STONE CRUSHER

PROJECT REPORT.

Name of the Project: Pruthviraj Stone Crusher.

Name of the Project Product: Stone 0 mm to 4.75 mm, 4.75 mm to 8 mm,

8 mm to 12 mm, 12 mm to 20 mm, 20mm
To 40 mm, 60mm to 80 mm, GSB, WMM.

Logo:

Slogan: Vishwas Hai Isme Kuch Khaas Hai.

The slogan shows the quality of our product is maintain.

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 STONE CRUSHER

1. INTRODUCTION:

Crushed stone is also known as metal jelly. Crushed stone is segregated into various sizes viz.
35mm, 20mm, 12mm etc. for different uses. Crushed stone aggregates are used for
construction of roads, bridges, housing, industrial building construction and other cement
based products like RCC pipes, PSC poles, pre-moulded slabs, frames and beams etc. for
fabrication.

2. PRODUCT & ITS APPLICATION:

Stone crushing industry is an important industrial sector in the country. The crushed stone is
Then used as raw material for various construction activities i.e. construction of roads, bridges,
buildings and canals. Over the last 10 years, the Construction sector has been registering
strong growth rates in the range of 7-8%. Housing and construction is one of the major drivers
of growth in more than 40 allied industries including STONE CRUSHING. In addition, for
the building of roads, flyovers and bypasses, there is a mass and consistent need of crushed
stone across the country. Several projects are in progress and are being commenced shortly
which will have high demand of crushed stone all over the country. In order to make up the
backlog and meet the projected requirements for the next 20 years, overall housing
construction has to raise 500,000 housing units per annum. The area under consideration is
badly affected by the earthquake and rehabilitation and reconstruction is in process. This
process leads to construction of roads, bridges, new houses; markets, etc. resultantly gear up
construction activities and more use of crushed stones. Construction of Diamir-Basha Dam
and Kohala Hydro –Electric Project are also synergic factor for this project. The
aforementioned facts and statistics provide enough evidences, assuring a steep and continuous
growth vis a vis investment opportunity in the STONE CRUSHING business. There are
increasing allocations from budget in the Public Sector Development Projects of Pakistan.
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There is sufficient skilled labor available at less cost to run the project. The raw material is
abundantly available. If the machinery needs to be imported there are less import duties. The
availability of initial depreciation made the project pragmatically five years tax free. There is
need to employ latest and modern exploration techniques and machinery. The lack of
coordination among various mineral sector agencies is also point of concern for the stone
crushing industry.

3. DESIRED QUALIFICATIONS FOR PROMOTER:

Graduate in any discipline. Promoter with high skill of chemical processing and having
contacts with building and construction industries is advantage.

4. INDUSTRY LOOK OUT AND TRENDS

At present, most of the mining crushing and industrial sand making plant produced a lot of
limestone powder waste (limestone powder content is high). This not only pollute the
environment, and the raw material waste is serious. It is imperative to find a reasonable
solution to deal with limestone powder waste "waste into treasure".

The results show that the limestone powder as the admixture of concrete has the effect of
improving the concrete structure, enhancing the workability of anti - sulphate attack ability of
concrete under low temperature. In recent years, limestone powder into the concrete as a
binder has become the hot topic and development trend in the concrete industry.

Commercial concrete mixing plant generally uses 325 mesh limestone powders; the sieving
rate is not less than 85%. The research shows that C30 ~ C50 limestone powder for concrete
can be produced completely.

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 5. MARKET POTENTIAL AND MARKETING ISSUES, IF ANY:

Stone Crushing Industry is an important industrial sector in the country engaged in producing
crushed stone of various sizes depending upon the requirement which acts as raw material for
various construction activities such as construction of Roads, Highways, Bridges, Buildings,
and Canals etc. It is estimated that there are over 12,000 stone crusher units in India. The
number is expected to grow further keeping in view the future plans for development of
infrastructure of roads, canals and buildings that are required for overall development of the
country. In India, the Stone Crushing Industry sector is estimated to have an annual turnover
of Rs. 5000 crore and is therefore an economically important sector. The sector is estimated to
be providing direct employment to over 500,000 people engaged in various activities such as
mining, crushing plant, transportation of mined stones and crushed products etc. Most of these
personnel are from rural and economically backward areas where employment opportunities
are limited and therefore it carries greater significance in terms of social importance in rural
areas. It is a source of earning for uneducated poor unskilled rural people. Since it is an allied
industry of the construction sector, growth in construction sector may be considered as proxy
for the growth in stone crushing sector, The market scope for crushed stone is found to be
encouraging in local market with the increased demand from building industry & construction
fields. There is also a sufficient demand from Government. Contractors for lying of roads and
construction of industries etc. The entry in the target market is easy and there is a narrow gap
in the supply and demand, which is expected to grow in the coming years. Stone Chips are
primarily used in construction activities including Building, Roads, and Bridges etc. Since the
area is undergoing tremendous infrastructure development work. Apart from above the Road
Construction work under P.W.D., P.M.G.S.Y increased vast scope for this unit. Looking at
the huge demand potential, easy marketing is possible.

6. RAW MATERIAL REQUIREMENTS:

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Raw materials required for this project is granite stone boulders of various sizes. Basic raw
material is boulder and same shall be obtained from rocks. Hard Lime and granite Stone will
be used as raw material for manufacturing crushed stone. Raw stone could be purchased
directly from the excavator (quarry lease holder) or crusher may hold his own quarry lease to
produce raw stone. It is recommended to obtain a quarry lease holding to avoid any possible
threat in procuring raw stone as well as to keep the project economically stable. For the
proposed project, a total of 15,000 C.ft. of Hard Lime/granite Stone would be the daily
requirement. This requirement could sufficiently be fulfilled from the obtained quarry site
over a period of years.

7. 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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 8. MANPOWER REQUIREMENT:

Sr. No. Designation of Salary Per Monthly

Number of employees required
Employees Person Salary ₹
Year-1 Year-2 Year-3 Year-4 Year-5
Variable Labour:
1 Machine Operators 12,000 24000.00 2 2 2 2 2
2 Helpers 8,000 64000.00 8 8 8 10 10
sub-total 88000.00 10 10 10 12 12
Fixed Staff:
1 Production supervisor 15,000 15000.00 1 1 1 1 1
2 Accounts/Stores Asst 12,500 25000.00 2 2 2 3 3
3 Office Boy 9,000 9000.00 1 1 1 1 1
sub-total 49000.00 4 4 4 5 5
Total 137000.00 14 14 14 17 17

9. IMPLEMENTATION SCHEDULE:

The project can be implemented in 4 months’ time as detailed below:

Sr. No. Activity Time Required (in months)

1 Acquisition of premises 1.00
2 Construction (if applicable) 1.00
3 Procurement & installation of Plant & Machinery 1.00
4 Arrangement of Finance 2.00
5 Recruitment of required manpower 1.00

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 Total time required (some activities shall run 4.00
concurrently)

10. 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
Other Assets including Preliminary / Pre-operative
5 1.82
expenses
6 Working Capital 40.00
Total 78.54

11. MEANS OF FINANCE:

Bank term loans are assumed @ 75 % of fixed assets. The proposed funding pattern is as
under:
₹ in
Sr. No. Particulars
Lacs
1 Promoter's contribution 21.51
2 Bank Finance 57.03
Total 78.54

12. WORKING CAPITAL CALCULATION:

The project requires working capital of ₹ 40.00lacs as detailed below:

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 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

13. LIST OF MACHINERY REQUIRED:

A detail of important machinery is given below: Power Requirement: 200 HP

Value
Sr. No. Particulars UOM Qtty Rate (₹)
(₹ in Lacs)
Plant & Machinery /
equipments
a) Main Machinery
Jaw crusher 400X225mm
i. NOS. 1 520000 5.20
25HP
Jaw crusher 350x150 mm
ii. Nos 1 450000 4.50
25HP
iii. Rotary screens for 35 mm, Nos 1 300000 3.00
b) Ancilliary machinery
Belt conveyor with 15 HP
i. Nos 1 100,000 1.00
motor
Pollution control cyclonic
ii. NOS. 1 150000 1.50
dust

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 sub-total Plant & Machinery 15.20
Furniture / Electrical
installations
a) Office furniture LS 1 100000 1.00
Sr. No. Particulars UOM Qtty Rate (₹) Value
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. Some of the machinery and dies and tooling suppliers are listed
here below:

 Kamdhenu Agro Machinery

Plot No. 6, Near Power House,
Wathoda Road, Wathoda
Nagpur - 440035
Maharashtra, India

 Future Industries Private Limited

Shed No. 15, Ambica Estate,
Corporation Municipal Plot,
Opposite Sadvichar Hospital,
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 Naroda, Ahmedabad - 382330,
Gujarat, India

 The Global Pharma Equipments

Star Industrial Estate,
D-32, Naik Pada,
Near Hanuman Mandir,
Opposite Dwarka Industrial Estate,
Vasai East, Vasai - 401208,
Maharashtra, India

14. PROFITABILITY CALCULATIONS:

Year-
Sr. No. Particulars UOM Year-1 Year-3 Year-4 Year-5
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1 Capacity Utilization % 60% 70% 80% 90% 100%
₹. In
2 Sales 90.00 105.00 120.00 135.00 150.00
Lacs
Raw Materials & Other ₹. In
3 73.18 85.37 97.57 109.76 121.96
direct inputs Lacs
₹. In
4 Gross Margin 16.82 19.63 22.43 25.24 28.04
Lacs
₹. In
5 Overheads except interest 5.14 5.47 6.11 6.30 6.43
Lacs
₹. In
6 Interest 5.70 5.70 3.80 2.85 2.28
Lacs
₹. In
7 Depreciation 10.64 7.60 5.32 3.80 3.42
Lacs

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 ₹. In
8 Net Profit before tax -4.66 0.86 7.20 12.28 15.91
Lacs

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.

15. BREAKEVEN ANALYSIS:

The project shall reach cash break-even at 30.20 % of projected capacity as detailed below:

Sr. No. 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
BEP = FC/(SR-VC) x 100
4 % of capacity 31.07%
=

16. 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

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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:

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

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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.

17. BACKWARD AND FORWARD INTEGRATIONS

Chemical companies often become integrated and undergo other activities outside the
chemical industry. Increased competition prompts many companies to reduce supply chain
costs by looking outside the chemical sector at suppliers and customers. While most
companies within the chemicals sector primarily produce chemicals, some companies also
conduct other manufacturing activities. The exact proportion of chemicals sector companies
that are integrated with other sector activities is unknown, but many companies actively seek
vertical integration. Many manufacturers pursue vertical integration to secure suppliers and
customers for their products.

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Mergers and acquisitions are a common way for companies to undertake new chemical
ventures. By purchasing their chemical suppliers, some manufacturers secure future chemical
feedstock for their products or other chemicals that they use in manufacturing. The company
making the purchase obtains valuable expertise and equipment. Some mining and
petrochemical production is more cost-effective when integrated within a chemical company.
Energy and feedstock costs are often a significant expense for chemical companies.
Integrating chemical production with activities that secure supplies of chemical feedstock and
energy is relatively common as chemical companies grow. Chemical companies are located
near mines, oil fields, ammonia factories and water supplies. This reduces transportation costs
and increases the reliability of supplies by reducing the distance between feedstock and the
factory.

Some companies, such as Sino-Coking Coal and Coke Chemical Industries Incorporated, own
their mines. BHP Billiton operates a broad range of mines and is primarily a mining company.
It does, however, also produce petrochemical feedstock for the chemical industry and
therefore operates within the chemical industry as well. These companies technically operate
within both the chemical and mining industries in their normal business operations.

Integrating a chemical company with other activities provides several direct benefits for the
company and is becoming increasingly common. High energy costs necessitate greater control
of energy resources and minimal reliance on expensive transportation. Chemical companies
experience volatile profitability due to fluctuations in feedstock and energy expenses. Some
companies control this volatility through careful supply chain management and by charging
supply surcharges. Actively researching and developing alternative feedstock and energy
supplies helps the company reduce costs.

Vertical integration supports these activities by eliminating redundant activities at multiple

companies and increasing efficiency. By consolidating activity among multiple, similar
operations, chemical companies achieve cost savings that contribute to higher profitability.
End products are often very profitable, and some chemical companies purchase their former
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customers to take advantage of the marked-up prices of products further along in the supply
chain.

Integration may become more common for many chemical companies as competition
strengthens and traditional feedstock becomes more expensive. Market demand for chemical
feedstock increases as emerging market economies grow and result in increased consumer
spending around the world.

17. TRAINING CENTERS AND COURSES

There is no such training required to start this business but, basic chemical bachelor’s degree
is plus point for enterpriser. Promoter may train their employees in such specialized
institutions to grow up the business. There are few specialised Institutes provide degree
certification in chemical Technology, few most famous and authenticate Institutions are as
follows:

1. Department of chemical LD college of engineering

No.120, Circular Road, University Area, Navrangpura,
Opposite Gujarat University, Ahmedabad, Gujarat 380015

2. MIT College of chemical Engineering, Pune

Gate.No.140, Raj Baugh Educational Complex,
Pune Solapur Highway,
Loni Kalbhor, Pune – 412201
Maharashtra, India.

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