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Model Project for Milk Processing Plant_NABARD

Aug 24, 2014

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Statement 1 Project at a glance for 10000 litres model milk processing plant 1 Land requirement 2 Milk handling capacity 3 Products to be manufactured 4 5 6 7 2 acres 10000 liters/day Toned milk, Standard milk, Cream, Gee Market Domestic Cost of the project Rs. 116.581 laches Bank loan Rs. 87.436 laches Margin money (Down payment) Rs. 29.145 laches

8 Financial viability ( at 15% D F ) BC R NPW IRR FRR ( Considering income tax liability) 9 Repayment

1.12 : 1 Rs.134.75 lakhs > 50% >50% 6 years with one year grace period

t

Statement 2 CALCULATION OF MARGIN MONEY ON WORKING CAPITAL (Rs. in lakhs) Sr.No.

Particulars

Unit cost Period (Rs.) days I 70% 0.546 0.84 0.147 0.399 0.394 0.22 0.4 6.686 5.67 13.301 3.822 9.479 2.37 7.11 0.569

Years

1 2 3 4 5

6

Stock in progress Packing material Chemicals & detergents Stores, spaces and fuel** Finished goods Toned Milk Standard Milk Saleable Cream Saleable Ghee Receivables Total ( 1 to 6) Less sundry creditors (days) Total working capital required Margin money @ 25% of working capital Bank Cash credit Interest on working capital @ 16%

7.8 0.4 0.07 -9 10 40 40

1 30 30 30 1 1 10 30 7 7

II 80% 0.624 0.96 0.168 0.408 0.45 0.25 0.46 5.577 6.523 15.42 4.368 11.052 2.763 8.289 1.326

** Outlay on stores and spares is considered @ Rs.0.19, Rs.0.17, Rs.0.15 per litre during first year, second year and t Note : 1. Interest on working capital during first year is considered for 6 months only. 2. It is assumed that payment to the producers are made once in a week.

Years

III onwards 0.702 1.08 0.189 0.405 0.504 0.28 0.54 6.798 7.452 17.95 4.914 13.026 3.259 9.377 1.564

ring first year, second year and third year onwards respectively on assuming 40% of power and fuel charges and repairs and mai

uel charges and repairs and maintenance. (statement 5).

Statement 3 CAPITAL COST OF THE PROJECT Sr. No. Particulars Specification Quantity Unit Total Cost (Rs) Cost (Rs. In lakhs) 2 LAND AND SITE DEVELOPMENT Land (including registration charges) Development charges Gates 3 4 5 6

1 A) i) ii) iii) iv) vi)

-brick wall Steel

2 acres

78000/a cre 424 RM 165/RM 2 15000 each LS LS

1.56 0.7 0.3 0.5 1.75

Land leveling and roads WBM Water Supply (borewell, -tank, pump) Total CIVIL WORKS Dairy plant building

---

4.81 RCC ACC 3000 sq.ft 1000 sq.ft. --450 sq.ft. 600 sq.ft. 300/sq.f t. 200/sq.f t. LS LS 250/sq.f t. 180/sq.f t. 9 2 0.75 0.57 1.12 1.08 14.52

B) i)

ii) iii) iv) v)

E T Tanks Condenser tank Superviser quarters Workers quarters Total PLANT AND MACHINERY Can conveying and washing system Weigh scale

--ACC ACC

C) i) ii)

-500 kg

--

LS 2 1,18,000

1.23 2.36

iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) xviii) xix)

Dump tank and accessories Detergent tank Milk chiller Cream Separator Milk pasteuriser Storage tanks S S tanks Packaging machine & accessories Ghee boiler Ghee storage tank Boiler & accessories D.G. set Refrigeration equipment Electrical panels & cables Pumps S S pipes & fittings Erection & commissioning Total MISC. FIXED ASSETS Furniture Computer Fire fighting equipment Collection centre equipment Work table Milk cans

1000 lts -30005000lph 2000-5000 lph 5000 lph 10,000 lts 300 lts 2500 pph 500 kg 1000 lts 300 kg/h 62.5KVA ------

1

59,000

0.59 0.31 0.97 5.7 7.82 6.38 0.76 3.14 1.76 0.99 5.46 3 15.21 3.02 1.2 2 2.5 64.38

1 LS 1 LS 1 LS 1 LS 2 3,19,000 1 75,500 1 3,13,500 1 1,76,000 1 99,000 1 LS 1 LS LS LS 4 --30,000 LS LS

-1 set

D) i) ii) iii) iv) v) vi) vii)

-Pentium --

------

LS LS LS 3000/ce ntre LS 500 600 LS

0.5 0.5 0.1 0.6 0.28 3 0.52

Centrifuge, butyr.20 -40 lts (plastic) Crate conveying system -& trolleys

--

viii) ix) x) E) i) ii) F) i) ii)

Lab equipment Effluent treatment plant Water softener Total VEHICLES Jeep Mahindra Scooter Bajaj Total DEPOSITS State electricity board

----

----

LS LS LS

2.5 3.25 0.2 12.45 3.25 0.25 3.5 0.35 0.25 0.6

1 3,25,000 1 25,000

--

---

LS LS

i) ii) iii) iv) v) vi) vii) viii)

H)

Telephone -Total PRELIMINARY & PREOPERATIVE EXPENSES Incorporation of company Project preparation Market survey Establishment ( Salary & wages ) Travelling Consultancy Administrative expenses Interest during construction Total CONTINGENCY ( @ 5% of cost of buildings, plant & machinery and misc. fixed assets )

0.2 0.25 0.3 4.73 0.3 1 1 2.5 9.38

4.57

I)

MARGIN MONEY FOR WORKING CAPITAL ( 25% of first year's requirement statement - 2 ) GRAND TOTAL ( A+B+C+D+E+F+G+H ) 2.37

J)

116.58

Statement 4 TECHNO ECONOMIC PARAMETERS S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 i) Ii) Iii) Iv) v) 16 Particulars Installed capacity Capacity utilisation No. of Working days Raw material Milk Cost price of milk Commission on milk collection Transportation charges Power and fuel Packing material Chemicals & detergents Salaries and wages Repairs and maintenance Over heads (incl. Of insurance) Milk distribution cost Product mix Toned milk (3% fat) Standard milk (4.5% fat) Cream (50% fat) Saleable cream (25% of iii approx.) Ghee Selling prices Toned milk Standard milk Cream Ghee Depreciation (%) Unit litres /day % Litres I 10000 70 7000 182 12.74 7.4 0.2 0.2 0.42 0.4 0.07 4.73 0.05 0.12 0.6 4375 2200 390 100 142 9 10 40 110 Straight line method 3 10 10 YEARS II III onwards 80 8000 365 29.2 7.4 0.2 0.2 0.37 0.4 0.07 9.49 0.05 0.12 0.6 5000 2500 460 115 169 9 10 40 110 90 9000 365 32.85 7.4 0.2 0.2 0.33 0.4 0.07 9.49 0.05 0.12 0.6 5600 2800 555 135 206 9 10 40 110 Written down value method 10 25 33

lakh litres/yr. Rs. /litre Rs. /litre Rs. /litre Rs. /litre Rs. /litre Rs. /litre Lakhs Rs./ yr Rs. /litre Rs. /litre Rs. /litre litres /day litres /day litres /day litres /day Kg/day Rs. /litre Rs. /litre Rs. /litre Rs./kg

17

Civil Structures Plant and Machinery Misc. Fixed assets

Statement 5 INCOME PROJECTIONS Particulars S.No

Unit I

Years II 7000 4375 2200 390 100 142 0.394 0.22 0.04 0.156

1 2 i) ii) iii) iv) v) 3 i) ii) iii) iv)

Milk procured Yield per day Toned milk ( 3% fat ) Standard milk (4. 5% fat ) Cream ( 50% fat ) Saleable cream ( 25% of iii approx. ) Ghee Income per day Toned milk (Rs.9.00 / litre ) Standard milk ( Rs. 10.00 / litre ) Cream ( Rs.40.00/ litre) Ghee ( Rs. 110.00/kg)

litres/day litres/day litres/day litres/day litres/day kg/day Rs. Lakhs Rs. Lakhs Rs. Lakhs Rs. Lakhs

III onwards 8000 9000 5000 2500 460 115 169 0.45 0.25 5600 2800 555 135 206 0.5 0.28 0.054 0.22763% 30% 5%

2%

0.046 0.186

4 5

Total income/day

Rs. Lakhs

0.81 147.411

0.932 340.144

1.065 388.579

Income per year (1st year for Rs. In 6 months i.e. 182 days) lakhs

Statement 6 EXPENDITURE PROJECTIONS S.No Particulars Unit I YEARS II III onwards 32.85 243.09 6.57 6.57 10.841 13.14 2.3 9.492 1.643 3.942 19.71 317.297

1 2 3 4 5 6 7 8 9 10 11

Milk processing per year Raw material - milk Commission on milk collection Transportation charges Power and fuel (As per statement No. 4) Packing material Chemicals & detergents Salaries and wages(as per statement4) Repairs & maintenance Overheads Milk distribution cost (As per statement 4) Total operational cost

Lakh litres/day Rs.7.40/litre Rs.0.20/litre Rs.0.20.litre Rs.0.40.litre Rs.0.07.litre

12.74 94.276 2.548 2.548 5.351 5.096 0.892 4.733 0.637 1.529 7.644 125.253

29.2 216.08 5.84 5.84 10.804 11.68 2.044 9.492 1.46 3.504 17.52 284.264

Rs.0.05.litre Rs.0.06.litre -Rs. lakhs

Statement 7

DEPRECIATION SCHEDULES OF CIVIL WORKS, PLANT & MACHINERY AND MISC. FIXED ASSET Note : The figures corresponding to each year represent end year values for the preceding year.

Y AND MISC. FIXED ASSETS

Statement 8 CASH FLOW ANALYSIS WITHOUT CONSIDERING THE INCOME TAX LIABILITY (Rs. In lakhs) Sr.No. Particula rs 1 Costs i) Capital cost $ ii) Recurring cost Total cost 2 I II Years III to V VI

114.212 125.253 284.264 317.296 317.296

239.465

284.265

317.297

317.297

3

Benefits 147.411 340.144 388.579 388.579 i. Residual value of a) Civil ---11.906 Structure s b) Plant ----& ---31.312 Total 147.411 340.144 388.579 431.797 benefits Net -92.054 55.88 71.283 114.501 benefits (3-(1+2)) D F at 15% a) P W of costs @ 15% DF b) P W of benefit @ 15% D F 0.869 208.095 0.756 214.904 1.726 547.654 0.432 137.072

4

128.1

257.148

670.687

186.536

5

D F at 50%

BCR = 1.12:1 NPW = + 134.75 0.667 0.444

0.625

0.088

6

N P W at 50% D F

-61.369

24.81

44.552

10.076

IRR is more than $ The capital cost considered excludes the capitalised margin money on working capital.

IABILITY

Statement 9 CASH FLOW ANALYSIS ON CONSIDERING THE INCOME TAX LIABILITY (Rs. in lakhs) Years Sr. Particula I II III IV V VI rs No. 1 Income 147.411 340.144 388.579 388.579 388.579 388.579 (Stateme nt 5) 2 Operatio 125.253 284.264 317.297 317.297 317.297 317.297 nal cost (Stateme nt 6) 3 Gross 22.158 55.88 71.283 71.283 71.283 71.283 operating profit 4 Less i) Interest 9.609 12.812 10.25 7.559 4.869 2.13 on term loan @ 16% ii) Interest 0.569 1.326 1.564 1.564 1.564 1.564 working capital @ 16% iii Depr. On straight line method Civil 1.452 1.307 1.176 1.059 0.953 0.857 works Plant and 16.096 12.07