Project Report

On

Stone Crusher Plant

Cost of Project: Rs. 5, 00, 00,000.00

CHITTALAX CONSTRUCTION PRIVATE LIMITED

Place of Business: Mangalvedha Tq Mangalvedha Dist. Sholapur

 STONE CRUSHER PLANT

1. INTRODUCTION
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, 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 (equivalent to
over US$ 1 billion) 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.
The stone crusher is one such industry that exists in the vicinity of almost all major cities/towns
throughout the country in all the states because the construction activities go on throughout the
country. As transportation of stone over long distances adds to cost of the crushed stone products,
the crushers need to be necessarily located nearer to the demand centers such as Cities, Bridges,
Canals etc. Stone Crushers also need electricity supply and large number of man power for its
operation. It also needs access roads for the movement of mined stone as well as crushed stone
products. It is for these reasons that most Stone Crushers are located along the periphery of Cities
or in the vicinity of major construction projects.
In most cases the Stone Crushers come up in clusters of number of units ranging from five to fifty in
one cluster. The crushers are located nearer to the source of raw material such as Stone mines,
River Beds etc. These stone crushers though socio-economically an important sector, gives rise to
substantial quantity of fine fugitive dust emissions which create health hazards to the workers as
well as surrounding population by way of causing respiratory diseases. The dust also adversely
affects visibility, reduces growth of vegetation and hampers aesthetics of the area.
In order to prevent/control these emissions, CPCB has already evolved Emission Standards and
guidelines in 1989, which has been notified under Environment (Protection) Act, 1986 by Ministry
of Environment & Forests vide Notification No. G.S.R. 742(E) dated 30th August 1990 & S.O. 8(E)
dated December 31, 1990 based on techno-economic feasibility to achieve the standards. But over
the years, as the need for more effective control and enforcement has been felt and to provide
more specific guidelines to the stone crushers to enable them control emissions satisfactorily.
 Crushed stone is segregated into various sizes like 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.
It is advantageous if the crushed stone unit is set up near the quarries 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.

Housing is a basic need of the society. Hence, it is receiving increased focus. All the building
constructions whether it is housing or industrial construction activities requires crushed stone.
Crushed stone is also required for cement based products like RCC pipes, PSC poles; cement
concrete hollow blocks, precast cement concrete slabs, well rings, window & door frames and road
lying. The demand for crushed stone will continue to grow with the growth of its user industry.
The unit can be set up depending availability of raw material and major commercial centre. Stone
crushed by stone crusher is segregated into various sizes like 35mm, 20mm, 12mm, etc for different
uses. The final product of stone crusher aggregates are used for construction of roads, bridges,
housing, industrial building construction and other cement based products like RCC pipes, PSC
poles, remolded slabs, frames and beams, etc for fabrication.
It is advantageous if the crushed stone unit is set up near the quarries 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.
Stone crushing plant for the crushing production line
SBM manufactures various equipments for whole set of stone crushing production line, and
provides superior technical support for customers. The whole sand-making production line consists
of vibrating feeder, jaw crusher, PCL vertical shaft impact crusher (sand making machine), vibrating
screen, sand washing machine, belt conveyor, electric control system, etc. We design different stone
crushing plant lines ranging 50 t/h to 500 t/h. We have been researching the sand-making machine
for years, and we have made it part of the stone crushing line. The whole set of sand-making
production line designed by our company is suitable to crush the hard limestone, granite, basalt,
gravel, slag, etc and artificially sand making for hydroelectric power, building material, high way,
city construction, etc. Different models of equipments are combined to meet different customers’
different demands according to different craft requirements.

2. STONE CRUSHING PROCESS

Big size stones are transferred to primary stone crusher through vibrating feeder from hopper for
first crushing, and then the crushed materials are transferred to impact crusher through belt
conveyor for secondary crushing. The crushed materials will be transferred to the vibrating screen,
and separated to different sizes. Those aggregate with suitable size will be transferred to the final
product pile and those with unsuitable size will be transferred to the impact crusher for re-crushing.
These forms a closed circuit manifold cycles. The sizes of final products will be graded and
separated according to customers’ requirements, and the deducted will be attached for the sake of
environment protection.

2.1 Inventorisation of Stone Crushers in Various States

Stone Crushers are primarily small scale industries mostly owned and operated by less educated
individuals and are scattered all over the country. This sector primarily being an un-organized
sector & has only local level (district/region level) associations. In the absence of any centralized
National or State Level association, the source to get a list of stone crushers in the state was
identified as the State Pollution Control Board. It was therefore, for the purpose of collecting
information on number of stone crushers in various states, their capacities, technologies used etc,
request letters were sent to all State Pollution Control Board offices through CPCB. Many SPCB
have responded with the list of stone crushers in their respective states, some states have sent only
partial list for some districts/region and some states have not responded.

2.2 Typical Set-up & Sizes of Stone Crushers

 There are large variations in the types of stone crusher setup across the country depending on
geographical locations, type of demand for crushed products, closeness to urban areas, type of raw
material, availability of plant and machinery locally etc. Primarily the stone crusher industry sector
could be divided in three categories small, medium & large. The typical characteristics of each
category of stone crushers are briefly discussed below.

2.2.1 Small Size Stone Crushers

There are different types of small crushers in various states with a production capacity ranging from
3 to 25 TPH. Typically, the units having only one Jaw type crusher used as primary or secondary
crusher along with one or maximum 2 screens are grouped as small stone crushers.

2.2.2. Medium Size Crushers

Typically those crushers having than one crusher i.e., one primary and one secondary or one/two
primary & two secondary crushers along with one or more vibratory screens are categorized as
medium size crushers. The mined stones are transported mostly by trucks/dumpers and unloaded in
to elevated stone wells. The stones are fed by gravity to primary crushers. The Crushed stones are
conveyed to vibratory screens. The screened products of various sizes are conveyed to stock piles
by belt conveyors. The oversize is returned to secondary crushers for further crushing and back to
the vibratory screen. Such type of medium type crushers has a production capacity in the range of
25 – 100 TPH. These types of crushers are mostly located near to the bigger cities and in the
vicinity of major construction projects such as Highways, Canals, and Dams etc.

2.3.1. Technologies used for Mining

The medium size stone crusher mostly have their own open-cast mines adjacent or in close vicinity
to the crusher site. The mining is done by drilling holes in the rock strata and blasting it generally
once in a day. The drilling is done mostly manually or by mechanical means. The blasted rock
boulders are at times manually broken to about 10 to 20 inch size so as to suit and are manually
the primary jaw crusher, loaded in to trailers or trucks. Mechanical Loaders are also used for
retrieving mined stones and loading in the vehicles.

2.3.2. Transportation Technologies

The mined stones are transported to the crusher sites using vehicles of various capacities starting
from bullock carts, trailers up to automatic dumpers. Most of the transportation vehicles have
hydraulically operated tilting arrangement for easy and faster unloading of stones at the crusher
sites. The capacity range of smaller vehicle like trailers is about 4 tones whereas bigger dumpers can
carry in the range of 15 – 20 tones materials per trip. The loading operations are manual in smaller
vehicles and are mostly mechanical using material handling equipment for large dumpers and
trucks. There are no continuous material handling system like long belt conveyors or trolley type
conveyors to carry stones from mines to crusher sites, even in the largest stone crushers in the
country and therefore transportation by vehicle is most common.

2.3.3. Crushing Technologies

Various types of crushers are used in the stone crushing industry such as Jaw Crushers, Roller
Crushers, Cone Crushers, Impactor, Rotopoctor etc. Generally, for secondary and tertiary crushing
application either of Jaw, cone, roller, Impactor or Rotopoctor type crushers are used. Various
types of crushers are briefly described below.

Jaw Crushers:
i. These are the oldest type of and most commonly used crushers in use and have changed little from
the original design. In Jaw Crusher the feed is compressed between a stationary and a movable
surface. A few of common types of Jaw crushers, in use, are described below.

• Double Toggle Crusher:

The Blake jaw crusher has a fixed jaw and a moving jaw pivoted at the top. The crushing faces
themselves are formed either of manganese steel or of chilled cast iron. The maximum pressure is
exerted on the large material, which is introduced at the top. These crushers are made with jaw
widths varying from about 2” to 48” and the running speed varies from about 100 to 400 RPM.
• Single toggle Jaw crusher: The single-toggle crusher is the simplest and the lightest of the jaw
crushers but is suitable only for producing low crushing forces and therefore used for soft rocks.

• Impact Jaw Crushers: In this type of crusher the crusher cavity is inclined. As there is larger stroke
and higher rotation speed (about 400 rpm) a stronger impact is achieved. As a result, hard, tough
materials can be processed.

2.3.4. Screening Technologies

Screening is a process of separating into groups of different products of various sizes. Each group
consists of products of approximately same size. The mass, which remains, on a screen are called
the oversize of the screen and the material, which passes through the screen, is, called the
undersize. The screens in between the primary and the secondary crusher help in separating the
oversize. The oversize goes to the secondary crusher while the undersize is discharged through a
chute on to the same conveyor belt, which receives the discharge from the secondary crusher. This
saves considerable power in the second crushing stage and also increases the capacity of the
secondary crusher, as it eliminates possible choking of material in the crusher, particularly during
wet weather or wet material.

Screening is generally classified into two types. (i) Course screening, which is achieved through
Grizzlies, Vibratory Screens, Revolving Screens or Shaking Screens and (ii) fine screening which is
achieved through Vibrating screens, Shaking Screens?

2.3.5. Washing Technologies

Sand and gravel often can be washed during the screening process but if the material carries
undesirable matter a scrubber washer should precede the screening process. When the stone from
the crushing plant is coated with clay or other sticky substances they are put through rotary
scrubber to scour the gravel before it goes to the screen. Material that contain smaller amount of
clay and silt may be cleaned satisfactorily by a log washer. Washing is very rarely employed in
Indian crushers, but it is common in developed countries.

2.3.6 Material Handling

Technologies used in Stone Crushing Units Various types of material handling technologies are used
in the stone crushing industry for the purpose of moving the stones from one equipment to other,
right from the point of raw material unloading up to stockpiles of products. Primarily, feeders and
conveyors are used in almost all crushers, which are briefly described below. i) Feeders Feeder is
used for conveying raw, mined stones from the stone well to the Primary Crusher. Feeder
movement is controlled by electrically operated switch. Some of the common feeders in use are
apron, belt and vibratory type feeders, which are briefly described below.

• Apron feeder:
This type consists of uniform overlapping pans attached on to chains or joined by integral links to
form an endless conveying medium that travels over supported rollers. The underside of these pans
is reinforced to withstand impact and pressure.

• Belt feeders:
Belt feeders can handle a wide range of materials including sand, gravel, crushed stone, crushed
rock, and other bulk materials.

• Vibratory feeders:
This type vibrates at relatively high frequency and small amplitude.

2.4 Types of Raw Material and Supply Zones

Various types of raw material are used in stone crushing unit such as Granite, Black Trap, River Bed
Pebbles, Semi Grade Stone, Soft Rock etc & varying in different geographical locations and as per
the local demand requirements. The type of material varies depending on the colour, hardness,
inherent moisture content etc. The supply zones for the various types of raw materials range from
local hillocks, open-cast mines, river bed, cliffs and other miscellaneous sources. Mostly small size
stone crushers source their raw materials from the supply zones like local hillocks, river bed and
 other miscellaneous sources. Medium and large size units with permanent type setup source their
raw material from leased or owned open cast mines. Royalty, as imposed by the Geology and
Mining department is paid on mined stones as per rates fixed in respective regions. Open cast
mines up to even 80 to 90 meter depth are quite common. Overburden is removed from the mine
top layers and stacked along periphery of mined area.

3. ENVIRIONMENTAL IMPACTS OF VARIOUS CONTROL TECHNOLOGIES

Application of emission reduction systems are associated with both beneficial and adverse impacts
on air, water, solid waste, energy and noise that may be directly or indirectly attributed to the
operation of these emission control systems.

a) Impact on Air Impacts on air emissions associated with the application of the alternative emissions
reduction systems for the control of particulate emissions from both process and fugitive dust
sources are discussed here. Because emissions form fugitive dust sources are typically large in area
and are discharged directly to the atmosphere in an unconstrained manner rather than through a
stack, such a quantitative measurement of these emissions is considered to be difficult, if not
impossible. Similarly because of the nature of wet dust suppression systems, no data are available
that permit a quantitative comparison of the control capabilities of wet systems versus dry
collection systems on process sources. Typically the uncontrolled emissions from 200 to 600
tons/hr. crushers range between 1000 to 3000 kg./hr which after reduction by over 99% in dry
type collection systems such as bag filters reduce to as low as 3 to 6 kg/hr

b) Impact on Water Pollution Dry collection control techniques generates no water effluent. When
wet dust suppression techniques are used, the water is absorbed by the material processed and
therefore, does not produce any water effluent either. The application of air pollution control
technology in the stone crushers has little impact on water quality.

c) Impact on Solid Waste Disposal The method of disposal of quarry, plant and dust collector waste
materials depends somewhat upon state and local government and corporate policies. When dry
type bag filter systems are used, the solid waste (dust) collected can be sold or used for a variety of
purposes. Collected fines are sometimes disposed of in an isolated location in the quarry if no
market is available which generally in the range of 0.5% of the total production. If such waste piles
are properly controlled by any of the techniques discussed above, no subsequent air pollution
problems develop. Thus, the solid waste generated by the application of dry collection methods
can be dispersed without any adverse impact on the environment. When wet dust suppression is
used, no solid waste disposal problem results over that produced by normal operation.

d) Impact on Energy Consumption Application of the alternative control techniques in stone crushers
necessarily result in an increase in energy consumption over that required to operate a plant
without air pollution control. Typical energy consumption with various types of air pollution
control technologies used in different capacity stone crushers

4. MARKET
Housing is a basic need of the society. Hence, it is receiving increased focus. All the building
constructions whether it is housing or industrial construction activities requires stone crusher. Stone
crusher is also required for cement based products like RCC pipes, PSC poles, cement concrete
hollow blocks, precast cement concrete slabs, well rings, window & door frames and road laing.
The demand for stone crusher will continue to grow with the growth of its user industry. The unit
can be set up depending availability of raw material and major commercial centre.

5. MANUFACTURING PROCESS
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 material 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 i.e.
from jaw crusher to the rotary screen.
 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.

6. BASIS & PRESUMPTIONS

1. The production has been calculated on the basis of single shift of 8 hours and 240 working days in
a year.

2. The full production capacity presumed to be achieved in the 2nd year of operation.

3. Labor wages has been considered basing on market rates but not less than the rates prescribed by
the Govt. at the locality.

4. The interest rate on an average has been taken on 12% on capital investment.

5. The entrepreneur is presumed to arrange 25% of the project cost as margin money.

6. An average plant life of 10th years has been taken into consideration.
The unit is supposed to repay the installment of interest after the first year of completion.

7. The cost of machinery and equipment has been taken based on prevailing market rates.

7. Quality Control and Standards:

There are no Indian Standard specifications for the quality of crushed granite stone. However,
crushed stone is graded into different sizes viz. over 35mm, 20mm, 12mm etc. for different uses.

8. Pollution Control:
Lot of fine dust emerges out at the time of crushing operation. Suitable dust collection is required
to be installed with extension pipes etc.

9. PRODUCTION CAPACITY

Capacity 3000 Brass per Year

Selling Price 2200 per Brass

ABOUT THE COMPANY & PRODUCTS

CHITTALAX CONSTRUCTION PRIVATE LIMITED with a desire and intention to manufacture/produce

crushed stones (size 40mm, 20mm, 10mm,Dust).The stone crusher will crush the stone daily except in the
rainy season. This is because it is difficult & risky to transport the stones and also very less construction
work is carried. Work will be carried for seven months while two months will be the period of storing
raw materials because after rainy season the price increases. As construction and road building is booming
in India, Stone crushing mills have proliferated throughout India to accommodate the huge demand for
stone used in Construction of roads, bridges, housing, industrial building construction and other cement
based products like RCC pipes, PSC poles, pre-molded slabs, frames and beams, etc for fabrication.
Housing is a basic need of the human being as well as society. Hence, it is receiving increased focus
towards crushed stones. This company wants to put its maiden step into crushed stone. Simultaneously,
the wastage from the stone industry will be of much use to the crushed stone and it is in the form of
sand.

CRUSHED STONES:-
The demand for crushed stone will continue to grow with the Growth of its user industry. The unit can
be set up depending availability of raw Material and major commercial centre.
Crushed stone is segregated into various sizes like 40mm,20mm, 10mm, 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-molded slabs, frames and
beams, etc for fabrication.

It is advantageous if the crushed stone unit is set up near the quarries where the granite boulders of
various sizes are available for the crushing unit.
The wastage from the stone industry will be of much use of the crushed stone unit.

Wastage of Stone:-
The wastage of the stone is in the form of sand. It has followings features & advantages.
Best material used in construction rather than sand. Rare to purchase as it is the wastage of stones.

Costly than sand & crushed stones.

Machinery & Equipment:

S.No. Description Qty Rate Amount
Nos.
1 Jaw crusher 400X225mm 25HP motor capacity 2 1 4,00,000 4,00,000
units per hour
2 Jaw crusher 350x150 mm 25HP motor capacity 1.2 1 3,00,000 3,00,000
units per hour
3. Rotary screens for 35 mm, 20 mm, and 12 mm 1 1,00,000 1,00,000
with 10 HP motor
4. Belt conveyor with 15 HP motor 3 3,50,000
5. Pollution control cyclonic dust collector with 3,00,000
connecting pipes, chutes & 12 HP motor
6. Erection, Electrification and commissioning @ 10% 1,45,000
7. Spare jaws, jigs, fixtures, tools etc. 1,00,000
8. Office equipment 40,000
Total fixed cost 31,85,000

10. PROJECT COST/CAPITAL INVESTMENT

S.No Description Amount Rs.

1 Fixed Capital 20, 50,000.00

2 Working Capital for 1.5 month(s) 3, 90,000.00
3 Preliminary & Preoperative Expense 60,000.00

Total Project Cost 25, 00,000.00

6. MEANS OF FINANCE

S.No Description %age Amount Rs.

1 Promoter Contribution 5% 1, 25,000.00

2 Govt. Share Capital 35% 8, 75,000.00
3 Term Loan from Govt. /Bank 60% 15, 00,000.00

Total 25, 00,000.00

7. FINANCIAL ASPECTS

A. FIXED CAPITAL

I. Land and Buildings

Land 1 acre 200000.00
Work shed 100 sq mts 350000.00
Office 5 sq mts 100000.00

Total 5500000
ii. Machinery and Equipment

S.No Description Qty. Rate Amount Rs.

1 Jaw crusher 400x225mm with 25 HP motor 1 525000 5, 25,000

2 Jaw crusher 350x150mm with 15 HP motor 1 250000 2, 50,000
3 Rotary screen for 35, 20, 12mm, 10 HP motor 1 100000 1, 0, 0000
4 Belt conveyor with 15 HP motor 2 100000 2, 00,000
5 Cyclonic dust collector with 12 HP motor 1 225000 2, 25,000
6 Erection and commissioning LS 1, 00,000
7 Spare jaws, jigs, fixtures and tools LS 50,000
8 Office equipments, etc LS 50,000

Total 15, 00,000

B. ORKING CAPITAL
i. Salaries & Wages (per month)

S.No Description Nos. Sal/mon. Amount Rs.

1 Manager/Entrepreneur 1 6000 6000

2 Supervisor 1 5000 5000
3 Skilled Workers 5 4000 20000
4 Unskilled Workers 8 3000 24000
5 Accountant cum clerk 1 4000 4000
6 Security 1 3000 3000

Total 62000
ii. Raw Material (per month)

S.No Description Unit Qty. Rate Amount Rs.

1 stone boulders MT 1300 200 260000

Total 260000

iii. Utilities (per month)

S.No Description Unit Amount Rs.

1 Power LS 48000
2 Water LS 2000

Total 50000
iv. Other Expenses (per month)

S.No Description Amount Rs.

 1 Postage, Telephones & Stationery Expenses 2000
2 Transportation & Conveyance Expenses 15000
3 Administrative expenses 2000
4 Consumable Stores 2000
5 Repairs and Maintenance Expenses 6000
6 Miscellaneous Expenses 3000

Total 30000

v. Total Working Capital (per month)

S.No Description
Amount Rs.

1 Salaries and Wages 62000

2 Raw Material 260000
3 Utilities 50000
4 Other Expenses 30000

Total 402000

8. COST OF PRODUCTION (PER ANNUM)

S.No Description Amount Rs.

1 Total Working Capital 48, 24,000

2 Depreciation @ 10% 2050000 205000
3 Interest on term loan @ 12% 180000

Total 5209000

9. TURNOVER (PER YEAR)

S.No Description Unit Qty. (Brass) Rate Rs.

Amount Rs.

1 Sales revenue MT 3000 2000 60, 00,000

Total 60, 00,000

COMPANY PROFILE
NAME : CHITTALAX CONSTRUCTION PRIVATE LIMITED
REGISTERED : AT POST DONGARGAON TAL MANGALVEDHA DIST SHOLAPUR
OFFICE NO.FACTORY : MANGALVEDHA DIST SHOLAPUR
ADDRESS : AT POST DONGARGAON TAL MANGALVEDHA DIST SHOLAPUR
STATUS : Private Company
PRODUCTS : Crushed Stone (Segregated into Various Sizes Like 40mm, 20mm,
10mm, etc)
QUALIFICATION : DCA