Beruflich Dokumente
Kultur Dokumente
Development Studies
Associates (DSA)
October 2008
Addis Ababa
Table of Contents
1. Executive Summary..................................................................................1
2. Product Description and Application....................................................1
3. Market Study, Plant Capacity and Production Program....................2
3.1 Market Study.......................................................................................................2
3.1.1 Present Demand and Supply........................................................................2
3.1.2 Projected Demand........................................................................................2
3.1.3 Pricing and Distribution...............................................................................3
3.2 Plant Capacity......................................................................................................3
3.3 Production Program.............................................................................................3
4. Raw Materials and Utilities....................................................................3
4.1 Availability and Source of Raw materials...........................................................3
4.1 Annual Requirement and Cost of Raw Materials and Utilities...........................4
5 Location and Site.....................................................................................4
6 Technology and Engineering..................................................................4
6.1 Production Process...............................................................................................4
6.2 Machinery and Equipment...................................................................................5
6.3 Civil Engineering Cost........................................................................................7
7 Human Resource and Training Requirement......................................7
7.1 Human Resource..................................................................................................7
7.2 Training Requirement..........................................................................................8
8 Financial Analysis...................................................................................8
8.1 Underlying Assumption.......................................................................................8
8.2 Investment............................................................................................................9
8.3 Production Costs................................................................................................10
8.4 Financial evaluation...........................................................................................10
9 Economic and Social Benefit and Justification..................................11
ANNEXES....................................................................................................13
1. Executive Summary
This project profile deals with establishment of plastic syringes and disposable needles in
Amhara National Regional State. The following presents the main findings of the study
Demand projection divulges that the domestic demand for plastic syringe and disposable needles
is substantial and is increasing with time. Accordingly, the planned plant is set to produce 6
million plastic syringes and disposable needles annually. The total investment cost of the project
including working capital is estimated at Birr 5.82 million and creates 46 jobs.
The financial result indicates that the project will generate profit beginning from the first year of
operation. Moreover, the project breaks even at 36.34% of capacity utilization and payback fully
the initial investment less working capital in third year of operation. The results further show that
the calculated IRR of the project is 22.3%.
In addition to this, the proposed project possesses wide range of economic and social benefits
such as increasing the level of investment, tax revenue, employment creation and import
substitution.
Generally, the project is technically feasible, financially and commercially viable as well as
socially and economically acceptable. Hence the project is worth implementing.
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3. Market Study, Plant Capacity and Production Program
The projected demand for plastic syringes and needles is shown in Table 1 below. The demand is
assumed to increase at 2% per annum, an assumption below the rate of population growth.
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The available retail and wholesale network shall be used by the envisaged plant to reach its
customer.
Thus, given the expected demand for syringes and disposable needles presented earlier, and the
planned technology, the envisaged plant is set to produce 6 million deposable syringe and needle
annually.
The program is scheduled based on the consideration that the envisaged plant will work 275 days
where the remaining days will be holidays and for maintenance. During the first year of
operation the plant will operate at 85 percent capacity, and then the capacity will grow to 100
percent starting from the 2rd year. This consideration is developed based on the assumption that
market and logistics barriers would take place within the first year of operation.
Total Cost
(Birr)
Material and Input Qy L.C. F.C.
3
PVC Plastic 36 tons 396,900
Brass Rod 24 tons 476,280
Ethyl Oxide 10 tos 90,720
Nickel Chromium 30 tons 102,060
Packing Material Lumpsum 68,040
Total Material Cost 260,820 873,180
Utility
Electricity 700 kwh 88,000
Water 200 m2 2,650
Total Utility Cost 90,650
The appropriate locations for the envisaged project in view of the availability of input,
infrastructures as well as market for the output are Combolcha and Bahir Dar.
Production of plastic syringe and needle has the following major steps.
Preparation of compounding mixture;
Manufacture of plastic parts;
Manufacture of needles;
Assembling of the syringes;
sterilization of the syringes and needless; and
Packing.
Plastic parts are prepared with suitable dies and moulds on an automatic injections molding
machine. Needles are manufactured by feeding a bright drawn brass rod into the capstan lathe to
turn out the hubs which has operations of turning drilling, cut off, and taper turning. The
miniature drilling is carried out on high precision drilling machine. Then the hubs are sent for
nickel chromium plating. After some additional processes are performed on the needle, both the
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needle and hubs are fitted to each other on the press machine. Once the manufacturing of parts is
completed, sterilization, autoclaving, exposure to ethylene oxide, exposure to ionizing radiation
and packing are performed.
Alternative technology
The needles are made by other specialized manufacturers. In this case the needles become
component or input to the syringes manufacturing plant. This option requires two independent
plants.
Many types of machines are involved in the production of disposable syringes and needles. The
most important include horizontal injection molding machine, printing and embossing machine,
assembling machine, precision drilling machine, precision cylindrical grinding machine, grinder,
needle cutting and finishing unit, moulds, power press, capstan lathe, electroplating, air
compressor.
The machineries and equipment required for producing plastic syringe and disposable needle is
detailed in Table 3 below.
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The total cost of machinery and equipment including freight insurance and bank cost is estimated
to be about Birr 4.5 million.
Suppliers Addresses:
Zhangjiagang Feiyun Machinery Co., Ltd.
Leyu Economic Industrial Park,
Zhangjiagang, Suzhou, Jiangsu,
Suzhou/Jiangsu
China
Zip/Postal Code: 215621
Telephone Number: 86-512-58119129
Fax Number: 86-512-58119130
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6.3 Civil Engineering Cost
The total site area for the envisaged plant is estimated to be 700m2 where 200m2 is allocated to
the building place. The cost of which is estimated at Birr 42,000 and Birr 400,000 respectively.
The envisaged plant therefore, creates 46 jobs opportunity and about Birr 585,360 of annual
household income from employment.
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7.2 Training Requirement
Training of key personnel shall be conducted in the early first year of operation. This can be
arranged with the suppliers of the plant machineries. The training should primarily focuses on the
production technology and machinery maintenance and trouble shooting. Birr 60,000 included in
the working capital for training expense.
8 Financial Analysis
8.1 Underlying Assumption
The financial analysis of plastic syringes and disposable needles producing plant is based on the
data provided in the preceding chapters and the following assumptions.
B. Depreciation
Building 5%
Machinery and equipment 10%
Office furniture 10%
Pre-production (amortization) 20%
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C. Working Capital (Minimum Days of Coverage)
Raw Material-Local 30
Raw Material-Foreign 120
Factory Supplies in Stock 30
Spare Parts in Stock and Maintenance 30
Work in Progress 10
Finished Products 15
Accounts Receivable 30
Cash in Hand 30
Accounts Payable 30
8.2 Investment
The total investment cost of the project including working capital is estimated at Birr 5.82
million as shown in Table 5 below. The Owner shall contribute 40% of the finance in the form of
equity while the remaining 60% is to be financed by bank loan.
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8.3 Production Costs
The total production cost at full capacity operation is estimated at Birr 2.83 million as detailed in
Table 6 below.
I. Profitability
According to the projected income statement attached in the annex part the project will generate
profit beginning from the first year of operation. Ratios such as the percentage of net profit to
total sales, return on equity and return on total investment are 23.66 %, 17.75% and 38.38% in
the first year and are gradually rising. Furthermore, the income statement and other profitability
indicators show that the project is viable.
The breakeven point of the project is estimated by using income statement projection.
Accordingly, the project will break even at 36.34% of capacity utilization.
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III. Payback Period
Investment cost and income statement projection are used in estimating the project payback
period. The projects will payback fully the initial investment less working capital in third year.
For the envisaged plant the simple rate of return equals to 17.8%.
Based on cash flow statement described in the annex part, the calculated IRR of the project is
22.3% and the net present value at 18 % discount is Birr 870,493.26.
The envisaged plant is profitable even with considerable cost increment. That is the plant
maintains to be profitable starting from the first year when 10 % cost increment takes place in
the sector. This result is accompanied by IRR value of 22.82% with payback period of the first
quarter of the fourth year.
A. Profit Generation
The project is found to be financially viable and earns on average a profit of Birr 827,391 per
year and Birr 8.3 million within the project life. Such result induces the project promoters to
reinvest the profit which, therefore, increases the investment magnitude in the region.
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B. Tax Revenue
In the project life under consideration, the region will collect about Birr 3.06 million from
corporate tax payment alone (i.e. excluding income tax, sales tax and VAT). Such result create
additional fund for the regional government that will be used in expanding social and other basic
services in the region
Based on the projected figure we learn that in the project life an estimated amount of US Dollar
3.7 million will be saved as a result of the proposed project. This will create room for the saved
hard currency to be allocated on other vital and strategic sectors
The proposed project is expected to create employment opportunity to several citizens of the
region. That is, it will provide permanent employment to 46 professionals as well as support
stuffs. Consequently the project creates income of Birr 585,360 per year. This would be one of
the commendable accomplishments of the project.
The proposed project helps to diversify ANRS’ and Ethiopian economy. It contributes to
industrialization of the ANRS as well as the country as a whole. It also has a potential to
strengthen the linkage between the manufacturing and the trade sub-sectors.
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ANNEXES
13
Annex 1: Total Net Working Capital Requirements (in Birr)
CONSTRUCTION PRODUCTION
Year 1 Year 2 1 2 3 4
1
Annex 1: Total Net Working Capital Requirements (in Birr) (continued)
PRODUCTION
5 6 7 8 9 10
Spare Parts in Stock and Maintenance 16,289 16,289 16,289 16,289 16,289 16,289
TOTAL NET WORKING CAPITAL REQUIREMENTS 699,897 699,897 699,897 699,897 699,897 699,897
2
Annex 2: Cash Flow Statement (in Birr)
CONSTRUCTION PRODUCTION
Year 1 Year 2 1 2 3 4
TOTAL CASH INFLOW 2,563,207 3,263,103 3,563,509 3,841,855 3,780,000 3,780,000
1. Inflow Funds 2,563,207 3,263,103 350,509 61,855 0 0
Total Equity 1,025,283 1,305,241 0 0 0 0
Total Long Term Loan 1,537,924 1,957,862 0 0 0 0
Total Short Term Finances 0 0 350,509 61,855 0 0
2. Inflow Operation 0 0 3,213,000 3,780,000 3,780,000 3,780,000
Sales Revenue 0 0 3,213,000 3,780,000 3,780,000 3,780,000
Interest on Securities 0 0 0 0 0 0
3. Other Income 0 0 0 0 0 0
TOTAL CASH OUTFLOW 2,563,207 2,563,207 3,486,807 3,053,912 3,128,591 3,079,650
4. Increase In Fixed Assets 2,563,207 2,563,207 0 0 0 0
Fixed Investments 2,488,550 2,488,550 0 0 0 0
Pre-production Expenditures 74,657 74,657 0 0 0 0
5. Increase in Current Assets 0 0 945,421 166,839 0 0
6. Operating Costs 0 0 1,609,821 1,884,948 1,884,948 1,884,948
7. Corporate Tax Paid 0 0 0 0 311,433 332,408
8. Interest Paid 0 0 931,565 419,494 349,579 279,663
9.Loan Repayments 0 0 0 582,631 582,631 582,631
10.Dividends Paid 0 0 0 0 0 0
Surplus (Deficit) 0 699,897 76,702 787,943 651,409 700,350
Cumulative Cash Balance 0 699,897 776,598 1,564,541 2,215,950 2,916,301
3
Annex 2: Cash Flow Statement (in Birr): Continued
PRODUCTION
5 6 7 8 9 10
TOTAL CASH INFLOW 3,780,000 3,780,000 3,780,000 3,780,000 3,780,000 3,780,000
1. Inflow Funds 0 0 0 0 0 0
Total Equity 0 0 0 0 0 0
Total Long Term Loan 0 0 0 0 0 0
Total Short Term Finances 0 0 0 0 0 0
2. Inflow Operation 3,780,000 3,780,000 3,780,000 3,780,000 3,780,000 3,780,000
Sales Revenue 3,780,000 3,780,000 3,780,000 3,780,000 3,780,000 3,780,000
Interest on Securities 0 0 0 0 0 0
3. Other Income 0 0 0 0 0 0
TOTAL CASH OUTFLOW 3,030,709 2,990,726 2,941,785 2,310,213 2,310,213 2,310,213
4. Increase In Fixed Assets 0 0 0 0 0 0
Fixed Investments 0 0 0 0 0 0
Pre-production Expenditures 0 0 0 0 0 0
5. Increase in Current Assets 0 0 0 0 0 0
6. Operating Costs 1,884,948 1,884,948 1,884,948 1,884,948 1,884,948 1,884,948
7. Corporate Tax Paid 353,383 383,316 404,291 425,266 425,266 425,266
8. Interest Paid 209,747 139,831 69,916 0 0 0
9. Loan Repayments 582,631 582,631 582,631 0 0 0
10.Dividends Paid 0 0 0 0 0 0
Surplus (Deficit) 749,291 789,274 838,215 1,469,787 1,469,787 1,469,787
Cumulative Cash Balance 3,665,592 4,454,866 5,293,081 6,762,867 8,232,654 9,702,441
4
Annex 3: DISCOUNTED CASH FLOW-TOTAL CAPITAL INVESTED
CONSTRUCTION PRODUCTION
Year 1 Year 2 1 2 3 4
TOTAL CASH INFLOW 0 0 3,213,000 3,780,000 3,780,000 3,780,000
Interest on Securities 0 0 0 0 0 0
2. Other Income 0 0 0 0 0 0
CUMULATIVE NET CASH FLOW -2,563,207 -5,126,413 -4,118,146 -2,328,078 -744,459 818,185
Net Present Value (at 18%) -2,563,207 -2,172,209 724,122 1,089,491 816,813 683,046
Cumulative Net present Value -2,563,207 -4,735,415 -4,011,294 -2,921,803 -2,104,990 -1,421,944
5
PRODUCTION
5 6 7 8 9 10
TOTAL CASH INFLOW 3,780,000 3,780,000 3,780,000 3,780,000 3,780,000 3,780,000
Interest on Securities 0 0 0 0 0 0
2. Other Income 0 0 0 0 0 0
Fixed Investments 0 0 0 0 0 0
Pre-production Expenditures 0 0 0 0 0 0
CUMULATIVE NET CASH FLOW 2,359,855 3,871,591 5,362,352 6,832,139 8,301,926 9,771,712
Net Present Value (at 18%) 571,083 474,572 396,599 331,372 280,824 237,986
Cumulative Net present Value -850,861 -376,289 20,310 351,683 632,507 870,493
6
Annex 4: NET INCOME STATEMENT ( in Birr)
PRODUCTION
1 2 3 4 5
Capacity Utilization (%) 85% 100% 100% 100% 100%
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Annex 4: NET INCOME STATEMENT (in Birr): Continued
PRODUCTION
6 7 8 9 10
Capacity Utilization (%) 100% 100% 100% 100% 100%
8
Annex 5: Projected Balance Sheet (in Birr)
CONSTRUCTION PRODUCTION
Year 1 Year 2 1 2 3 4
TOTAL ASSETS 2,563,207 5,826,310 6,341,070 6,788,489 6,932,536 7,125,524
1. Total Current Assets 0 699,897 1,722,019 2,676,801 3,328,211 4,028,561
Inventory on Materials and Supplies 0 0 364,142 428,402 428,402 428,402
Work in Progress 0 0 56,028 65,916 65,916 65,916
Finished Products in Stock 0 0 112,057 131,832 131,832 131,832
Accounts Receivable 0 0 350,509 412,364 412,364 412,364
Cash in Hand 0 0 62,685 73,747 73,747 73,747
Cash Surplus, Finance Available 0 699,897 776,598 1,564,541 2,215,950 2,916,301
Securities 0 0 0 0 0 0
2. Total Fixed Assets, Net of Depreciation 2,563,207 5,126,413 4,619,050 4,111,688 3,604,325 3,096,963
Fixed Investment 0 2,488,550 4,977,100 4,977,100 4,977,100 4,977,100
Construction in Progress 2,488,550 2,488,550 0 0 0 0
Pre-Production Expenditure 74,657 149,313 149,313 149,313 149,313 149,313
Less Accumulated Depreciation 0 0 507,363 1,014,725 1,522,088 2,029,450
3. Accumulated Losses Brought Forward 0 0 0 0 0 0
4. Loss in Current Year 0 0 0 0 0 0
TOTAL LIABILITIES 2,563,207 5,826,310 6,341,070 6,788,489 6,932,536 7,125,524
5. Total Current Liabilities 0 0 350,509 412,364 412,364 412,364
Accounts Payable 0 0 350,509 412,364 412,364 412,364
Bank Overdraft 0 0 0 0 0 0
6. Total Long-term Debt 1,537,924 3,495,786 3,495,786 2,913,155 2,330,524 1,747,893
Loan A 1,537,924 3,495,786 3,495,786 2,913,155 2,330,524 1,747,893
Loan B 0 0 0 0 0 0
7. Total Equity Capital 1,025,283 2,330,524 2,330,524 2,330,524 2,330,524 2,330,524
Ordinary Capital 1,025,283 2,330,524 2,330,524 2,330,524 2,330,524 2,330,524
Preference Capital 0 0 0 0 0 0
Subsidies 0 0 0 0 0 0
8. Reserves, Retained Profits Brought Forward 0 0 0 164,251 1,132,447 1,859,124
9.Net Profit After Tax 0 0 164,251 968,195 726,678 775,619
Dividends Payable 0 0 0 0 0 0
Retained Profits 0 0 164,251 968,195 726,678 775,619
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Annex 5: Projected Balance Sheet (in Birr): Continued
PRODUCTION
5 6 7 8 9 10
TOTAL ASSETS 7,367,452 7,679,226 8,039,941 9,032,228 10,024,514 11,016,801
1. Total Current Assets 4,777,852 5,567,126 6,405,341 7,875,128 9,344,914 10,814,701
Inventory on Materials and Supplies 428,402 428,402 428,402 428,402 428,402 428,402
Work in Progress 65,916 65,916 65,916 65,916 65,916 65,916
Finished Products in Stock 131,832 131,832 131,832 131,832 131,832 131,832
Accounts Receivable 412,364 412,364 412,364 412,364 412,364 412,364
Cash in Hand 73,747 73,747 73,747 73,747 73,747 73,747
Cash Surplus, Finance Available 3,665,592 4,454,866 5,293,081 6,762,867 8,232,654 9,702,441
Securities 0 0 0 0 0 0
2. Total Fixed Assets, Net of Depreciation 2,589,600 2,112,100 1,634,600 1,157,100 679,600 202,100
Fixed Investment 4,977,100 4,977,100 4,977,100 4,977,100 4,977,100 4,977,100
Construction in Progress 0 0 0 0 0 0
Pre-Production Expenditure 149,313 149,313 149,313 149,313 149,313 149,313
Less Accumulated Depreciation 2,536,813 3,014,313 3,491,813 3,969,313 4,446,813 4,924,313
3. Accumulated Losses Brought Forward 0 0 0 0 0 0
4. Loss in Current Year 0 0 0 0 0 0
TOTAL LIABILITIES 7,367,452 7,679,226 8,039,941 9,032,228 10,024,514 11,016,801
5. Total Current Liabilities 412,364 412,364 412,364 412,364 412,364 412,364
Accounts Payable 412,364 412,364 412,364 412,364 412,364 412,364
Bank Overdraft 0 0 0 0 0 0
6. Total Long-term Debt 1,165,262 582,631 0 0 0 0
Loan A 1,165,262 582,631 0 0 0 0
Loan B 0 0 0 0 0 0
7. Total Equity Capital 2,330,524 2,330,524 2,330,524 2,330,524 2,330,524 2,330,524
Ordinary Capital 2,330,524 2,330,524 2,330,524 2,330,524 2,330,524 2,330,524
Preference Capital 0 0 0 0 0 0
Subsidies 0 0 0 0 0 0
8. Reserves, Retained Profits Brought Forward 2,634,743 3,459,303 4,353,708 5,297,053 6,289,340 7,281,627
9. Net Profit After Tax 824,560 894,405 943,346 992,287 992,287 992,287
Dividends Payable 0 0 0 0 0 0
Retained Profits 824,560 894,405 943,346 992,287 992,287 992,287
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