Chapter 6 : Manufacturing Industries

Introduction to Manufacturing

Definition:

• Manufacturing is the production of goods in large quantities by processing raw materials into more valuable products.
• Examples: Paper from wood, sugar from sugarcane, iron and steel from iron ore, aluminium from bauxite.
• Secondary activities involve manufacturing primary materials into finished goods (e.g., steel factories, textile industries, bakeries).

Importance of Manufacturing:

• Backbone of economic development:
• Modernizes agriculture, reduces dependence on agricultural income by providing jobs in secondary/tertiary sectors.
• Eradicates unemployment and poverty (philosophy behind public and joint sector industries in India).
• Reduces regional disparities by establishing industries in tribal/backward areas.
• Expands trade and commerce through exports, earning foreign exchange.
• Countries transforming raw materials into high-value goods are prosperous.
• Interdependence with Agriculture:
• Agro-industries boost agricultural productivity by providing irrigation pumps, fertilizers, pesticides, machines, etc.
• Depend on agriculture for raw materials and sell products to farmers.
• Global Competitiveness:
• In globalization, industries must be efficient and competitive, producing high-quality goods for international markets.

Classification of Industries

Based on Source of Raw Materials:

• Agro-based: Cotton, woollen, jute, silk textiles, rubber, sugar, tea, coffee, edible oil.
• Mineral-based: Iron and steel, cement, aluminium, machine tools, petrochemicals.

Based on Main Role:

• Basic/Key Industries: Supply products as raw materials for other goods (e.g., iron and steel, copper smelting, aluminium smelting).
• Consumer Industries: Produce goods for direct consumer use (e.g., sugar, toothpaste, paper, sewing machines, fans).

Based on Capital Investment:

• Small Scale Industry: Maximum investment in assets up to ₹1 crore.

Based on Ownership:

• Public Sector: Owned/operated by government (e.g., BHEL, SAIL).
• Private Sector: Owned/operated by individuals/groups (e.g., TISCO, Bajaj Auto, Dabur).
• Joint Sector: Jointly run by state and individuals (e.g., Oil India Ltd.).
• Cooperative Sector: Owned/operated by producers/suppliers/workers pooling resources (e.g., sugar industry in Maharashtra, coir industry in Kerala).

Based on Bulk and Weight:

• Heavy Industries: Use/produce heavy/bulky materials (e.g., iron and steel).
• Light Industries: Use/produce light materials (e.g., electrical goods).
• Activity Classification (Bulk/Weight):
• Heavy: Oil, Shipbuilding, Automobiles.
• Light: Sewing Machines, Knitting Needles, Brassware, Fuse Wires, Watches, Electric Bulbs, Paint Brushes.

Agro-based Industries

Textile Industry:

• Unique position in Indian economy: Significant contribution to industrial production, employment, and foreign exchange earnings.
• Self-reliant, complete value chain from raw material to high-value products.

Cotton Textiles:

• Historical Context:
• Ancient India used hand spinning and handloom weaving.
• Post-18th century, power-looms introduced; colonial period saw decline due to competition from English mill-made cloth.
• First successful textile mill in Mumbai (1854).
• World Wars increased UK cloth demand, boosting Indian cotton textile industry.
• Location Factors (Maharashtra, Gujarat):
• Availability of raw cotton, market, transport, port facilities, labour, moist climate.
• Linkages:
• Supports agriculture (farmers, cotton pluckers) and industries (chemicals, dyes, packaging, engineering).
• Processes: Ginning, spinning, weaving, dyeing, designing, packaging, tailoring, sewing.
• Spinning vs. Weaving:
• Spinning centralized in Maharashtra, Gujarat, Tamil Nadu.
• Weaving decentralized, incorporates traditional skills (cotton, silk, zari, embroidery).
• India excels in spinning but weaving produces lower quality fabric due to limited use of high-quality yarn.
• Handspun Khadi:
• Promoted by Mahatma Gandhi for self-reliance and employment in homes as a cottage industry.
• Keeping mill sector loomage lower than power loom/handloom preserves traditional skills and employment.

Jute Textiles:

• India: Largest producer of raw jute and jute goods, second largest exporter after Bangladesh.
• Location: Mostly in West Bengal, along Hugli river (first mill at Rishra, 1855).
• Factors for Hugli Basin Location:
• Proximity to jute-producing areas, inexpensive water transport, good railway/roadway/waterway network, abundant water for processing, cheap labour (West Bengal, Bihar, Odisha, Uttar Pradesh), Kolkata’s banking/insurance/port facilities.
• Post-Partition (1947): Jute mills in India, but 75% of jute-producing area went to Bangladesh.

Sugar Industry:

• India: Second largest sugar producer, first in gur and khandsari.
• Raw Material: Bulky sugarcane, loses sucrose during haulage.
• Location: Uttar Pradesh, Bihar (60% of mills), Maharashtra, Karnataka, Tamil Nadu, Andhra Pradesh, Gujarat, Punjab, Haryana, Madhya Pradesh.
• Seasonal Nature: Suited for cooperative sector due to seasonal production cycles.
• Shift to Southern/Western States (e.g., Maharashtra):
• Higher sucrose content in cane, cooler climate for longer crushing season, successful cooperatives.

Mineral-based Industries

Iron and Steel Industry:

• Basic industry: Supplies machinery for heavy, medium, light industries (engineering goods, construction, defence, medical, scientific equipment, consumer goods).
• Steel consumption/production: Index of a country’s development.
• Heavy Industry: Bulky raw materials (iron ore, coking coal, limestone in 4:2:1 ratio, some manganese) and finished goods require heavy transport.
• Ideal Location: Near raw materials, with efficient transport for distribution.
• Manufacturing Process:
• Blast Furnace: Iron ore melted, limestone (flux) added, slag removed, coke burnt to heat ore.
• Pig Iron: Molten material poured into moulds.
• Steel Making: Pig iron purified, oxidized, alloyed with manganese, nickel, chromium.
• Shaping Metal: Rolling, pressing, casting, forging.
• Chhotanagpur Plateau: Maximum concentration due to low-cost iron ore, high-grade raw materials, cheap labour, vast market potential.

Aluminium Smelting:

• Second most important metallurgical industry.
• Properties: Light, corrosion-resistant, heat conductor, malleable, strong when alloyed.
• Uses: Aircraft, utensils, wires; substitute for steel, copper, zinc, lead.
• Location: Odisha, West Bengal, Kerala, Uttar Pradesh, Chhattisgarh, Maharashtra, Tamil Nadu.
• Raw Material: Bauxite (bulky, reddish rock); Process: 4-6 tonnes bauxite → 2 tonnes alumina → 1 tonne aluminium.
• Location Factors: Regular electricity supply, assured raw material at minimum cost.

Chemical Industries:

• Fast-growing, diverse, includes large/small-scale units.
• Inorganic Chemicals: Sulphuric acid (fertilizers, synthetic fibres, plastics, paints), nitric acid, alkalies, soda ash (glass, soaps, paper), caustic soda.
• Organic Chemicals: Petrochemicals (synthetic fibres, rubber, plastics, dyes, drugs, pharmaceuticals), located near oil refineries/petrochemical plants.
• Self-consuming: Basic chemicals processed for industrial, agricultural, consumer use.

Fertilizer Industry:

• Produces nitrogenous fertilizers (urea), phosphatic fertilizers, ammonium phosphate (DAP), complex fertilizers (N, P, K).
• Potash: Entirely imported (no domestic reserves).
• Location: Gujarat, Tamil Nadu, Uttar Pradesh, Punjab, Kerala (half of production); others: Andhra Pradesh, Odisha, Rajasthan, Bihar, Maharashtra, Assam, West Bengal, Goa, Delhi, Madhya Pradesh, Karnataka.
• Expansion: Post-Green Revolution to various regions.

Cement Industry:

• Essential for construction (houses, factories, bridges, roads, airports, dams).
• Raw Materials: Bulky/heavy (limestone, silica, gypsum); requires coal, electric power, rail transport.
• Location: Strategically in Gujarat for Gulf market access; first plant in Chennai (1904).

Automobile Industry:

• Produces trucks, buses, cars, motorcycles, scooters, three-wheelers, multi-utility vehicles.
• Post-liberalization: New models increased demand, leading to growth.
• Location: Delhi, Gurugram, Mumbai, Pune, Chennai, Kolkata, Lucknow, Indore, Hyderabad, Jamshedpur, Bengaluru.

Information Technology and Electronics Industry:

• Products: Transistors, TVs, telephones, cellular telecom, telephone exchanges, radars, computers, telecommunication equipment.
• Location: Bengaluru (electronic capital), Mumbai, Delhi, Hyderabad, Pune, Chennai, Kolkata, Lucknow, Coimbatore, Noida.
• Impact: Significant employment generation; growth in hardware/software drives IT industry success.

Industrial Pollution and Environmental Degradation

Types of Pollution:

• Air Pollution:
• Caused by undesirable gases (sulphur dioxide, carbon monoxide), particulate matter (dust, sprays, smoke).
• Sources: Chemical/paper factories, brick kilns, refineries, smelting plants, fossil fuel burning.
• Effects: Harms human health, animals, plants, buildings, atmosphere; toxic gas leaks (e.g., Bhopal Gas Tragedy) have long-term effects.
• Water Pollution:
• Caused by organic/inorganic wastes, effluents from paper, pulp, chemical, textile, dyeing, refineries, tanneries, electroplating industries (dyes, detergents, acids, heavy metals, pesticides, plastics).
• Thermal Pollution: Hot water from factories/thermal plants harms aquatic life.
• Solid Wastes: Fly ash, phospho-gypsum, iron/steel slags.
• Land Pollution:
• Caused by dumping glass, chemicals, effluents, packaging, garbage; renders soil useless.
• Rainwater carries pollutants to groundwater.
• Noise Pollution:
• Caused by industrial/construction activities, machinery, generators, drills.
• Effects: Irritation, hearing impairment, increased heart rate, blood pressure, stress.
• Nuclear Wastes: Cause cancers, birth defects, miscarriages.

Control of Environmental Degradation:

• Water Pollution Control:
• Minimize water use by reusing/recycling in multiple stages.
• Harvest rainwater.
• Treat effluents in three phases:
• Primary: Mechanical (screening, grinding, flocculation, sedimentation).
• Secondary: Biological.
• Tertiary: Biological, chemical, physical (recycling wastewater).
• Regulate groundwater overdrawing legally.
• Air Pollution Control:
• Use electrostatic precipitators, fabric filters, scrubbers, inertial separators on smokestacks.
• Use oil/gas instead of coal to reduce smoke.
• Noise Pollution Control:
• Fit silencers on machinery/generators, redesign for energy efficiency, use noise-absorbing materials, earplugs/earphones.
• NTPC’s Approach:
• ISO 14001 certified for Environment Management System.
• Actions: Optimize equipment, minimize waste, maximize ash utilization, create green belts, manage ash ponds, recycle ash water, monitor ecology.
• Sustainable Development: Integrate economic development with environmental concerns.

Activity: One-Word Answers

• (i) Used to drive machinery: Power (5)
• (ii) People who work in a factory: Worker (6)
• (iii) Where the product is sold: Market (6)
• (iv) A person who sells goods: Retailer (8)
• (v) Thing produced: Product (7)
• (vi) To make or produce: Manufacture (11)
• (vii) Land, Water, Air degraded: Pollution (9)

Puzzle Answers

• 1. Agro-based (Textiles, sugar, vegetable oil, plantation industries).
• 2. Sugarcane (Basic raw material for sugar industry).
• 3. Jute (Known as the 'Golden Fibre').
• 4. Iron and Steel (Uses iron ore, coking coal, limestone).
• 5. Bhilai (Public sector steel plant in Chhattisgarh).
• 6. Varanasi (Railway diesel engines manufactured in Uttar Pradesh).