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Colloid-mill skid and brown emulsion tanks - YUGA bitumen emulsion plant
Product · YUGA PMC

Bitumen Emulsion

Water-based bitumen for cold-application road works (IS 8887)

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Overview

What is Bitumen Emulsion?

Bitumen emulsion is a stable mix of bitumen droplets dispersed in water with an emulsifier, allowing bitumen to be used cold (without high-temperature heating). It is graded as Rapid (RS), Medium (MS) and Slow (SS) setting, and specified under IS 8887.

Emulsions are widely used for tack coats, prime coats, surface dressing, fog seals, patch repair and cold-mix works — making them ideal for maintenance, rural roads and eco-friendly, low-energy applications.

Bitumen emulsion plant - interior view
Why this business

Benefits

  • Cold application — no heating to high temperature — safer, less fuel
  • Eco-friendly — water-based, lower emissions and energy use
  • Versatile — tack, prime, surface dressing, fog seal, cold mix, repair
  • Good for maintenance — ideal for patchwork and rural roads
  • Standardised — RS / MS / SS grades per IS 8887
Demand

Applications & buyers

  • Tack coat and prime coat between/under pavement layers
  • Surface dressing and fog seal
  • Pothole / patch repair and cold-mix maintenance
  • Rural roads (PMGSY-type works) and all-weather repair
Technical

Specifications

StandardIS 8887 (Bitumen Emulsion)
GradesRS-1/RS-2 (rapid), MS (medium), SS-1/SS-2 (slow)
CompositionBitumen + water + emulsifier (cationic common)
PlantColloid mill, soap/water phase tanks, dosing system
UseTack/prime coat, surface dressing, cold mix, repair
Setup

Plant & machinery

Capacity to showSmall 1 TPH; Common 5 TPH; Commercial 10–20 TPH; custom up to 50 TPH
Area required5–10 TPH: 10,000–25,000 sq ft; with bitumen/emulsion tanks, lab & drum filling 0.5–1 acre
Approx. cost (without land)1 TPH ₹25–60 lakh; 5 TPH ₹75 lakh–1.75 Cr; 10 TPH ₹1.5–3 Cr; 20 TPH ₹3–5 Cr
UtilitiesPower, heating fuel/thermic oil, clean water, compressed air, lab chemicals, firefighting water, packing/drums
ApprovalsSPCB CTE/CTO, factory/fire, storage safety, IS 8887 / project testing
Best-use noteBuyers understand application: tack coat, prime coat, cold mix, maintenance, rural roads
Bitumen storage & heating tankWater tank & soap-solution tankAcid/amine/emulsifier dosing systemColloid mill / high-shear millBitumen, water & soap pumpsFlow meters & dosing controlsEmulsion cooling & storage tanksDrum filling / bulk loading systemPLC/MCC/control panelLaboratory for emulsion testsFire safety, spill containment, effluent handling
YUGA founder Prince Shah at a bitumen emulsion plant
Bitumen emulsion plant - establishing wide view
Bitumen emulsion plant - establishing wide view
Feedstock & Output

What goes in, what comes out.

Per 1 tonne emulsion

Input
Bitumen
~60–70%
Water
~30–40%
Emulsifier/acid
~0.5–2%
Output
Bitumen emulsion (IS 8887)
1 tonne
Quality & Compliance

Standards & testing.

IS (BIS)
IS 8887:2018 (Bitumen Emulsion)
ASTM
ASTM D977 (anionic) / D2397 (cationic)
MSDS / SDS
MSDS/SDS for emulsion, emulsifier/acid
Investment & Returns

Cost, output & payback.

Indicative for a ~5–20 TPD bitumen emulsion plant.

Bitumen Emulsion

Cost & ROI

Investment (CAPEX)
₹0.25–0.6 Cr
Output / year
1,500–3,000 MT emulsion/yr
Revenue / year
₹1–3 Cr
Profit / year
₹0.1–0.4 Cr
Land required
small plot
Payback
2–3 yr

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

Project investment (CAPEX)₹40 lakh – ₹1.5 crore
Capacity basis~5 – 20 TPD emulsion
Approx. annual revenue₹3 crore – ₹15 crore
Approx. gross profit (GP) margin12% – 20%
Approx. net profit / year₹30 lakh – ₹1.2 crore
Approx. payback period2 – 3 years

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.

UP, MP, Bihar, Maharashtra, Rajasthan (+ all states)

Large PMGSY/rural & maintenance road programmes; low-energy cold application.

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
1 TPH
small plot
Capacity
5 TPH
10,000–25,000 sq ft
Capacity
10 TPH
0.5–1 acre
Capacity
20 TPH
~1 acre

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
BIS / IS 8887 product certificationBISMarket

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)
~220
Top states
Across all 18 active states
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 emulsion plant - plant inauguration ceremony
Plant Views

One plant, four angles.

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

Bitumen emulsion plant - one plant from four angles
Questions

Top questions, answered.

Bitumen dispersed in water with an emulsifier, so it can be applied cold without high-temperature heating.

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Plan your Bitumen Emulsion plant with YUGA.

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

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