Detailed Project Report on MARBLE PROCESSING PLANT (MARBLE CUTTING AND POLISHING UNIT)

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.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




MARBLE PROCESSING PLANT (MARBLE
CUTTING AND POLISHING UNIT)
(EIRI/EDPR/4707) J.C. 2927XL


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.

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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.

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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

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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

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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 INSTITUTIONSREGISTRATI ON AND LICENSE
REQUIRED FOR WATER PARK

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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 IMPLEMENTATI ON SCHEDULE

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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)

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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%