MILL PLANT

LAYOUT/
PLACEMENT
MILL PLANT LAYOUT/ PLACEMENT
• Plant location may be understood as the function
of determining where the plant should be located
for maximum operating economy and
effectiveness.
 MAJOR FACTORS WHICH AFFECT
PLANT LAYOUT
• Policies of • Availability of floor
management space

• Plant location • Nature of

manufacturing
• Nature of the product process

• Volume of Production • Repairs and

maintenance of
equipment and
machines
POLICIES OF MANAGEMENT
• political, social and legal policies (plans,
regulation, incentives, taxes)
• includes managerial policies and plans
PLANT LOCATION
• Location of a plant greatly influences the layout
of the plant.
• Topography, shape, climate conditions, and size
of the site selected will influence the general
arrangement of the layout and the flow of work
in and out of the building.
NATURE OF THE PRODUCT
• Nature of the commodity or article to be
produced greatly affects the type of layout to be
adopted. In case of process industries, where the
production is carried in a sequence, product
layout is suitable.
• Production of heavy and bulky items need
different layout as compared to small and light
items. Similarly to products with complex and
dangerous operations would require isolation
instead of integration processes.
VOLUME OF PRODUCTION
• Plant layout is generally determined by taking
into consideration the quantum of production to
be produced.
VOLUME OF PRODUCTION
(CLASSIFICATIONS)
a. Job production
• special or non- standardized products are produced in
accordance with the orders received from the
customers.

b. Mass Production
• involves a continuous production of standardized
products on large scale.
• Under this classification, production remains
continuous in anticipation of future demand.
Standardization is the basis of mass production.
VOLUME OF PRODUCTION
(CLASSIFICATIONS)
• Standardized products are produced under by using
standardized materials and equipment.
• There is a continuous or uninterrupted flow of
production obtained by arranging the machines in a
proper sequence of operations.

c. Batch Production
• form of production where identical products are
produced in batches on the basis of demand of
customers or of expected demand for products.
• generally similar to job production except the quality
of production.
AVAILABILITY OF FLOOR SPACE
• Availability of floor space can be other decisive
factor in adopting a particular mode of layout (if
there is a scarcity of space), availability of land.
NATURE OF MANUFACTURING
PROCESS
• The type of manufacturing process undertaken by
a business enterprise will greatly affect the type
of layout to be undertaken.
NATURE OF MANUFACTURING
PROCESS
(VARIOUS PROCESSES)
a. Synthetic Process
• Under this process two or more materials are mixed to
get a product.

b. Analytical Process
• This is just the reverse of synthetic process.
• Under this method different products are extracted
from one material.
NATURE OF MANUFACTURING
PROCESS
(VARIOUS PROCESSES)
c. Conditioning Process
• Under this process the original raw material is given
the shape of different products and nothing is added to
it.

d. Extractive Process
• involves the extraction of a product from the original
material by the application of heat or pressure.
• involves the process of separation
REPAIRS AND MAINTENANCE OF
EQUIPMENTS AND MACHINES
• The plant layout should be designed in such a
manner as to take proper care with regard to
repairs and maintenance of different types of
machines and equipment being used in the
industry.
• The machines should not be installed so closely
that it may create the problems of their
maintenance and repairs.
 FACTORS AFFECTING PLANT
LOCATION
1. Transport Facilities 4. Disposal Facility for
Waste Products
2. Availability of
power, fuel, or gas 5. Climatic and
Atmospheric
3. Water Supply Conditions

6. Site Location
TRANSPORT FACILITIES
• Since freight charges of raw materials and
finished goods enter into the cost of production,
therefore transportation facilities are becoming
the governing factor in economic location of the
plant.
• Depending upon the volume of the raw materials
and finished products, a suitable method of
transportation like rail, road, water transportation
(through river, canals or sea) and air transport is
selected and accordingly plant location is
decided.
TRANSPORT FACILITIES
• Important consideration should be that the cost of
transportation should remain fairly small in
comparison to the total cost of production.
AVAILABILITY OF POWER, FUEL, OR
GAS
• Because of the wide spread use of electrical
power the availability of fuel or gas has not
remained a deciding factor in most of the cases
for plant location.
• The location of thermal power plants and steel
plants near coal fields are for cutting down cost
of the fuel transportation.
• The reliability of continuous supply of these
facilities is an important factor.
WATER SUPPLY
• Water is required for processing as in chemical,
sugar and paper industries and is also used for
drinking and sanitary purposes.
• Investigation for quality and probable source of
supply is important, since the cost of treating
water is substantial so the chemical properties
like hardness, alkalinity and acidity.
DISPOSAL FACILITY FOR WASTE
PRODUCTS
• Thorough study should be made regarding
disposal of water like effluents, solids, chemicals
and other waste products likely to be produced
during the production process.
CLIMATIC AND ATMOSPHERIC
CONDITIONS
• The climate of the region/ area where the plant is
to be located has an important bearing on both
the capital and operational costs.
CLIMATIC AND ATMOSPHERIC
CONDITIONS
(ASPECTS)
(a) Rain fall or snow fall in the area concerned
(b) Ambient temperatures
(c) Humidity
(d) Wind velocities and direction
(e) Incidence of cyclones, storms etc
SITE LOCATION
• The cheap availability of land for current and
future requirements, soil characteristics sub soil
water, availability or possibility of economic
drainage and waste disposal system are desirable
parameters.
• The site should be easily accessible to various
modes of transport as required so that apart from
input materials, employees can also reach the site
conveniently.
• The site should be free from zonal restrictions
like from railways or civil aviation restrictions.
 REQUIREMENTS FOR MINERAL
PROCESSING PLANT DESIGN
• Preliminary to mill design the mine must be
developed to the point where a decision may be
made on daily mill tonnage and representative
samples can be obtained for metallurgical test
work a flowsheet is worked out and mill site is
then selected.
 REQUIREMENTS FOR MINERAL
PROCESSING PLANT DESIGN
• When the mill site is selected and cleared a
detailed contour map of a reasonably broad area
around the mill location is required so that full
consideration may be given to access roads,
tailing disposal, water supply, and service
facilities.
 REQUIREMENTS FOR MINERAL
PROCESSING PLANT DESIGN
• Test pits for foundation information must be dug
in most cases. The next step is completion of a
preliminary layout based on the selected
flowsheet and mill site contour. This is followed
by determination of all machinery sizes so that
manufacturers’ drawings can be obtained as
quickly as possible.
 REQUIREMENTS FOR MINERAL
PROCESSING PLANT DESIGN
a. Power Supply
b. Electrical Installation
c. Lighting
d. Features