Marble Processing Plant (Marble Cutting and Polishing Unit) (Capacity: 600 sq meters per day)

MARBLE PROCESSING PLANT (MARBLE CUTTING AND POLISHING UNIT)

(EIRI/EDPR/4707) J.C. 2927XL

INTRODUCTION

Marble business in India is presently a rapidly thriving business considering the scope and promising future that it holds for marble business enthusiasts. If targeted in the right market, the marble and granite business can shine and mint huge profits in India’s geographical boundaries. Marbles and granites are considered the vital elements required in the building, and they are widely getting acclaim for the beauty and glittering touch that it gives to the indoor surface within the premise or building.

The demand for marbles and granites in India is soaring high, thereby giving the push to marble business in India and opening the windows of hope for the business enthusiasts who are willing to enter this form of business. In order to witness the accelerating demand for marble tiles in India, you can visit hospitals, colleges, hotels, houses (especially in urban parts of India), and even other places and you will be getting a glimpse of eye-captivating and highly appealing visuals that is a result of usage of marbles in such places.

The attraction value of marble depends upon its smoothness, hardness, durability, and finish, which enhances the value of a building. The Indian government is quite aware of the potential and value of polished tiles, and thus, it has made the marble tiles industry a crucial part of the export thrust domain.

The term marble is derived from the latin work "MARMOR" which itself comes from the Greek root "MARMAROS" meaning these by a shining stone. In ancient times, any stone capable of taking polish, without any regard to its chemical composition was designated as marble. Even the serpentines, alabaster and granites was categorized as marble - if they could take polish. However, in course of time, earth sciences developed a more sophisticated and accurate classification which can categories rocks on the basis of their birth-history.

The marble industry in India has a chequered history. The first marble stone in India was found in the Makrana of erstwhile Rajputana, It was the marble of Makrana that was used in fabulous monumental structure erected centuries ago in India and elsewhere. The world-famous Taj Mahal at Agra, the Victoria Memorial at Kolkata and Jaswant Memorial at Jodhpur bear the testimony to the marble supplied from Makrana. The construction viability of marble stone has been proved beyond doubt as these structures have weathered the vagaries of climate through the centuries.

Gone are the days when marble was considered to be an item of luxury and used only in palaces, temples, mosques and other prestigious buildings. It is now extensively used in ordinary buildings, in drawing rooms, dining rooms, bath rooms and kitchens. Central Public Works Department has specified marble to be used in the Kitchen Platform of even staff quarters.

Once marble was used in the flooring of Supreme Court of India, it was questioned in the Parliament. In reply, a comparative cost study was undertaken which revealed that marble was an item of ultimate economy. Similarly in fascia of multistoreyed buildings, it is economical to use marble which saves high cost of painting and maintenance. The requirement of marble has, therefore, grown tremendously during the last one decade and there is a wide gap between demand and mining output. Rajasthan is pioneer in the mining and processing of marble because the State has been endowed with large deposits of marble.

In the state of Rajasthan, marble is currently commercially mined in nearly eight districts, Nagaur, (Makrana and Borawar), Jaipur (Bhainslana and Kotputli), Bundi (Umar), Sirohi (Abu Road and Khandara), Ajmer (Kishangarh), Pali (Bar and Sendra), Udaipur (Rajnagar, Amet, Agaria, Rikhabhdeo and Kankroli), Chittorgarh (Mandalgarh), Banswara and Dungarpur. Among these places, Makrana is one where marble ahs been mined and processed for a very long time and its quality has earned a world-wide reputation. Another promising regions where marble deposits are fairly large and comparable to Makrana are Udaipur.

COST ESTIMATION

Plant Capacity            600 sq.mt./Day

Land & Building (5 Acres)    Rs. 17.50 Cr

Plant & Machinery                    Rs. 19.60 Cr

Working Capital for 2 Months    Rs. 1.16 Cr

Total Capital Investment          Rs. 38.67 Cr

Rate of Return                          15%

Break Even Point                      64%

CONTENTS

INTRODUCTION

USES AND APPLICATION

BLENDING EXTERIOR

BUILDING INTERIORS

STATUARY MARBLE

NOVELTIES

SPECIFICATIONS

STRUCTURAL GRANITES ARE GROUPED INTO TWO TYPES

SPECIFICATIONS FOR STONES GENERALLY DEPEND ON FOLLOWING PROPERTIES

MARKET POSITION OF MARBLE IN ETHIOPIA

PROJECTED DEMAND OF MARBLE PRODUCTS

MARKET SURVEY (GLOBAL)

TABLE 1: MAIN COUNTRIES EXPORTING NATURAL STONE

US AND MIDDLE EAST

FEASIBLE USES OF MARBLE WASTE

1. AS A FILLER MATERIAL FOR ROADS AND EMBANKMENTS

2. FOR MANUFACTURE OF BRICKS

3. MANUFACTURE OF PORTLAND CEMENT

4. MANUFACTURE OF CERAMIC TILES

5. MANUFACTURE OF THERMOSET RESIN COMPOSITES

6. MANUFACTURE OF LIME

7. MANUFACTURE OF ACTIVATED CALCIUM CARBONATE

8. HOLLOW BLOCKS AND WALL TILES

9. MANUFACTURE OF GROUND CALCIUM CARBONATE

OTHER POSSIBLE USES OF MARBLE SLURRY/MARBLE WASTE

INDIAN STANDARD SPECIFICATIONS OF BUILDING STONES

1) IS : 1121

IS : 1121 (PART - 1) 1974

IS : 1121 (PART - III) 1974

IS : 1121 (PART - IV) 1974

2) IS : 1122 - 1974

3) IS : 1123 - 1975

4) IS : 1124 - 1974

5) IS : 1125 - 1974

6) IS : 1126 - 1974

7) IS : 1127 - 1970

8) IS : 1128 - 1974

9) IS : 1129 - 1974

10) IS : 1130 - 1969

11) IS : 1706 - 1972

12) IS : 1401

13) IS : 4121 (1967)

14) IS : 4122 - 1967

15) IS : 4348 - 1973

16) IS : 5218 - 1969

MANUFACTURING PROCESS

1. SAWING:

GANG SAWS

WIRE SAWS

CIRCULAR SAWS

GRINDING AND POLISHING

RUBBING:

GRITTING:

BUFFING:

EDGE CUTTING

CUTTING OF COLUMNS

PROCESS IN DETAILS

PRIMARY SAWING

SURFACE POLISHING

CUT TO SIZE

QUALITY CONTROL

PACKAGING

MARBLE TILES MANUFACTURING PROCESS

PROCESS FLOW DIAGRAM

TYPES OF WASTE GENERATED IN MARBLE QUARRING AND PROCESSING

AND DISPOSAL PRACTICES

TYPES OF WASTE GENERATED

PERCENTAGE OF WASTE GENERATED

QUANTUM OF QUARRYING WASTE PRODUCED WITH RESPECT TO METHOD OF PRODUCTION

QUALITY OF WASTE GENERATED

QUARRYING WASTE DISPOSAL PRACTICES

PERCENTAGE OF WASTE GENERATED

QUANTUM OF PROCESSING WASTE PRODUCED WITH RESPECT TO METHOD OF PRODUCTION

QUALITY OF WASTE GENERATED

PROCESSING WASTE DISPOSAL PRACTICES

ENVIRONMENTAL IMPACT IN MARBLE PROCESSING

ENVIRONMENTAL DAMAGE DUE TO SLURRY

ENVIRONMENTAL DAMAGE DUE TO QUARRYING & TRIMMING WASTE

NEEDED INITIATIVES

DETAILS OF MACHINERIES

SLIDE CUTTING MACHINE

TROLLEY TYPE CUTTING MACHINE

POLISHING MACHINE (HAND OPERATED)

POLISHING MACHINE (PNEUMATICALLY OPERATED)

TWIN HEAD AUTO POLISHER

FOREIGN COLLABORATION

SUPPLIERS OF PLANT & MACHINERIES

SUPPLIER OF PLANT & MACHINERY CIRCULAR SAW

POLISHING MACHING

GRINDING MACHINE

EDGE CUTTING MACHINE

MARBLE CUTTING MACHINE

SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)

RAW MATERIAL SUPPLIERS

MARBLE BLOCK

D.G. SET MANUFACTURERS & SUPPLIERS

ELECRICAL GOOD & SWITCH MANUFACTURE

FIRE FIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS

SUPPLIERS/MANUFACTURERES OF EOT CRANE

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONSREGISTRATION AND LICENSE REQUIRED FOR WATER PARK

OTHER LICENSES REQUIRED FOR THE SETUP:

KEY REGULATIONS AND POLICIES IN INDIA

EXCISE LAWS

LABOUR LAW LEGISLATIONS

PRINCIPLES OF PROJECT LAYOUT

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)