societies created this new institution to safeguard their interests. The number of co-operative societies associated with IFFCO has risen from 89 in 1968 to 39,000at present. Indian Farmers Fertilizer Co-operative Limited (IFFCO) was registered on November 3, 1967 as a Multi-unit Co-operative Society. On the enactment of the Multistage Cooperative Societies act 1984 & 2002, the Society is deemed to be registered as a Multistage Cooperative Society. The Society is primarily engaged in production and distribution of fertilizers. The byelaws of the Society provide a broad frame work for the activities of IFFCO as a Cooperative Society. IFFCO commissioned ammonia - urea complex at Kalol .Kandla both in the state of Gujarat in 1975. Ammonia - urea complex was set up at Phulpur in the state of Uttar Pradesh in 1984. The ammonia - urea unit at Aonla was commissioned in 1989. In 1995, IFFCO had drawn up a major expansion programme of all the four plants under overall aegis of IFFCO VISION 2000 . The expansion projects at Aonla, Kalol, Phulpur and Kandla have been completed on schedule. Thus all the projects conceived as part of Vision 3000 have been realized without time or cost overruns.
COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU
IFFCO : Indian Farmers' Success Story

During mid- sixties the Co-operative sector in India was responsible for distribution of 70 per cent of fertilizers consumed in the country. This Sector had adequate infrastructure to distribute fertilizers but had no production facilities of its own and hence dependent on public/private Sectors for supplies. To overcome this lacuna and to bridge the demand supply gap in the country, a new cooperative society was conceived to specifically cater to the r requirements of farmers. It was an unique venture in which the farmers of the country through their own Co-operative Societies created this new institution to safeguard their interests.
The number of co-operative societies associated with IFFCO have risen from 60 in 1970 to more than 39000at present. Indian Farmers Fertilizers Co-operative Limited (IFFCO) was registered on November 3, 1967 as a Multi-unit Co-operative Society. On the enactment of the Multistage Cooperative Societies act 1984 & 2002, the Society is deemed to be registered as a Multistage Cooperative Society. The Society is primarily engaged in production and distribution of fertilizers. The byelaws of the Society provide a broad frame work for the activities of IFFCO as a Cooperative Society. IFFCO commissioned an ammonia - urea complex at Kalol and the NPK/DAP plant at Kandla both in the state of Gujarat in 1975. Ammonia - urea complex was set up at Phulpur in the state of Uttar Pradesh in 1981. The ammonia - urea unit at Aonla was commissioned in 1988. . The expansion projects at Aonla, Kalol, Phulpur and Kandla have been completed on schedule. Thus all the projects conceived as part of Vision 2000 have been realized without time or cost overruns. All the production units of IFFCO have established a reputation for excellence and quality which is presently under implementation. As part of the new vision, IFFCO has acquired fertilizer unit at Paradeep in Orissa in September 2005. As a result of these expansion projects and acuisition, IFFCO's annual capacity has been increased to 3.69 million tunes of Urea and NPK/DAP equivalent to 1.71 million tones of P2O5
IFFCO
IFFCO was established as the farmers own
Initiative in Cooperative Sector on 3rd Nov.67 with The proposed plants at Kalol & Kandla. With the enactment of Multi State Co-operative Largest producer of fertilisers in the country No. of Plant Locations : Five UREA - 3689.4 NPK/DAP - 4335.0 TOTAL N - 2380.7 TOTAL P2O5 - 1784.5 Only Fertilizer Institution in the country to have Societies Act 2002, the Society is deemed to be
Surpassed 60 lakh MT per annum in terms of production And 80 lakh MT per annum in respect of sales
IFFCO, KALOL UNIT
Unit profile -1
The Rs. 75 crore IFFCO, Kalol Unit, located 26 kms. From Ahmedabad on the Ahmedabad Mehasana highway, started commercial production in April, 1975 in a area covering 96 hectares. The unit consists of plants to produce 1100 tpd Ammonia, 1650 tpd Urea, 6 tpd Dry Ice and 12 tpd Liquid CO2 along with necessary offsite facilities. The natural gas available in the vicinity of the unit is used as the feed stock for the manufacture of ammonia along with 250 tpd naphtha feed based pre-reformer system. Associated gas, naphtha and LSHS are used as fuels. Water is supplied by GIDC from 15 bore wells around the Unit.
VISION
To augment the incremental incomes of farmers by helping them to increase their crop productivity through balanced use of energy efficient fertilizers, maintain the environmental health and to make cooperative societies economically & democratically strong for professionalized services to the farming community to ensure an empowered rural India.
VISION 2010
NCDEX is one of the four licenses/exchanges set up nation Wide for On line trading In commodity futures agricultural produce occupiers a quarter of commodity basket be IFFCO has picked up 12% equity stake in NCDEX at RS.3Cr. With an objective of empowiring farming community & Cooperatives Societies & for giving better return on their Crop produce. To augment the incremental incomes of farmers by helping them to increase their crop productivity through balanced use of energy efficient fertilizers To maintain the environmental health To make cooperative societies economically and democratically strong for professionalized services to the farming community to ensure an empowered rural India. The Society has embarked upon another growth plan titled VISION 2010 Society is exploring avenues for diversification into other profitable business areas, apart from fertilizer sector, for sustained growth and adequate return to Member shareholders. Generation of Power .Value addition to agri-products and marketing Banking and Financial Services Information Technology and IT enabled services Establishments of Retail Chain in urban and semi-urban Locations
Mission
To make plants energy efficient and continually review various schemes to conserve energy. Commitment to health, safety, environment and forestry development to enrich the quality of community life. Commitment to social responsibilities for a strong social fabric. To institutionalise core values and create a culture of team building, empowerment and innovation which would help in incremental growth of employees and enable achievement of strategic objectives. Foster a culture of trust, openness and mutual concern to make working a stimulating and challenging experience for stake holders. . A true commitment to transparency, accountability and integrity in principle and practice. To acquire, assimilate and adopt reliable, efficient and cost effective technologies Sourcing raw materials for production of phosphatic fertilisers at economical cost by entering into JointVentures outside India.
FORM OF ORGANISATION
UNIT PROFILE -2
IFFCO, kalol unit, located 26 kms. From the Ahmedabad mehsana highway, started commercial production in April, 1975 in a area covering 96 hectares. The unit consist of plants to produce 1100 tpd ammonia, 1650 tpd urea, 6tpd dry ice and 12 tpd liquid CO2 along with necessary offsite facilities. The natural gas available in the vicinity of the unit is used as the feed stock for the manufacture of ammonia along with 450 tpd naphtha feed based pre-reformer system. Associated gas, naphtha and lshs are used as fuels. Water is supplied by GIDCfrom 15 bore wells around the unit
IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT organization
CHART OF GENERAL INFORMATION CHAIRMAN
MANAGING DIRECTOR
BOD
PRODUCTION MANAGER MACHINE OPERATOR ASSISTANT
FINANCE MANAGER REFINERY OPERATOR ACCOUNTANT
HR MANAGER SUPERIOR
MARKETING MANAGER MARKETING OFFICER
ASSISTANT
SALESMAN
.Management
General Body (RGB) which is the General Body forms the supreme body that guides the various activities of IFFCO. The RGB consists of: 1. Members of the Board of Directors. 2. One delegate from each of the Member Societies holding shares of the value of Rs.100 thousand and above; such delegate shall be as per the provisions of the Multi-State Cooperative 3. Delegates to be elected from amongst the representatives of Member-Societies (other than Members holding shares of the value of Rs.100 thousand and above) in each State/ Union Territory at the rate of one delegate for every 200 societies or part thereof. However, the maximum number of such delegates from any State / Union Territory shall not exceed 25. Such elected delegates shall be as per the provisions of the Multi-State Cooperative Societies Act/ Rules amended from time to time. The Board of Directors of IFFCO carry out all functions as specified under the Multistate Cooperative Societies Act/Rules. The Board of Directors frame policies, direct the various activities of the Society, and under take any other activities conducive to overall growth and development of Societies. the organisation with responsibilities for general conduct, supervision and management of day to day business and affairs of IFFCO., Director (HRD) is responsible for all the Human Resources, Director (Joint ventures) oversees all the Joint Venture operations and Director (Coop. Development) looks after Cooperative .
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main head office in Delhi.

Board of Directors
Shri Surinder Kumar Jakhar, Chairperson Shri. N. P. Patel, Vice-Chairperson
Directors
Shri Kartick Chandra Sarkar Shri Harminder Singh Jassi Shri S.K.Vashishtha Dr. Dinesh Kumar Goyal Shri Pramod Kumar Singh Shri Ajit Kumar Singh Shri Vithalbhai H. Radadia Shri Sheesh Pal Singh Shri Raj Kumar Tripathi Shri Balvinder Singh Nakai Shri Ravindra Pratap Singh Shri K. Srinivasa Gowda Dr U.S.Awasthi (Managing Director) Shri. D.K. Bhatt (Marketing Director) Shri. Rakesh Kapur (Finance Director) Shri V.K. Bali , Director(Technical) Shri S.K Mishra , Director (HRD) Mr. K.L Singh , Director (Joint ventures)
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BANKERS
Indian Overseas Bank State Bank of India Bank of Baroda The Karnataka State Co-operative Bank Ltd. The Punjab State Co-operative Bank Ltd.
AUDITORS
M/s. S.P. Chopra & Co. Chartered Accountant N Block, Bombay Life Bombay Connaught Place New Delhi -110001 M/s.Arun Singh & Co. Chartered Accountant F-7, Lagpat Nagar-3 New Delhi 110024
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Kalol Unit
NATIONAL SAFETY AWARD FOR THE PERFORMANCE YEAR 2009
Kalol Unit has been selected as a Joint Winner under Scheme No. I the National Safety Award Performance Year 2006. This is considered to be the highest award in Industrial Safety in India. This award was presented by the Hon'ble Union Minister for Labour & Employment, New Delhi. This award is in appreciation of the operation of Kalol Unit with the Longest Accident-free Period. For more details & related photos, pleace open the attached file
First Prize in maintaining the Best Institutional Gardens in Gujarat

Kalol Unit has been awarded the First Prize in maintaining the best Institutional Gardens by Gujarat Horticulture Association, Gujarat. This is the third consecutive year when the Unit has been awarded the First Prize for maintaining the Best Institutional garden in Gujarat State. Also, Kalol Unit has displayed 113 varieties of flowers and 21 varieties of fruits & vegetables during the competition and awarded the
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IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT First Prize in- /Vegetables Competition. Shri Bhupenderasinh Chudsama, Minister for Agriculture, Govt. of Gujarat, handed over the trophies. The trophies were received by Shri A.K. Singh, JGM (P&A), Mgr (Estate), and the horticulture staff .
IFFCO Kalol Wins "National Energy Conservation Award: 2006"
Safety Award to IFFCO, Kalol

our Shri V S Amin, Sr. Manager (Fire & Safety), at a function jointly organized COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU 14
IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT by the Gujarat Safety Council and the Directorate of Industrial Safety & Health, Govt. of Gujarat, at Jamnagar on 15.12.2006.
IFFCO bags three FAI Awards

Indian Farmers Fertilizer Cooperative Limited, worlds largest fertilizer cooperative, received three awards at a glittering function to mark inauguration of Fertilizer Association of India (FAI)s Annual Seminar on 5th December, 2007. The Phulpur Unit I of IFFCO bagged the FAIs Award for the year 2006 07 for the Best Overall Performance of an operating fertilizer unit for Nitrogen (Ammonia and Urea) Plant jointly with Zuari Industries Limited, Goa. The Societys Aonla Unit has pocketed FAIs Award for Excellence in Safety for the year 2006 07. IFFCOs Kolar film on Water Harvesting has been adjudged the Best Video Film for the year 2006 07. The Awards were presented by Union Minister for Chemicals & Fertilizers, Shri Ram Vilas Paswan. As one of the dominant players in fertiliser industry, IFFCO had been recipient of several prestigious awards in the fields of production, energy conservation, transfer of farm technology and safety in the past. IFFCOs Kolar film on rain water harvesting is a very educative, informative and useful film. The film depicts IFFCOs stupendous efforts in recharging of around 700 sinking bore wells in Kolar District of Karnataka in collaboration with Karnataka Government. COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU 15
IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT With its superlative performance on the all fronts year after year, IFFCO has expanded its global presence.
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CHART OF PRODUCTION DEPARTMENT

PRODUCTION
COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU 18
MANAGER
MALTING IN CHARGE FURNACE SUPERVISOR
CHIEF OPRATOR
CUTTING IN CHARGE
LABORATORY IN CHARGE
OPERATOR
SUPERVISOR
CHEMIST
HELPER
HELPER
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RAW MATERIALS OF THE PRODUCTION

Iffco is using various types of raw materials in the production. It is as under Natural gas Associated gas Bore well water Fuel oil Electric power
Ammonia Plant
1. Replacement of ejector assembly of surface condenser. 2. Diversion of LP case seal oil off-gases of synthesis compressor 3. Use of AG for deaeration in pre-reformer 4. Stoppage of associated gas supply during plant turnaround Retuning of Heat exchangers 5...Washing of convection zone coils. 6. Reduction of MP steam in Air-Steam coil in convection zone of primary reformer. 7. Replacement of LT steam superheat coilDesuperheating of Mixed Feed Coil Inlet gas 8...Diaphragm replacement in BFW Pump turbine
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AMONIA PLANT AT IFFCO
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Urea Plant
1. Heat recovery from LP steam condensate by CO2 turbine surface condensate. 2. Heat recovery from desorber effluent by CO2 turbine surface condensate. 3. HP case rotor modification for CO2 compressor. 4. Pressurized operation of ammonia oil separator. 5. Ammonia recovery by diversion of LP off gas. 6. Low level heat recovery from desorber effluent. 7. Condensate recovery from inter stage coolers of CO2 compressor 8. Replacement of high pressure stripper 9. Provision of inert gas for ammonia supply system 10. Use of 4-ata steam for LSHS heating upstream of 14-ata heater
UTILITY
Replacement of bulk effluent pump by smaller capacity pump Existing (242 M3/hr) bulk effluent pump is replaced with (150 M3/hr). Power consumption of old pump was 35 kWh and power consumption of New Pump is 30 kWh. About 5 kWh power will be saved which is equivalent to Rs. 2.2 lakhs per annum. The cost of the new pump is 2.75 lakhs. The payback period is 1.25 years.
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UREA PLANT AT IFFCO
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MATERIAL HANDLING
4 Nos. of single deck, circular design urea vibrating screens each having a capacity of 26 t/hr in the transfer area of B&MH plant are installed for separation of 1 mm and below urea fines/dust.
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GODOWN AT IFFCO
Fertilizer Production
IFFCO commissioned ammonia - urea complex at Kalol and an NP/NPK plant At Kandla in Gujarat in 1975. Ammonia - urea complex was set up at Phulpur In Uttar Pradesh in 1981. The ammonia - urea unit at Aonla was first commissioned in 1989 and then expanded in 1996. The installed capacity of all the plants in terms of the Nutrient is 1.2 million tonnes of nitrogen and 309 thousand tonnes of phosphates. All The units of IFFCO have consistently shown good performance and have received National and international recognition.
"Vision 2000"
IFFCO has visualized a long-term comprehensive plan titled Vision 2000 for Making a significant contribution to the process of nation building. This plan envisages The expansion of existing units, establishment of new fertilizer production facilities inside And outside the country, production of agro-chemicals and augmentation of the acreage Under seed production. In addition, debottlenecking and productivity enhancement Schemes have also been undertaken at the existing units to further improve the Production performance. The project for the doubling of the production capacity at the Existing unit at Aonla has already been completed. The expansion project at Kalol is at an advanced stage of completion. The Phulpur expansion project is expected to Commence production towards the end of 1996-97. A grass root project at Nellore in COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU 25
IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT Andhra Pradesh is starting this year. Once all the envisaged projects are completed
PERFORMANCE:
Plant was commissioned for revamped capacity in August 97 well within the cost & time schedule. Guarantee Test Run was successfully performed in February 1998 in presence of Stamicarbon & TICB engineers meeting all the Guarantee figures as listed in Table - 4. Presently the plant is producing around 1750 MTPD on continuous basis and Maximum production achieved recently was 1800 MTPD. 5. Low pressure steam export KG/tonne of urea 179 408 4. Sp. consumption of steam KG/ton of Urea 871 853 3. Sp. consumption of CO2 KG/tonne of Urea 737 733 2. Sp. consumption of Ammonia KG/ tonne of Urea 570 566 1. Daily production capacity MTPD 1650 1690
BIO FERTILISERS
A biofertiliser unit was established at Cooperative Rural Development Trust, Phulpur (Uttar Pradesh) in 1996 - 97 and other at Kalol (Gujarat) in 2003-04 with an annual capacity of 75 MT and 165 MT respectively of different cultures such as Rhizobium, Azotobacter, PSM, Azospirillium and Acetobacter.
Phosphate Solubilising Micro Organism - Several soil bacteria and fungi possess the ability to bring insoluble phosphates into soluble forms by secreting organic acids. They can be applied to and recommended for all crops COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU 26
Rhizobium - It is the most important nitrogen fixing organism. It live symbiotically in the root nodules of leguminous plants and supply nitrogen to the plant through nitrogen fixation. Besides, supplying nitrogen to the crop, nitrogen fixed by legume - Rhizobia association would also leave residual nitrogen for the succeeding crops. The beneficiary crops are Groundnut, Soybean, Red-gram, Green-gram, Black-gram, Lentil, Cow pea, Bengal-gram and Fodder legumes.
Azotobacter - It is non symbiotic nitrogen fixing bacteria recommended for non leguminous crops like Paddy, Wheat, Millets, Cotton, Tomato, Cabbage, Mustard, Safflower and Sunflower. The Azotobacter performs well if the soil organic matter content is high.
Acetobacter - It is a symbiotic bacteria capable of fixing atmospheric nitrogen by living within the sugar plant. They are found in all parts of plant body. It is suitable for sugarcane cultivation.
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Azospirillium - It is an associative microaerophilic nitrogen fixer is commonly found in association with the roots of cereals and forage grasses. The beneficiary crop include Sugarcane, Vegetables, Maize, Pearl millet, Rice, Wheat, Fodders and Oil seeds
PRODUCATION DEPARTMENT
Annual consumption of major inputs
Item Natural Gas Associated Gas Naphtha LSHS Caustic soda (46%) HCL (31%) Sulphuric Acid (98%) Unit MMSM3 MMSM3 MT MT MT MT T 2001-02 150 72 87415 39195 452 11197 51 2002-03 130 79 96045 45197 312 11087 34 2003-04 115 71 117181 42285 270 10762 29 2004-05 62 64 55934 42162 263 11432 32
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PLANT MODIFICATION
Ammonia Plant
PGR Plant Combination type auxiliary boiler burners Natural gas compressor Additional surface condenser Installation of BFW coil in LT convocation zone Ammonia converter retrofit LTS catalyst reduction system Natural gas booster compressor Naphtha pre-reformer system Process air compressor revamp MEA solution swap by MDEA IN CO2 removal May.1980 Jan.1981 Aug.1984 Aug.1984 May.1986 Sep.1993 Sep.1993 Aug.1997 Aug.1997 May.1997 May.1997
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UREA PLANT
LP absorber for HP scrubber off gases Urea recovery system Atmospheric ammonia scrubber foe LP system vent gases Fluidized bed Urea prills cooling system Hydrolyser stripper system Centrifugal CO2 compressor High efficiency reactor trays Additional LPCC Pre-evaporator system New second stage evaporate, condenser, ejectors etc. Modified prill bucket DCS control system Ammonia recovery from LP system vent gases Mar.1978 Fab.1981 May 1986 Aug 1988 Dec 1992 Aug 1997 Aug 1997 Aug 1997 Aug 1997 Aug 1997 Aug 1997 Aug 1997 1998-99
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TECHNOLOGY
Kalol Unit- Technology Ammonia Urea Dry ice/ Liquid CO2
Basic Technology AMMONIA PLANT: MTPD 1100 M/S M.W. KELLOGG UREA PLANT: MTPD 1650 M/S STAMICARBON BV, THE NETHERLANDS DRY ICE: MTPD 6 M/S BORSIG, GERMANY
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HUMAN RIGHTS
Principle 1: Business should support and respect the protection of international Human rights within their sphere of influence; and Principle 2: Make sure they are not complicit in human right abuses.
COMMITMENT
Towards making the cooperative societies economically and democratically strong for professionalized services to the farming Community to ensure an empowered rural India. Towards farmers for their welfare, prosperity and growth. Towards abolition of child labour. Towards indiscrimination on the basis of gender in employment. Towards providing employment opportunity to weaker sections.
SYSTEMS
Cooperative Development Programmes through marketing Field Officers. Rural and Agricultural Development Programmes through marketing Field Officers. Services through IFFCO Foundation a Trust promoted by IFFCO; Services through Indian Farm Forestry Development Cooperative Ltd. (IFFDC) a Cooperative Society promoted by IFFCO. ACTIONS IFFCO adopts villages with an objective of bringing about over all Economic development and improvement in living standards of rural Community through integrated rural development with particular emphasison agricultural development. COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU 32
IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT To make Cooperative societies economically viable, IFFCO adopt them And provide infrastructure and financial support, for their revival, through Sale of IFFCO fertilizers. In order to strengthen Cooperative societies, IFFCO appoints some of them as Franchisees for storage and handling of fertilizers which includes warehousing, transportation and rake handling; Organize programs viz; Farmers Meeting, Crop Seminars, Field societies to enhance crop productivity through balanced use of nutrients; Organize community based programs viz; Women Training, Medical / lihood assets. Emphasis is laid on formation of women SHGs. Promoted a Charitable Trust known as IFFCO KISAN SEWA TRUST to provide relief and rehabilitation to victims in the event of natural calamities. Promoted a Trust IFFCO Foundation with an objective to promote The Cooperative Rural Development Trust (CORDET) promoted by IFFCO provides practical training to farmers to improve their skills in
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PERSONAL &ADMINISTRATION DEPARTMENT

STRUCTURE OF PERSONAL DEPARTMENT
PERSONAL
INDUSTRIAL
ADMINISTRATION
MANAGE THE SELECTION TRAINING RECRUITING CRIVANCE& COURT
GENERAL TOWNSHIP TRANSPOR
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FUNCTIONS
Preparing capital budget by coordinating all sections of P & A dept. Procurement of office furniture. Physical verification of asset. Supervision of dispatch section. Good housekeeping of administration building. Maintenance of files pertaining to above jobs.
WELFARE FACILITIES *Welfare scheme

Canteen Conveyances advance Sports Culture activities Educational facilities Assistance scheme Post retirement medical benefits scheme LTC Liveries Recreational clubs Transport facilities Scholarship EST
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FIRE & SAFTEY

INTRODUCTION
While preparing the emergency/disaster control plan, the detail information on hazards presents in process of the plant and at storages of hazardous and toxic chemicals is must. This information can obtain only by identification, analysis and assessment of hazards and risks through HAZOP and HAZAN study. The risk assessment and analysis study helps in deciding the possible major scenario, gas dispersion modules , environment impact of disaster and to prepare full proof and effective emergency plan. After detail risk assessment and analysis study, the possible major scenarios have been decided as under.
CRITERIA FOR EXPECTING MAJOR INCIDENTS

List of scenarios are prepared based on plant areas/sections where the highest level of hazard was foreseen with respect to: Toxic inventory. Flammable inventory Temperature of storage
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TIME OFFICE
OBJECTIVE:
It requires for retaining all records of employees relating their absenteeism, on duty, presents, shift, etc,to provide the inputs to accounts departments for the salary of employees. All employees have their punching card so when they come, they punch and when they return; they again punch so that time details are recorded in computer in this department. Their leave record and overtime all details are taken by it so that their total hours work are calculated and on this basis account department pay salary to the employees for their work. For that HUMAN RESORCE MANAGEMENT SYSTEM, computer based program is used so that speed and accuracy are increased in the work.
EMPLOYEES TYPES:In the IFFCO, there are different types of employees employed are as follow:
1. APPRENTICE 2. CASUAL WORKERS 3. DESPATCH 4. REGULAR
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SERVICE TO FARMERS
Agricultural Extension and fertiliser use promotion Programmes are an integral part of the marketing activity. Programmes are conducted at Area/State/Zonal offices under the guidance of agricultural scientists. Programmes undertaken are Balanced Fertilization programmes Adoption of villages for all round socio-economic development Farmers Meetings, Field Days and Crop Seminars Static/Mobile Soil Testing Laboratories with Audiovisual
THERE ARE VARIOUS REPORTS PREPARED WHICH ARE AS FOLLOWS
(1) SHIFT REPORT

There are four shifts which are as following table:
SHIFTS
GENERAL SHIFT A(MORNING SHIFT) B(NOON SHIFT) C(NIGHT SHIFT) ON SATURDAY (HALF DAY)
DURATION
8 TO 17.15HRS 6 TO 14 HRS 14 TO 22HRS 22 TO 33HRS 8 TO 12HRS
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(2) LEAVE REPORT

There are 14 causal leave,33 earning leave encashment and other leave as follow: 1. COMPANSATORY OFF 2. EARN LEAVE 3. JONNING LEAVE 4. LEAVE WITHOUT PAY 5. EXTRA ORDINARY LEAVE WITHOUT PAY 6. MATERNERY LEAVE 7. SPECIAL CAUSAL LEAVE 8. SICK LEAVE 9. STUDY LEAVE
(3) OVERTIME REPORT
In it employees are work more than their regular work are compensate by management for motivate them so recoded of it maintain.
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TRAINING (TRAINING CENTER & GUEST HOUSE)

TRINING
IN HOUSE
OUTSIDE
INTERNAL FACULTY
OUTSIDE FACULTY
RESIDETIAL PROGRAME NONRESIDENTIAL PROGRAME LOCATION
TRAINING CENTER
GUEST HOUSE (INTERPLANT)
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UNIT. KASTURI NAGAR TOWNSHIPIFFCO, KALOL
Kasturi nagar is the residential colony of Indian farmers fertilizers co-operative (IFFCO), Kalol unit. This compact township with 315 residential quarters meets the housing need of the factory complex for essential production, maintenance and supporting service staff. Factory is 5kms down towards mehsana from township. The township has a wholesome establishment having full-fledged infrastructure such as bank ,post office , drinking water , electricity supply, sewage recreation club and a temple complex. Kasturi nagar residents were well aware of the environmental issues threatening life existence, as they had exposure to environmental management system while IFFCO plant was going for ISO 140001 certification. .
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MARKETING DEPARTEMENT
Marketing research means collection analysis & reporting of data to a Marketing department in the organization.IFFCO use marketing research in wild verity of situation.IFFCO collect information on primary data bases. The process of marketing is as follow.
IFFCO Sedan,
C-1, District Centre, Saket Place , New Delhi -110017 Phone: 011-42592626,26542625 Fax: 011-42592650
North Zone
(Chandigarh)IFFCO Complex,Plot No.2(B&C), Sector 28-A, Madhya Marg, Chandigarh -160002 Fax 0172-2654838 Phone - 2652791, 2638925 Email : pssidhu@iffco.nic.in
East Zone
(Kolkata) 8, Acharya J C Bose Road,

Circular Court , Kolkata - 700017 Fax-033-22400443 Phone- 22478025 Email :zmeast@iffco.nic.in
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I.T. and Fertilizer Marketing

In order to create suitable I.T. infrastructure it is necessary to formulate the broad Issues that are sought to be addressed. It is necessary to summaries areas of concern for which Solutions from I.T. can be expected in relation to fertilizer marketing so that suitable I.T. strategy can be evolved. The basic expectations from I.T. would be with respect to the following issues : y Effective Executive Information Systems : A well designed executive information systems that will ensure that the activities at all the levels of marketing function are directed at Achieving the goals of the organisation. Necessary monitoring and decision making tools are required to be provided. Breaking Distance Barriers: The operations related to fertilizer marketing involve large Territories. I.T. should provide means of acquiring latest information from all parts of the Country so that the managers have access to latest information. Meaningful Information: The problem of too much data or too little data needs to be Addressed. Mere provision of access to a large volume of data can lead to confusion. The Decision makers should not be inundated with too much of raw data. The data should be Provided as meaningful information which contributes to proper judgment in decision making. Raising Alerts: The systems should provide alerts to exceptions and achievements. Projection and speculation reporting may also be provided. Interactivity: Interactive communication with facts and figures between various layers of Management needs to be provided. Online Support : Online support to sort out any problems along with dynamic identification of an expert to assist in solving the problem, online access to policy guide lines, etc. may be Provided. Transforming the present marketing activity to a new paradigm of conducting business Electronically by switching over to e-business.
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Internet & Fertilizer Marketing

The fertilizer industry needs to ensure that the above mentioned applications are in place at the earliest so as to not lose competitive advantage. A whole gamut of economical solutions exist for this purpose. A discussion on technological options presently available is beyond the scope of this paper. It may be useful to adopt Internet based technologies as major developments are focused in this arena and substantial efforts on standardisation are already undertaken. Since it is difficult to extend speedy and reliable support to most of the field personnel, web based technologies will minimise the number of tools to be used by them to a simple browser, like Internet Explorer, Netscape, etc. Once the Home PC revolution catches up in the rural India, the opportunities that will open up could be unlimited. As it is, India has 37 million cable TV connections with a substantial portion of it in rural India. This broadly gives a guestimate on the size of possible target segment which can be reached through Internet. It is also pertinent to note, thanks to a series good monsoons, rural markets are no longer ignored by even major luxury automobile producers like Benz. Since the fertilizer industry has a talented pool of field personnel who can be one of the conduits to spread electronic services to rural India, it may be useful to be ready to avail diversification opportunities through information technology in the new economy. Technological obsolesence is a known source of risk with respect to information technology, yet, the web based technologies and world wide web (WWW) are here to stay for a long time. The point to be noted is that these are only a means by which the world as a whole is moving towards a knowledge based society which promises to bring in drastic changes in the course of human civilisation. During this process, technologies may under go radical changes but the basic underlying course towards a knowledge based society itself is unlikely to. Further, the growing popularity of internet, its penetration and web enabling of new gadgets like cell phones, etc. can alter the course of the way fertilizer marketing transactions will be handled in the future. It would be useful to be ready and be on the right side of the course of society. At the very least, the fertilizer industry can ensure that it is prepared to carry the knowledge revolution to rural India without delay as and when such an opportunity fully materialises. COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU 44
E-Commerce and Fertilizer Marketing

Enormous potential for e-commerce exists in various activities of the industry such as supply chain management, etc. which is beyond the scope of this paper. But the immediate questions which are pertinent to the subject are : Why should the fertilizer industry consider introduction of e-commerce? Is e-commerce feasible in fertilizer marketing? If yes, is the basic infrastructure available in the country to extend e-commerce to fertilizer marketing? Not withstanding the general reservations expressed, there appears to be reason to believe that there is substantial scope for it in the near future. The sheer extent and volume of the fertliser marketing and its impact on the countrys agriculture should make it a first, and not a last, candidate for operations in more than three states and handles lakhs of tonnes of fertilizer. In addition to possessing robust bricks and mortar infrastructure for production, & marketing, the major segment of the industry has adequate I.T. strength at the organisation level to initiate clicks & mortar technology through e-revolution. Fertilizer marketing involves consumers who are farmers and a channel to reach them. Distributor/dealer and cooperative networks are the usual channel through which the fertilizer industry reaches out fertilizer material to farmers. A symbiotic relationship exists between the channel and the fertilizer industry which goes beyond a seller/buyer relationship. Substantial inputs are received from the distribution channel on farmers practices & preferences, anticipated demand, etc.
45
MARKETING CHANNELS
4 Distribution of fertilisers mainly through the Cooperative System: State level Apex Cooperative Marketing Federation acts as wholesaler 4 Direct supplies to Societies in some States 4 IFFCO-NCDC Cooperative Societies 4 Small quantities to institutional agencies like Agro Industries Corporation etc 4 158 IFFCO Farmers Service Centres
TRANSPORTATION
B Both by Rail (87%) and Road (13%) B WAREHOUSING B Federations & Cooperative Godowns, B Central Warehousing Corporation (CWC) and B State Warehousing Corporation (SWC)
46
TOTAL SALE OF FERTILISERS
SALES PERFORMANCE
47
BALANCE SHHET AS AT 31 ST MARCH, 2008
48
IFFCO INDIAN FARMER FERTILISERSAS AT 31-3-2007 LTD, KALOL UNIT CO-OPERATIVE AS AT CHANGE % 31-3-2008 SOURCES OF FUNDS SHARE HOLDERS FUNDS SAHARE CAPITAL SHARE APLICATION MONEY RESERVS &SURPLUS LOAN FUNDS SECURE LOANS UNSECURE LOAN DEFFERED TAX LIABILITY(NET) TOTAL APPLICATION OF FUNDS FIXED ASSETS GROSS BLOCK LESS:ACCUMULATED DEPRICIATION NET BLOCK CAPITAL WORKING IN PROGRESS INVESTMENTS CURRENT ASSETS, LOANS&ADVANCES INVENTORIES SUNDRY DEBTORS CASH AND BANK BALANCES LOAN AND ADVANCES TOTAL LESS:CURRENT LIABILITIES AND PROVISION CURRENT 1048.49 1028.47 20.02 1.9465808 87.010882 14.180465 49 -9.751539 -33.72982 3.156168 1577.1 413.76 243.52 3541.56 5775.74 2283.94 361.68 330.84 3104.82 6081.28 -706.84 52.08 -87.52 436.74 -305.54 -30.94827 14.399469 -26.45387 14.066516 -5.024271 423.93 422.83 0.09 3218.92 2398.91 4087.21 3641.84 6486.12 534.02 10662 1.1 0.260151 & CHANGE
3264.73 3688.66 2404.67 4370.97 6775.64 534.19 10998.49
45.81 5.76 283.76 0.17 336.51
1.4231481 0.240109 6.9426332 0.031834 3.156168
8138.98 3400.04 4738.94 430.85 5169.79 1416.73
7808.44 3006.42 4802.02 227.68
330.54 393.62 -63.08 203.17 676.27
4.2331119 13.092648 -1.313614 4.0394059 91.331064
5029.7 740.46
LIABILITIES PROVISIONS 323.08 172.76 150.32 TOTAL 1371.57 1201.23 170.34 COLLEGE STUDIES, -475.88 NET CURRENT ASSETSOF COMPUTER & MANAGEMENT 4880.05 VADU 4404.17 MISCELLANEOUS 7.8 11.77 -3.97 EXPENDITURE TOTAL 10998.49 10662 336.51
ANALYSIS:
1. In 07-08, share capital is increased by 0.26 % and reserve &surplus is increased also by 45.81 crore. 2. Secured loan is increased 5.76 crore,while unsecured loan is increased by 6.94 %in 07-08. 3. Differed tax liabilities are also increased by 0.03 % , so total is increased by 3.15 % in current year. 4. Net asset is decreased by1.3 % because depreciation is increased by 13% in 07-08 compare to 06-07. 5. Current working in progress is increased by 4 % . while investment is increased by 91.3 %, because of in current year new investment is purchased. 6. Current asset is decreased by 5 % and inventories are decreased by 30.9% and while sundry debtors are increased by 14.4 % so current liabilities are increased by 14.2 %. 7. so IFFCOs financial position is sound compare to all data.
50
PROFIT AND LOSS ACCOUNT FOR THE YEAR ENDED 31st MARCH, 2008
PARTICULARS
YEAR ENDED 31-3-08
YEAR ENDED 31-3-07 CHANGE
% CHANGE
INCOME FROM OPERATION S TURNOVER SALES(NET OF EXISE DUTY) SUBSIDY FROM GOVERNMENT OF INDIA OTHER REVENUE INCREASE/(DECREASE)IN SOTOCK LESS:COST OF OPERATIONS CONSUMPTION OF RAW MATERIALS,STORES ETC.: RAW MATERIALS STORES AND SPARES CHEMICAL AND CATALYSTS PACKING MATERIALS POWER,FUEL AND WATER LESS:STOCK TRANSFER FOR SELF CONSUMPTION PURCHASE OF PRODUCT FOR RESALE EMPLOYEES REMUNERATION& BENEFITS MANUFACTURING,ADMINISTRATION DISTRIBUTION EXPENSES INTREST DEPRECIATON / AMORTIZATION PRIOR PERIOD ADJUSTMENTS (NET) DEFERRED REVENUE EXP. WRITTEN OFF (VOLUNTARY RETIREMENT SCHEME COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU 51 6646.44 96.26 38.22 170.43 756.48 7707.83 -118.81 1245.44 405.75 959.49 389.37 410.93 -3 3.86 6428.37 96.47 30.53 173.46 629.26 7358.09 128.83 1875.34 312.55 916.39 353.94 391.49 -5.37 3.92 218.07 -0.21 7.69 -3.03 127.22 349.74 -247.64 -629.9 93.2 43.1 35.43 19.44 2.37 -0.06 3.3923063 -0.217684 25.188339 -1.746800 20.217398 4.7531357 -192.2223 -33.58857 29.81229 4.7032377 10.010171 4.9656441 -44.13407 -1.530612 5968.47 6194.35 354.77 -1136.21 11381.38 5557.97 4775.58 244.6 754 11328.7 410.5 1418.77 110.17 -1890.21 52.68 7.3857901 29.71 45.040883 -250.6909 0.4650136
IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT EXPENSES) PROFIT BEFORE TAX PROVISION FOR TAXATIONCURRENT TAX FRINGE BENEFIT TAX DEFERRED TAX EARLIER YEARS PROFIT AFTER TAX PROFIT TRANSFERRED TO: CAPITAL REPATRIATION FUND NET PROFIT AS PER MULTI STATE COOPERATIVE SOCIETIES ACT,2002 11000.86 380.52 61.8 6.5 56.14 -1.51 11077.52 251.25 76.66 129.27 61.8 0.7 -19.48 3.68 -6.9 51.450756
5.8 75.62 -5.19
12.068966 -25.76038 -70.90558
0.46 257.13
0.45 174.57
0.01 82.56
2.2222222 47.293349
ANALYSIS:
1. In this year sales are increased by 7.39 % and subsidy from government is also increased by 29.71 % 2. In cost of operations is decreased by 6.9 % because of decreased in stores and spares, packing materials, purchase of products for resale and differed revenue exp. Are increased. while employee remuneration increased by 29.82 % , interest by more than 10 % and depreciation also increased . thus IFFCO should regulate this fixed cost. 3. The second thing noticed was that provision this year gets increased by 61.8 that is not in the previous year.
52
IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT 4. The profit before tax is increased by 51.45 % that is 1.5 times of previous years and after tax is 1.5 times of is 1.5 times of previous years so financial position of IFFCO is became better compare to previous year.
53
CONCLUSION
I visited IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT. A response from every department helped me a lot to collect information, thats why I am very thankful to IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD. The main objective of industrial visit is to develop practical knowledge of industrial activity that may not be achieved by just getting through looks. This point helped me a lot to get practical experience with knowledge. So that I am thankful to the officers and employees of IFFCO INDIAN FARMER FERTILISERS COOPERATIVE LTD, KALOL UNIT who helped me during my industrial visit.
54
BIBLIOGRAPHY
BOOKS: Human resources management: aswathappa Marketing management: Philip kotler Finance management: b.s.shah WEBSITE; www.iffco.nic.com http://www.plantemoran.com
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IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

HISTORY & DEVELOPMENT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

IFFCO : Indian Farmers' Success Story

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

IFFCO, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT organization

CHART OF GENERAL INFORMATION CHAIRMAN

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

PRODUCTION MANAGER MACHINE OPERATOR ASSISTANT

FINANCE MANAGER REFINERY OPERATOR ACCOUNTANT

MARKETING MANAGER MARKETING OFFICER

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

main head office in Delhi.

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

First Prize in maintaining the Best Institutional Gardens in Gujarat

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO Kalol Wins "National Energy Conservation Award: 2006"

Safety Award to IFFCO, Kalol

IFFCO bags three FAI Awards

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

CHART OF PRODUCTION DEPARTMENT

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

MALTING IN CHARGE FURNACE SUPERVISOR

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

RAW MATERIALS OF THE PRODUCTION

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

AMONIA PLANT AT IFFCO

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

UREA PLANT AT IFFCO

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

IFFCO INDIAN FARMER FERTILISERS CO-OPERATIVE LTD, KALOL UNIT

COLLEGE OF COMPUTER & MANAGEMENT STUDIES, VADU