Are you embarking on a new mining project and wondering how to set up a stone crushing plant? Whether you’re expanding your operations or starting from scratch, understanding the essential components and features of a stone crushing plant is crucial for your project's success. In this guide, we’ll walk you through everything you need to know, from key components and must-have features to budgeting and compliance requirements. Let’s dive in! Call 824093968 to get a quote for a Crusher machine
MANUFACTURING PROCESS
It is advantageous if the crushed stone unit is set up near the queries where the granite boulders of various sizes are available for the crushing unit. The wastage from the granite industry will be of much use to the crushed stone unit. The granite stones of various sizes are fed into the jaw crushers for size reduction. Depending on the desired output size of the crushed stone, the raw materials may be fed to one or two jaw crushers in a sequence. Then these crushed stones are passed on to the rotary screen for size gradation. Material is handled through a belt conveyor to the different places of operation. The main machinery involved in the stone crushing industry is Hammer Crusher, Screen, Conveyors etc. The process involved is to feed the stone in to the Hammer Crushers to make it further smaller in size as required by the customer. In the hammer crusher, the stone is crushed. The crushed stone is screened to separate the produce in different sizes by the separator. The crushed stone is conveyed by the conveyors to trucks for transport to the market place or storage area.
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MANPOWER REQUIREMENT
Designation of Employees | Salary/person | MonthSalary | ||||||
Y1 | Y2 | Y3 | Y4 | Y5 | ||||
Variable Labour: | ||||||||
1 | Machine Operators | 12,000 | 24000 | 2 | 2 | 2 | 2 | 2 |
2 | Helpers | 8,000 | 64000 | 8 | 8 | 8 | 10 | 10 |
sub-total | 88000 | 10 | 10 | 10 | 12 | 12 | ||
Fixed Staff: | ||||||||
1 | Production supervisor | 15,000 | 15000 | 1 | 1 | 1 | 1 | 1 |
2 | Accounts/Stores Asst | 12,500 | 25000 | 2 | 2 | 2 | 3 | 3 |
3 | Office Boy | 9,000 | 9000 | 1 | 1 | 1 | 1 | 1 |
sub-total | 49000 | 4 | 4 | 4 | 5 | 5 | ||
Total | 137000 | 14 | 14 | 14 | 17 | 17 |
IMPLEMENTATION SCHEDULE
The project can be implemented in 4 months’ time as detailed below:
Sr. No. | Activity | Time Required |
1 | Acquisition of premises | 1 month |
2 | Construction (if applicable) | 1 month |
3 | Procurement & installation of Plant & Machinery | 1 month |
4 | Arrangement of Finance | 2 months |
5 | Recruitment of required manpower | 1 month |
Total time required | 4 months |
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COST OF PROJECT
Sr. No. | Particulars | ₹ in Lacs |
1 | Land | 5.00 |
2 | Building | 15.00 |
3 | Plant & Machinery | 15.20 |
4 | Furniture, Electrical Installations | 1.52 |
5 | Other Assets including Preliminary / Pre-operative expenses | 1.82 |
6 | Working Capital | 40.00 |
Total | 78.54 |
MEANS OF FINANCE
Bank term loans are assumed @ 75 % of fixed assets. The proposed funding pattern is as under:
Sr. No. | Particulars | ₹ in Lacs |
1 | Promoter's contribution | 21.51 |
2 | Bank Finance | 57.03 |
Total | 78.54 |
WORKING CAPITAL CALCULATION
The project requires working capital of ₹ 40.00lacs as detailed below:
Sr. No. | Particulars | Gross Amt | Margin % | Margin Amt | Bank Finance |
1 | Inventories | 20.00 | 0.25 | 5.00 | 15.00 |
2 | Receivables | 8.00 | 0.25 | 2.00 | 6.00 |
3 | Overheads | 12.00 | 100% | 12.00 | 0.00 |
4 | Creditors | - | 0.00 | 0.00 | |
Total | 40.00 | 19.00 | 21.00 |
LIST OF MACHINERY REQUIRED
A detail of important machinery is given below: Power Requirement: 200 HP
Sr. No. | Particulars | UOM | Qty | Rate (₹) | Value |
(₹ in Lacs) | |||||
Plant & Machinery | |||||
a) | Main Machinery | ||||
i. | Jaw crusher 400X225mm 25HP | NOS. | 1 | 520000 | 5.20 |
ii. | Jaw crusher 350x150 mm 25HP | Nos | 1 | 450000 | 4.50 |
iii. | Rotary screens for 35 mm, | Nos | 1 | 300000 | 3.00 |
b) | Ancilliary machinery | ||||
i. | Belt conveyor with 15 HP motor | Nos | 1 | 100,000 | 1.00 |
ii. | Pollution control cyclonic dust | NOS. | 1 | 150000 | 1.50 |
sub-total Plant & Machinery | 15.20 | ||||
Furniture / Electrical installations | |||||
a) | Office furniture | LS | 1 | 100000 | 1.00 |
b) | Stores Almirah | LS | 1 | 15,000 | 0.15 |
c) | Computer & Printer | L. S. | 37000 | 0.37 | |
sub total | 1.52 | ||||
Other Assets | |||||
a) | preliminary and preoperative | 1.82 | |||
sub-total Other Assets | 1.82 | ||||
Total | 18.54 |
All the machines and equipment are available from local manufacturers. The entrepreneur needs to ensure proper selection of product mix and proper type of machines and tooling to have modern and flexible designs. It may be worthwhile to look at reconditioned imported machines, dies and tooling.
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PROFITABILITY CALCULATIONS
Particulars | UOM | Year-1 | Year-2 | Year-3 | Year-4 | Year-5 | |
1 | Capacity Utilization | % | 60% | 70% | 80% | 90% | 100% |
2 | Sales | ₹. In Lacs | 90.00 | 105.00 | 120.00 | 135.00 | 150.00 |
3 | Raw Materials & Other direct inputs | ₹. In Lacs | 73.18 | 85.37 | 97.57 | 109.76 | 121.96 |
4 | Gross Margin | ₹. In Lacs | 16.82 | 19.63 | 22.43 | 25.24 | 28.04 |
5 | Overheads except interest | ₹. In Lacs | 5.14 | 5.47 | 6.11 | 6.30 | 6.43 |
6 | Interest | ₹. In Lacs | 5.70 | 5.70 | 3.80 | 2.85 | 2.28 |
7 | Depreciation | ₹. In Lacs | 10.64 | 7.60 | 5.32 | 3.80 | 3.42 |
8 | Net Profit before tax | ₹. In Lacs | -4.66 | 0.86 | 7.20 | 12.28 | 15.91 |
The basis of profitability calculation:
The growth of selling capacity will be increased 10% per year. (This is assumed by various analysis and study; it can be increased according to the selling strategy.)
Energy Costs are considered at Rs 7 per Kwh and fuel cost is considered at Rs. 65 per litre. The depreciation of plant is taken at 10-12 % and Interest costs are taken at 14 -15 % depending on type of industry.
BREAKEVEN ANALYSIS
The project shall reach cash break-even at 30.20 % of projected capacity as detailed below:
Particulars | UOM | Value | |
1 | Sales at full capacity | ₹. In Lacs | 150.00 |
2 | Variable costs | ₹. In Lacs | 121.96 |
3 | Fixed costs incl. interest | ₹. In Lacs | 8.71 |
4 | BEP = FC/(SR-VC) x 100 = | % of capacity | 31.07% |
STATUTORY / GOVERNMENT APPROVALS
As per the allocation of business rules under the Constitution, labour is in the concurrent list of subjects. It is dealt with by the MOLE at the Central and Departments of Labour under State Governments in respective States / UTs. The MOLE has enacted workplace safety and health statutes concerning workers in the manufacturing sector, mines, ports and docks and in construction sectors.
Further, other Ministries of the Government of India have also enacted certain statutes relating to safety aspects of substances, equipment, operations etc. Some of the statutes applicable in the manufacturing sector are discussed below:
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The Static and Mobile Pressure Vessels (Unfired) Rules, 1981
These (SMPV) Rules are notified under the Explosives Act, 1884. These rules regulate storage, handling and transport of compressed gases. These rules stipulate requirements regarding construction and fitments, periodic testing, location, fire protection, loading and unloading facilities, transfer operations etc. in respect of pressure vessels whose water capacity exceeds one thousand litres. These rules are enforced by the Chief Controller of Explosives under the Ministry of Industry and Commerce, Govt. of India (PESO).
The Manufacture, Storage and Import of Hazardous Chemicals Rules (MSIHC), 1989
These MSIHC Rules are notified under the Environment (Protection) Act, 1986. These rules are aimed at regulating and handling of certain specified hazardous chemicals. The rules stipulate requirements regarding notification of site, identification of major hazards, taking necessary steps to control major accident, notification of major accident, preparation of safety report and on-site emergency plan; prevention and control of major accident, dissemination of information etc. These rules are notified by the Ministry of Environment and Forests (MOEF) but enforced by the Inspectorates of Factories of respective States / UTs in the manufacturing sector.
The Factories Act, 1948 and State Factories Rules
The Factories Act, 1948 is very comprehensive legislation dealing with the matters of safety, health and welfare of workers in factories. The Act places duties on the occupier to ensure safety, health and welfare of workers at work. Some of the salient provisions of the Act include:
Guarding of machinery
Hoists and Lifts; Lifting Machines and Appliances
Revolving Machinery
Pressure Plant
Excessive Weight
Protection of Eyes
Precautions against dangerous fumes, gases etc.
Explosive or inflammable dust, gas etc.
Precautions in case of fire
Safety of buildings and machinery
Permissible limits of exposure of chemical and toxic substances
Entrepreneur may contact State Pollution Control Board where ever it is applicable. Call 824093968 to get a quote for a Crusher machine
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