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YUGA
Drum-melting decanter oven at a YUGA bitumen plant
Product · YUGA PMC

Bitumen Decanter

Drum decanting / packaging system for safe bitumen handling

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Overview

What is Bitumen Decanter?

A bitumen decanter is a system that safely melts and discharges bitumen from drums (or processes bulk bitumen) using controlled heating, so it can be transferred to storage tanks, tankers or packaging without manual breaking of drums.

Decanting improves safety, reduces wastage and labour, and supports value-added packaging (e.g. converting bulk/imported bitumen into drums, bags or modified products). It is a key utility for terminals, emulsion and PMB/CRMB plants.

Bitumen decanter plant - interior view
Why this business

Benefits

  • Safe handling — controlled heating avoids hazardous manual drum cutting
  • Less wastage — clean, near-complete recovery of bitumen
  • Lower labour — mechanised, faster decanting
  • Feeds value addition — supplies tanks for emulsion / PMB / CRMB / packing
  • Flexible — handles drums or bulk depending on configuration
Demand

Applications & buyers

  • Bitumen terminals and storage depots
  • Emulsion, PMB and CRMB manufacturing plants (feed system)
  • Drum / bag / small-pack repackaging units
  • Contractors needing reliable molten bitumen supply
Technical

Specifications

FunctionMelt & discharge bitumen from drums / bulk
HeatingThermic-fluid / hot-oil coil heating (indirect)
Typical add-onsStorage tanks, pumps, weighing, filling station
ThroughputSized to plant demand (drums per hour)
Use withEmulsion / PMB / CRMB / packaging lines
Setup

Plant & machinery

Capacity to showSmall 2–4 TPH; Common 6–10 TPH; Large/terminal 12 TPH+
Area requiredStandalone 4–10 TPH: 5,000–15,000 sq ft; with tank farm & loading 20,000–40,000 sq ft
Approx. cost (without land)Basic decanter ₹15–45 lakh; with thermic heater, tankage & installation ₹75 lakh–2 Cr
UtilitiesHeating fuel/electricity, power, firefighting water, forklift/chain pulley, thermic oil, maintenance tools
ApprovalsFactory/fire, fuel storage, boiler/thermic-fluid safety, SPCB consent if part of a larger unit
Best-use noteUsually supports emulsion/PMB/CRMB/hot-mix/road-site ops rather than a standalone high-margin business
Drum/bag loading platform or hydraulic loadingMelting chamber / decanter bodyThermic-fluid heater / hot-oil systemBitumen pump, strainer & pipelinesHot bitumen storage tankTemperature control & electrical panelInsulation, chimney/stack & safety valvesDrip collection / spill containmentFirefighting & unloading equipment
YUGA founder Prince Shah inspecting a bitumen decanter plant
Bitumen decanter plant - establishing wide view
Bitumen decanter plant - establishing wide view
Feedstock & Output

What goes in, what comes out.

Per batch (utility)

Input
Bitumen drums / bulk
as fed
Heating fuel/thermic oil
as required
Output
Molten bitumen to tank/tanker
~98%+ recovery (low wastage)
Quality & Compliance

Standards & testing.

IS (BIS)
Equipment — follows boiler/thermic-fluid & factory safety norms
ASTM
—
MSDS / SDS
MSDS/SDS for bitumen handled; hot-oil safety data
Investment & Returns

Cost, output & payback.

A decanter is a utility/value-addition system, not a standalone product; figures are equipment-based.

Bitumen Decanter

Cost & ROI

Investment (CAPEX)
₹0.15–0.45 Cr
Land required
5,000–15,000 sq ft
Payback
within plant

Indicative only — actual figures depend on capacity, location, raw-material price and utilisation. Contact us for an exact DPR.

Equipment / system cost₹15 lakh – ₹75 lakh (capacity-dependent)
RoleFeeds emulsion / PMB / CRMB / packaging lines
Value additionEnables drum/bulk handling & repackaging margin
Approx. payback (as part of unit)1 – 2 years (with downstream sales)
Best assessedWithin the overall plant DPR

Figures are for plant supply only — land and working capital are separate — and reflect a batch / semi-continuous build. Fully-continuous, automated, premium-spec production plants cost more (roughly ₹0.8–1.2 Cr per TPD). Your exact cost is fixed in a site-specific DPR.

Where to build

Best Indian states for this plant.

All states (terminal/depot hubs)

Needed wherever bitumen is stored, repacked or fed to emulsion/PMB/CRMB plants.

Site & Footprint

How much land you'll need.

Indicative plot size by capacity — we lock the exact figure to your layout and feedstock plan during feasibility.

Capacity
Basic decanter
5,000–15,000 sq ft
Capacity
Full setup
20,000–40,000 sq ft

Indicative footprint per capacity tier. Actual plot size depends on layout, feedstock storage, effluent/ZLD provisions, future expansion and statutory setbacks — finalised in the feasibility / DPR stage.

Regulatory

Licences & permissions you'll need.

Core approvals plus the extras specific to this plant — pick your state to see the nodal authority. We handle the full filing as part of PMC.

Licences & permissions

Gujarat PCB + Investor Facilitation Portal (single-window) under the Gujarat Industrial Policy.

Udyam (MSME) registrationMinistry of MSMESetup
GST registrationGST DepartmentSetup
Company / firm incorporationMCA / RegistrarSetup
Factory licenceState Factories & Boilers DeptPre-build
Fire NOCState Fire ServicesPre-build
Consent to Establish (CTE)State Pollution Control BoardPre-build
Consent to Operate (CTO)State Pollution Control BoardPre-commissioning
PESO licence (storage of petroleum/flammables)PESO (Petroleum & Explosives Safety Org)Pre-commissioning
Trade / municipal licenceLocal municipal bodySetup
Electricity & power connectionState DISCOMPre-build

Indicative — the exact licence set depends on product, capacity, category (red/orange) and the latest state norms. We handle the full filing as part of PMC. Verify on application.

Client couple at their commissioned YUGA plant - idea to income
Carbon & Market

Extra revenue, and where it's running.

Carbon
~0.35 t
CO₂ saved per MT of bio-bitumen
Carbon
₹2,500+
Indicative credit value / MT
Carbon
~2.5 MT
Crop residue diverted / MT output
Carbon
MRV
Puro.earth-style verified pathway

Indicative — actual eligibility, methodology, credit volume and price depend on the registry, feedstock and verification. We structure the MRV pathway as part of PMC; contact us for a project-specific assessment.

Approx plants running (India)
~35
Top states
Gujarat · Maharashtra
What You Get

Documents & deliverables we provide.

Reports, drawings, working procedures and compliance docs — the full pack that takes the plant from paper to production.

Reports & financials

  • Detailed Project Report (DPR)
  • Bank DPR + CMA data (bank format)
  • 5-year financial model — P&L, balance sheet, cash flow
  • ROI / IRR / break-even & sensitivity analysis
  • Feasibility & techno-economic report
  • Subsidy & loan eligibility memo

Drawings & engineering

  • Plant layout & general-arrangement drawings
  • Process flow diagram (PFD) & P&ID
  • Civil & foundation drawings
  • Electrical & utility layout
  • Equipment & machinery specification sheets
  • Site plan & location scoring

Working & process docs

  • Standard Operating Procedures (SOPs)
  • Production & blending process manual
  • Quality-control test protocols (penetration, softening, ductility)
  • Raw-material & input–output (mass balance) sheets
  • Operator training & safety manual
  • Vendor / OEM list with negotiated pricing

Compliance & market

  • Licence & permission checklist (product + state)
  • Standards pack — IS / ASTM / MSDS
  • Tender & empanelment documentation (NHAI / PWD)
  • Buyer network & sales-support pack
  • Carbon-credit MRV documentation (optional)

Exact deliverables are scoped per engagement and product. The full pack is provided as part of PMC — contact us for a project-specific document list.

Bitumen decanter plant - plant inauguration ceremony
Plant Views

One plant, four angles.

Front, both sides and the working floor — the same facility from every angle.

Bitumen decanter plant - one plant from four angles
Questions

Top questions, answered.

A heated system that melts and discharges bitumen from drums or bulk so it can be pumped into tanks, tankers or packaging.

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Plan your Bitumen Decanter plant with YUGA.

From feasibility to first commercial production - and the capital to fund it.

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