Ultimate Guide for Granite Crushing
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!
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Manufacturing Process
It is advantageous if the crushed stone unit is set up near quarries where granite boulders of various sizes are readily available. Waste material from the granite processing industry can also be repurposed effectively as raw material.
Granite boulders of various sizes are fed into primary jaw crushers for initial size reduction. Raw material passes sequentially through one or two jaw crushers depending on output size targets.
Crushed stones enter high-impact hammer crushers to further reduce particle sizes according to client aggregate specifications.
Rotary screens separate the output into precise aggregate fractions (e.g., 35mm and below). Heavy-duty belt conveyors transport finished products directly to loading bays or stockyards.
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Manpower Requirement
| Designation of Employees | Salary / Person (₹) | Monthly Cost (₹) | Y1–Y3 Qty | Y4–Y5 Qty |
|---|---|---|---|---|
| Variable Labour | ||||
| Machine Operators | ₹ 12,000 | ₹ 24,000 | 2 | 2 |
| Helpers | ₹ 8,000 | ₹ 64,000 | 8 | 10 |
| Fixed Staff | ||||
| Production Supervisor | ₹ 15,000 | ₹ 15,000 | 1 | 1 |
| Accounts / Stores Asst | ₹ 12,500 | ₹ 25,000 | 2 | 3 |
| Office Boy | ₹ 9,000 | ₹ 9,000 | 1 | 1 |
| Total Monthly Salary | — | ₹ 1,37,000 | 14 Staff | 17 Staff |
Implementation Schedule (4 Months)
| 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 Project Implementation Timeline | 4 months | |
Cost of Project & Means of Finance
Cost of Project
- Land:₹ 5.00 Lacs
- Building:₹ 15.00 Lacs
- Plant & Machinery:₹ 15.20 Lacs
- Furniture & Electricals:₹ 1.52 Lacs
- Pre-operative Expenses:₹ 1.82 Lacs
- Working Capital:₹ 40.00 Lacs
- Total Project Cost:₹ 78.54 Lacs
Means of Finance (75% Debt)
- Promoter's Contribution:₹ 21.51 Lacs
- Bank Term Loan (75% Fixed Assets):₹ 57.03 Lacs
- Total Funding:₹ 78.54 Lacs
Working Capital Breakdown (₹ 40.00 Lacs)
| Particulars | Gross Amt (₹ Lacs) | Margin % | Margin Amt (₹ Lacs) | Bank Finance (₹ Lacs) |
|---|---|---|---|---|
| Inventories | ₹ 20.00 | 25% | ₹ 5.00 | ₹ 15.00 |
| Receivables | ₹ 8.00 | 25% | ₹ 2.00 | ₹ 6.00 |
| Overheads | ₹ 12.00 | 100% | ₹ 12.00 | ₹ 0.00 |
| Total Working Capital | ₹ 40.00 | — | ₹ 19.00 | ₹ 21.00 |
Required Plant & Machinery (200 HP Power)
| Machine Description | Qty | Unit Rate (₹) | Value (₹ in Lacs) |
|---|---|---|---|
| Main Machinery | |||
| Jaw Crusher 400x225mm (25 HP) | 1 No | ₹ 5,20,000 | ₹ 5.20 |
| Jaw Crusher 350x150mm (25 HP) | 1 No | ₹ 4,50,000 | ₹ 4.50 |
| Rotary Screens (35mm) | 1 No | ₹ 3,00,000 | ₹ 3.00 |
| Ancillary Machinery | |||
| Belt Conveyor (15 HP motor) | 1 No | ₹ 1,00,000 | ₹ 1.00 |
| Pollution Control Cyclonic Dust Collector | 1 No | ₹ 1,50,000 | ₹ 1.50 |
| Furniture, Electricals & Other Assets | |||
| Office Furniture, Stores Almirah & Computers | L.S. | — | ₹ 1.52 |
| Preliminary & Pre-operative Assets | L.S. | — | ₹ 1.82 |
| Total Machinery & Fixed Setup Costs | ₹ 18.54 Lacs | ||
5-Year Profitability Calculations
| Particulars (₹ in Lacs) | Year 1 | Year 2 | Year 3 | Year 4 | Year 5 |
|---|---|---|---|---|---|
| Capacity Utilization (%) | 60% | 70% | 80% | 90% | 100% |
| Gross Sales Revenue | ₹ 90.00 | ₹ 105.00 | ₹ 120.00 | ₹ 135.00 | ₹ 150.00 |
| Raw Materials & Direct Inputs | ₹ 73.18 | ₹ 85.37 | ₹ 97.57 | ₹ 109.76 | ₹ 121.96 |
| Gross Margin | ₹ 16.82 | ₹ 19.63 | ₹ 22.43 | ₹ 25.24 | ₹ 28.04 |
| Overheads (excl. interest) | ₹ 5.14 | ₹ 5.47 | ₹ 6.11 | ₹ 6.30 | ₹ 6.43 |
| Interest on Term Loan | ₹ 5.70 | ₹ 5.70 | ₹ 3.80 | ₹ 2.85 | ₹ 2.28 |
| Depreciation (10-12%) | ₹ 10.64 | ₹ 7.60 | ₹ 5.32 | ₹ 3.80 | ₹ 3.42 |
| Net Profit Before Tax | -₹ 4.66 | ₹ 0.86 | ₹ 7.20 | ₹ 12.28 | ₹ 15.91 |
Break-Even Analysis (BEP)
Cash break-even point is achieved at 31.07% of full capacity utilization (Sales ₹150L, Variable Costs ₹121.96L, Fixed Costs incl. interest ₹8.71L).
Statutory & Government Approvals
Under the Indian Constitution, labor is on the Concurrent List and regulated by the Ministry of Labour and Employment (MOLE) and respective State Labor Departments.
Notified under the Explosives Act, 1884. Regulates storage, handling, and transport of compressed gases (exceeding 1,000L). Enforced by PESO (Chief Controller of Explosives).
Notified under Environment (Protection) Act, 1986. Mandates site notification, major hazard identification, and emergency plan preparation. Enforced by State Factory Inspectorates.
Comprehensive safety legislation governing worker safety and health. Key provisions include:
- Guarding of machinery
- Hoists, lifts, and lifting tackle
- Revolving machinery & pressure plant
- Precaution against gases & explosive dust
- Fire precautions & structural safety
- Permissible chemical exposure limits
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