An attempt has been made to develop the relation between the different variables for inherent system of a sugar mill.The crushing mill elements are Housing,Grooved rollers, Pinions,Journal Bearings,Trash Plates,Under feed roller & Lubrication system.The research provides a new metric of success for Mechanical,R & D Organizations, FEA Engineers & Sugar Industry.The author validates the mathematical,FEA analysis & experimental results & optimizes the mill elements & operating parameters for higher efficiency.The findings are: •Fatigue strength of mill roller bearing surface is improved by cold roller Burnishing. •Analyzing metal Journal Bearing as well as Nylon, Delirin, PTFE & Lubron.Without lubrication, Lubron provides best results with no wear & tear and no rise in temperature. •The static & dynamic forces on rollers & pinions deflect the Limbs.Optimized load reduces deflection & increases life. •Characteristics of a Trash plate enhance more noise & vibration.But with smooth curvature & designed Feed Angle,it consumes less power. •The pinion wears out due to bending load by scoring action. Its life increases with proper Lubrication, alignment of shaft, equal load distribution.