Total Process Flow – From Raw Material to Pellet Output
A 1 TPH plant converts raw agro/wood waste into compact biomass pellets. Here’s the step-by-step process:
1.1 Raw Material Procurement & Storage
1.2 Size Reduction
1.3 Fine Grinding
1.4 Drying
1.5 Pelletizing
1.6 Cooling & Screening
1.7 Packing & Storage
Section 2: Land, Utilities & Manpower Requirements
2.1 Land Requirements
For a 1 TPH pellet plant, plan for:
| Area Type | Size (Approx.) |
| Built-up plant area | 8,000–10,000 sq. ft. |
| Raw material yard | 10,000 sq. ft. |
| Storage & packing | 5,000 sq. ft. |
| Total Land | 0.75–1 Acre |
2.2 Utilities Required
| Utility | Specs |
| Power | 80–100 HP connected load (~75 kW) |
| Water | 500–1,000 L/day (cooling + dust) |
| Manpower | 8–12 persons |
| Fuel (for dryer) | Biomass or agro waste (self-sustaining) |
Section 3: Raw Material – Types, GCV & Suitability
BELOW ARE IDEAL FEEDSTOCKS AND THEIR ENERGY CONTENT (GCV):
| Raw Material | Moisture (Raw) | GCV (kcal/kg) | Availability | Pellet Suitability |
| Sawdust | 10–15% | 3500–4000 | High | Excellent |
| Groundnut Shell | 6–10% | 4200–4500 | Medium | Excellent |
| Paddy Husk | 10–15% | 3000–3200 | High | Moderate (abrasive ash) |
| Cotton Stalk | 12–20% | 3500–3800 | Seasonal | Good |
| Sugarcane Bagasse | 30–50% | 2300–2700 | Very High | Needs Drying |
| Corn Cob | 10–15% | 3700–3900 | Medium | Very Good |
| Bamboo Waste | 15–25% | 3800–4200 | Region Specific | Very Good |
Important: Uniform particle size and low moisture content are critical for pellet quality.
Section 4: Detailed Cost Breakdown for 1 TPH Plant
| Component | Estimated Cost (INR) |
| Land & Civil Work | ₹25–30 lakhs |
| Machinery & Pellet Line | ₹45–60 lakhs |
| Dryer (Flash or Rotary) | ₹10–15 lakhs |
| Electricals & Installation | ₹5–8 lakhs |
| Dust Collector & Conveyors | ₹5–7 lakhs |
| Packing System | ₹2–4 lakhs |
| Working Capital (Raw + Ops) | ₹10–15 lakhs |
| Total Project Cost | ₹1.1 – ₹1.5 crore |
Section 5: Subsidy & Financial Support in India (2025)
5.1 MNRE (Ministry of New and Renewable Energy)
Under the Waste to Energy Programme:
Website: https://mnre.gov.in
5.2 PMEGP (Prime Minister Employment Generation Programme)
5.3 NABARD / State Renewable Energy Boards
Tip: Get a DPR (Detailed Project Report) made and approach MSME-DI and District Industries Centre for approvals.
Section 6: Best Pellet Machine Manufacturers in India (with Links)
⭐ Recommended for 1 TPH Projects:
| Company | Location | Highlights | Website |
| FABON Engineering | Nashik Maharashtra | Turnkey biomass pellet plants, flash dryer, pellet burner | fabon.in |
| Servoday Group | Gujarat | Complete biomass and feed pellet solutions | servoday.com |
| Ecostan India | Punjab | Pellet machines, shredders, briquetting units | ecostan.com |
| Pellet India | Punjab | Specializes in agro pellet machines | pelletindia.com |
| Keyul Enterprise | Maharashtra | Mini pellet mill setups and agricultural shredder machines | keyulenterprise.com |
| Namdhari Agro | Punjab | Feed and pellet processing machinery | namdhariagro.com |
FABON Engineering is among the top for complete solutions from raw material processing to pellet burner integration.
Section 7: Business Potential & ROI (Rough Estimate)
| Item | Value (Approx.) |
| Production | 8 tons/day (1 ton/hr x 8 hrs) |
| Selling Price (avg.) | ₹8,000–₹10,000/ton |
| Daily Revenue | ₹64,000–₹80,000 |
| Raw Material Cost | ₹2–3/kg (~₹20,000/day) |
| Electricity + Labor | ₹10,000–₹12,000/day |
| Net Profit/Day | ₹30,000–₹40,000 |
| ROI Period | 12–18 months |
Bonus: Where Are Pellets Used?
Summary
| Topic | Key Info |
| Land Needed | 0.75–1 Acre |
| Investment | ₹1.1–₹1.5 crore |
| Output | 1 ton/hour |
| Subsidy | Up to ₹40 lakh (MNRE) + state-level benefits |
| Best Manufacturers | FABON, Servoday, Ecostan, Pellet India |
| Raw Material Needed/Day | 24–30 tons (wet basis) |
| Profit Potential | ₹30,000–₹40,000/day |
| ROI | ~1–1.5 years |
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