Beruflich Dokumente
Kultur Dokumente
Development (ASMED)
2
Project Overview
Afghan Economy & ASMED
Context:
• Afghanistan is a fast-growing economy (double digit average growth p.a. over the
past five years).
• SMEs constitute the bulk of Afghanistan’s companies:
- “Micro-enterprises: up to 10 employees and total assets or total annual revenues
of up to $100,000; small enterprises: up to 50 employees and total assets or
total revenues of up to $3 million, and medium enterprises: up to 300 employees
and total assets or total annual revenues of up to $15 million.” – IFC, Small and
Medium Business Development Department.
- The above definition contains a notion of scale appropriate to developing nations.
This project uses the IFC definition as a basic parameter, which should be
considered as a guideline and not an absolute measure.
• Potential for SME development in a variety of sectors.
5 components of ASMED:
PUBLIC -
BUSINESS BUSINESS
MARKET PRIVATE CAPACITY
DVPT. & MGT. ASSOCIATIONS
INFORMATION SECTOR BUILDING
SERVICES DVPT.
ALLIANCES
3
Project Overview
Objectives & Approach
Component 1 - Market Information:
MARKET COLLECTION
STUDIES AND AND DISSEM. BUILDING
IDENTIFICATION DEVELOPMENT
VALUE CHAIN OF MARKET MARKET
OF SECTORS STRATEGY
MAPPING INFORMATION LINKAGES
Approach:
• Detailed Sector Analysis: market study of demand, value chain mapping, key player
identification, sector dynamics, business environment, etc.
• Growth Potential and Strategy Formulation: SWOT analysis to assess growth potential
and formulation of a development strategy to promote SMEs in such sectors.
1: Milk and Yoghurt, Cashmere, Gemstones, Flour, Industrial Bread, Cakes and Candies.
2: Food Retail Distribution, Metalworking, Renewable Energy and4Energy Efficiency, Edible Vegetable Oil.
Project Overview
Sector Selection - Phase 2
■ Criteria for sector selection included among others: existence of initial production capacity,
potential for future growth, presence of a comparative advantage, value-adding
activities, potential for SME development and job creation, pro-poor/“bottom of the
pyramid” dimension.
Food Retail Distribution: Potential to build upon existing retail distribution and local
production in a view to provide better access to low-cost, reliable quality consumer
products in main cities as well as in remote areas of the country.
Edible Vegetable Oil: Coupling a high demand for vegetable edible oil products and
an existing oil production industry, this sector offers import substitution
opportunities based upon locally-cultivated, and locally-produced vegetable oils.
5
Project Overview
Research Approach
320 qualitative interviews have been conducted along with 8 in-depth sector analyses.
Literature research of ~400 secondary sources of information (E.g.: reports, websites)
was also led.
Renewable Energy
Food Retail
Metalworking and Energy Edible Vegetable Oil
Distribution
Efficiency
Core Tools Used:
SME Interviews 55 61 29 35
Key Informant
25 27 50 38
Interviews
Kabul, Parwan,
Kabul, Balkh, Kabul, Balkh, Kabul, Balkh,
Provinces Nangarhar, Bamyan,
Nangarhar, Herat, Nangarhar, Herat, Nangarhar, Herat,
Covered Badakhshan,
Kandahar Kandahar Kandahar, Kunduz
Kandahar
Specific Tools Used:
Quantitative
x - x x
Demand Survey
Oil Consumer
Solar Lantern and
Retail Shop Mapping Preferences Testing
Solar Cooker
(7 provinces) Country case study (Kabul, Mazar)
Other Product Testing
Country case study (Pakistan) Oil Press Product
(Kabul), BSH Plant
(India) Testing
Oil Stove study
(Balkh rural areas)
6
METALWORKING
Project Overview
Sector Overview
Farm Machinery
Rickshaws
Water Turbines
Reinforcement Bars
Bibliography
Units and Acronyms
7
Sector Overview
A Key for Economic Development
Motorcycle
production line,
Workers building Herat. A production
roof trusses, Herat. line is a particular
The job shop model, type of flow shop
employed here, is
ideal for building
specialized parts
Micro-hydro installation
1:
Armenia, Azerbaijan, Belarus, Georgia, Kazakhstan, Kyrgyzstan, in Bamyan
Moldova, Russia, Tajikistan, Ukraine, Uzbekistan and Turkmenistan. 11
METALWORKING
Project Overview
Sector Overview
Farm Machinery
Rickshaws
Water Turbines
Reinforcement Bars
Bibliography
Units and Acronyms
12
Farm Machinery
Sub-sector Overview
Farm machinery is defined as “tractor-powered agricultural tools”.
Starting from a low total of 840 tractors in Afghanistan in 20001, official imports from
Pakistan, Iran and Belarus now alone account for between 800 and 1,200 additional
units per year. Unofficial, third party imports are thought to be much higher.
The farm machinery sector is dependent on Afghanistan’s growing and mechanizing
agricultural sector. Cereal production and other non-fruit crops, the easiest sectors to mechanize,
account for 30% of Afghanistan’s legal GDP2 and are increasing (10% growth between 2004 and
2005), which indicates that demand for farm machinery is bound to follow the same trend.
An FAO study estimates that only 32% of farms had access to tractor power in 20033 which
confirms the growth potential of this sub-sector.
26%
1: www.fao.org.
32%
2: CSO, GDP Data, 1384 (2005-2006).
3: FAO Survey of the Horticulture Sector, 2003.
13
Farm Machinery
Product Categories
The nascent Afghan farm machinery sector accounts for $2 Mn of an increasing market
that is worth up to $20+ Mn overall (if imports are included). Retail prices vary significantly
according to location as transportation costs of finished goods are very high.
Total Market Low High Wholesale Price of plow or cultivator In Mazar, both Afghan
Value/Year Estimate Estimate Price/Unit in Mazar, Taluqan and and Pakistani wheat
of: Kunduz is variable, but threshers cost $3,000.
Wheat $2 Mn $6 Mn $2,500
averages $500 if imported In Taluqan and
Threshers
and $400 if Afghan. Kunduz, where only
Others1 $5 Mn $14 Mn Variable imported threshers are
Iranian wheat thresher sold, the price is
Total $7 Mn $20 Mn N/A in Herat costs $1,400. $3,200.
Iranian plows and
cultivators cost from
Note: Wholesale prices are used due to the variability of North-
$360 to $520.
retail prices. North
North
North-East
East
East
East
Units per Year Afghan Imports Total Center
West-Central Kabul
West
West
Wheat 130 700 – 830 – South
South
Contract:
Millat and Al Ghazi contract
Millat builds most Massey-Ferguson with other companies to
tractors sold in Pakistan. It builds ~30,000 manufacture items that are not C
tractors a year. The company is not directly part of tractors, such as u
active in the Afghan market, though its cultivators. These smaller s
companies also have the right t
products enter Afghanistan through
to market their own products. o
middlemen.
m Massey Ferguson tractors
Al Ghazi manufactures Fiat – New Holland e built by Millat, in front of
tractors in Pakistan under license. It r Millat’s Lahore factory
produces more than 26,000 tractors a year. Manufacturers s
Al Ghazi has offices in Afghanistan, in part on Contract
due to its cooperation with an agricultural
mechanization program run by UNIDO and
DACAAR.
18
Farm Machinery
Description of Retailers
Afghan farm machinery is only distributed in the eastern and northern economic
centers of the country.
Pakistani companies, primarily Batala, are the only companies to have completely
overcome the obstacles of geography in the highly atomized Afghan market. Farm
implements of Iranian and CIS are only strong with retailers near those borders, though they can
sometimes be found with retailers in other parts of the country.
Wheat threshers, plows and
cultivators are the most
North-East common products offered by
North
farm implement retailers. Other
East
items include rice and harvesters
West-Central and farm trailers. Corn threshers are
primarily sold in the south.
West
South
Dealer imports have helped
Pakistani products dominate
the Afghan market with the
South-West Manufacturers of farm machinery exception of Herat, where Iranian
goods dominate.
Afghan farm machinery sold
Afghan farm machinery not sold Nearly all implement retailers in
Pakistani farm machinery sold
Afghanistan sell imported farm
machinery, whereas only retailers
Iranian farm machinery sold
in the eastern half of the country
CIS farm machinery sold carry Afghan farm machinery.
19
Farm Machinery
Marketing Opportunities
There is an opportunity for Afghan machinery to expand its market share as the
reputation between Afghan machinery and imported machinery in general is comparable, and its
equal or lower price compared with imported machinery gives it a comparative advantage.
Lack of Nearly all the respondents who did Factory-to-Retailer Price of Batala
Awareness not know about the quality of and Jawed Afghan Threshers ($)
Afghan farm machinery did not 3,000
Standardized
Truck
Trailers
Small
Windows
Simple Complex
Man painting machine parts in Truck
Lahore’s farm machinery cluster Boxes
Large Water
Windows Turbines
Infra-
structure
Projects
Specialized
21
Farm Machinery
SWOT Analysis
Strengths Weaknesses
Afghanistan’s agricultural sector is mechanizing. The average size of farms in Afghanistan is very
small, making it uneconomical for many farmers to
Afghan products have a comparative advantage over
possess their own machines.
imports in both price and quality.
Farm machinery producers do not receive payment
There is a nascent but assertive group of farm
for their products until the retailer sells them,
machinery producers on which to build a more
causing financial difficulties.
advanced and capable cluster.
Afghanistan lacks the assertive governmental
Afghan producers primarily use steel from CIS
support for the agricultural industry that is found in
countries, considered to be of higher quality than
countries such as Pakistan.
Pakistani steel.
Opportunities Threats
Potential customers can be assisted with the Heavy dependence on imported materials,
financing of their machines via either leasing or more especially the CIS steel prized by buyers, leaves the
standard small business loans. Afghan industry dependent on raw material
fluctuations.
The western half of Afghanistan is a potentially new
market for Afghan machinery, if a means to Anything agricultural is heavily dependent on the
overcome production capacity issues and high success or failure of crop production. Afghanistan’s
transportation costs is found. frequent climate difficulties can have a concrete
effect on farm machinery producers.
Contracting and licensing agreements would allow to
increase the output of Afghan producers, while
potentially transferring skills and technologies to
Afghanistan.
22
Farm Machinery
Strategic Objectives
23
Farm Machinery
Strategic Objectives (1/2)
Strategic Objective 1: Facilitate for producers the overcoming of obstacles to
growth.
• Provide Global Development Alliances (GDAs) to producers seeking to upscale their
productive machinery, both in terms of quantity and quality.
• Provide technical and financial assistance to companies willing to contract the
assembly of machinery parts in other parts of Afghanistan such as Herat, (E.g.: Mohamed
Daoud & Sons Co.), so full machines could be assembled there avoiding transport issues.
• Facilitate through funding mechanisms the movement of farm machinery producers to
larger, more appropriate facilities in the Jalalabad industrial park, for instance.
• Support Afghan farm machinery producers in better communicating on their products in
the various key economic centers of Afghanistan.
• Organize trip to Pakistan for machinery producers to visit farms, manufacturers and
research institutes, with the goal of providing awareness of new developments in machinery.
26
Rickshaws
Sub-sector Overview
Motorized rickshaws are an affordable and common means of transportation. Most are
second-hand imported rickshaws or are assembled from imported parts, but Afghanistan has
demonstrated the potential to manufacture them.
There may be as many as 12,500 rickshaws now in Afghanistan, worth up to $12 Mn
brand new. The number of motorized rickshaws in Afghanistan has been increasing in the past
several years1. This resulted in more than 6,000 direct employments created in the past two years.
Rickshaws in Afghanistan2
Projection Documented
14,000
12,000
10,000
8,000
6,000
4,000
2,000
0
2002/03 2003/04 2004/05 2005/06 2006/07
28
Rickshaws
Marketing Chain
The Afghan rickshaw market is mainly composed of Pakistani rickshaws near the
Pakistani border and Afghan rickshaws elsewhere in the country. Herati rickshaw producers
have an Afghan-wide distribution network, whereas Jalalabad’s producer, Ahmadzai, sells only
directly to local customers.
Imports of rickshaws are dropping
due to 16% import duties1. Used
Afghan Producers Pakistani Producers
imports are repaired and resold. Still,
almost all rickshaws in Afghanistan are
either imports or assembled from
imported parts.
Retailers/ Importers/ Imports of Pakistani rickshaws into
Wholesalers Retailers Jalalabad have been banned due to
the noise and pollution of their 2-
~5% ~95%
stroke engines. Jalalabad dealers are
currently refurbishing old models, but this
Retailers Retailers situation creates important marketing
opportunities for Afghan rickshaws.
Zarang is making inroads into the
Kandahar market, having built between
Rickshaw Buyers 15% and 25% of the rickshaws in use
within the city.
Many retailers function as
Retailers of imported and Afghan rickshaws either
wholesalers, selling a small percentage
have small operations or are also automobile
of their inventory to other retailers in
retailers. Sales are between 2 and 4 rickshaws per month.
other provinces.
29 1: Ministry of Finance.
Rickshaws
Producers, Diversification & Size
There are only 4 major producers of rickshaws in Afghanistan. Three producers from Herat
account for the majority of production, but one producer in Jalalabad is responsible for the most
innovative product (Ahmadzai’s Ahoo).
1,345 515
500 200
0 0
Raw Cost of Labor Others Producer Final Raw Cost of Labor Others Producer Final Price
Material Machines Margin Price Material Machines Margin
31
Rickshaws
Demand in Urban Centers
Rickshaws are especially common in Jalalabad, Kandahar and Herat, but are also found
in limited numbers in Mazar-e-Sharif and Kabul.
Mazar-e-Sharif
North-East
North
Kabul
East
Herat West-Central
Jalalabad
West The Zarang and similar offerings by Al Akhtar
South and Afghan Ariana are ubiquitous in Herat
Kandahar
Urban area with high use of rickshaws
South-West Urban area with low use of rickshaws
The value chain at the right is for a driver leasing a Value Chain of Rented Rickshaw
rickshaw at a daily rate of 120 PKR ($2). The driver is ($/Month)
responsible for all expenses. 400
Standardized
Truck
Trailers
Small
Windows
Simple Complex Rickshaws
Truck
Boxes
34
Rickshaws
SWOT Analysis
Strengths Weaknesses
Rickshaws are becoming a common form of Colder cities, such as Kabul, are difficult markets for
transportation in some of the main cities of rickshaws.
Afghanistan, where their low cost and small size
The cost of transport in an east-west direction
make them easy to purchase and use as taxis.
makes it challenging to sell rickshaws in other parts
Rickshaw production does not require a large factory of the country, far away from production sites.
but still allows the development of vehicle production
Poor road conditions in most parts of the country
within Afghanistan.
(including urban centers) limit market growth of
Local markets are protected given the high rickshaw transportation.
transportation costs of finished goods.
Opportunities Threats
Employment generation opportunities as a reviving Noise and pollution from rickshaws is under scrutiny
Afghan economy means demand for transportation from Afghan authorities (E.g.: Jalalabad). Broadly
of goods and individuals is increasing. written regulations could lessen demand for Afghan
rickshaws.
By ramping up production, thereby reducing labor
and machinery costs on a per-unit basis, Afghan Market entry by more inexpensive Pakistani or
companies can manufacture more competitive Chinese models such as the Qing Qi could
products. undermine the basic offerings by Herati producers.
The purchase and maintenance costs, as well as the The entry of small cars, as are currently being
low fuel consumption, mean that rickshaws can be developed and sold in India, could pull away
marketed beyond taxi drivers to small businesses as demand for higher-end rickshaws, such as the
a means of delivery and transport. Ahoo.
35
Rickshaws
Strategic Objectives
36
Rickshaws
Strategic Objectives (1/2)
Strategic Objective 1: Assist Herati companies (Zarang, Al Akhtar and Afghan
Ariana) in scaling up their production and increasing their use of Afghan parts.
• Arrange specific technical assistance for the process of producing the constituent
parts of rickshaws, such as frames, handlebars, gas tanks and steering mechanisms, as well
as the process of configuring such production.
• Facilitate grants/loans to each rickshaw manufacturer for the purchase of machinery
necessary for the manufacture of the constituent parts of a rickshaw.
37
Rickshaws
Strategic Objectives (2/2)
Strategic Objective 3: Provide help to Afghan rickshaw companies in expanding
retail presence into untapped markets (E.g.: Jalalabad, Kandahar, etc.).
• Support penetration of new markets by assisting in negotiations with local retailers
for the latter to distribute Afghan products locally.
• Arrange negotiations between retailers and Afghan rickshaw manufacturers to allay
doubts regarding the sales of Afghan products (E.g.: arranging a limited buyback guarantee for
unsold inventory).
• Assist in the elaboration of marketing campaigns and set up product demonstrations
in areas where rickshaw drivers usually congregate.
• Arrange small-scale loans with partner micro-finance institutions for the purchase of
inventory for retailers selling Afghan rickshaws for the first time.
• Establish dealer financing programs in conjunction with financial institutions whereby they
can utilize ASMED resources to provide loans through rickshaw dealers to drivers who wish to
finance the purchase of their own vehicle.
Rickshaw driver,
Jalalabad
38
METALWORKING
Project Overview
Sector Overview
Farm Machinery
Rickshaws
Water Turbines
Reinforcement Bars
Bibliography
Units and Acronyms
39
Water Turbines
Processing Chain
Turbine manufacturing is one of the key elements for the development of the micro-
hydro power (MHP) industry, one of the most promising sources of energy to provide access
to electricity to communities living in rural areas with no access to the public grid1.
Turbine manufacturing is a skills-based industry which requires very specific expertise to
assess output potential of a stream (kW) and produce customized equipment adapted to the micro-
hydro power site environment.
turbine
This producer mainly sells turbines for micro-hydro projects developed by AKF for the NSP in
Bamyan (70% of his activity).
Sales: 6 turbines/month (HKT, T-7 and M-10 models). Yearly sales: $98,400. Number of employees: 7.
Raw materials represent 65% of the turbine’s final price. Net profit margin is 5%.
1,200 64
33 10
109
1,000
200
800
600 1,200
400 784
200
0
Raw Labor Energy Shop rent Machinery Net profit Sales price
materials
(incl.
transport.) 45
Water Turbines
Local Turbine Manufacturers (3/3)
Pervaiz Amidi Workshop, Kabul
This producer mainly sells turbines for micro-hydro projects developed by the National
Solidarity Program in the northern provinces (70% of his activity).
Sales: 20 turbines/month (5 TMT, 15 HKT). Yearly sales: $216,000. Number of employees: 18
Raw materials represent 70% of the turbine’s final price. Net profit margin is 11%.
Due to a large production, this manufacturer manages to have economies of scale and
increase his net profit margin.
200 416
100
0
Raw Labor Energy Shop rent Machinery Net profit Sales price
materials
(incl.
transport.) 46
Water Turbines
Demand
It is estimated that there are around 1,000 micro
and mini-hydro power plants around the Hydro power potential: Main locations
country1, collectively generating around 15 MW2.
75% to 80% of the units are below 10 kW, Mazar
17-18% are between 10 kW and 50 kW and 2-3%
are over 50 kW1.
The potential for micro-hydro power units in
Afghanistan is estimated to be 5,000 additional Jalalabad
units (~75 MW)1. This would represent a $15 Mn
to $30 Mn market for turbine
manufacturers2.
Hydro power potential is mainly located in Kandahar
the northern regions of the country: Amu
Darya watershed (Parwan, Kapisa, Panjshir),
Kokcha watershed (Badakhshan) and Kabul
watershed (Kabul, Nangarhar)3.
The plants currently operating are mainly
providing electricity for lighting Afghan
households since most of them have a very low
capacity.
1: Remote Hydro Light Company, Kabul, 2007.
2: For project development costs between $1,000 and $2,000 per kW and a
turbine cost equivalent to 20% of the project costs. Micro-hydro power plant in Jabulsaraj
3: Asian Development Bank, 2005. (Parwan)
47
Water Turbines
SWOT Analysis
Strengths Weaknesses
■ Existing local turbine manufacturing industry which ■ Turbine manufacturing activities are concentrated in
is able to provide equipment for the development and around Kabul (Parwan). Due to high transportation
of micro-hydro power projects adapted to the costs, imported turbines are sometimes better options
country’s needs. in some areas (E.g.: Pakistani and Chinese turbines in
Badakhshan).
■ Most turbines locally produced are below 25 kW
which corresponds to the majority of market ■ Limited capacity to produce turbines >25 kW.
needs.
■ No possibility to test the locally-produced turbines and
■ Technical support provided by international micro- thus to offer customers guaranteed performance
hydro power experts working on the improvement levels.
of local production standards.
■ Dependence on imported raw materials with
fluctuating prices.
Opportunities Threats
■ High need for improved access to electricity in ■ Competition from neighboring countries which are also
rural areas. developing their micro-hydro power sector at a large
scale and have built up a competitive turbine
■ Afghanistan hosts an important micro-hydro power
manufacturing industry (India, Nepal, Pakistan).
development potential.
■ Competition from local generalist metal workshops
■ Numerous international agencies, along with the
with no expertise in the turbine sector which can
Government, support the development of the
discredit the whole local turbine manufacturing
micro-hydro power sector (NSP, NABDP, PRT,
industry, selling bad quality equipment to project
GTZ) and are keen on increasing the domestic
developers.
content of projects.
48
Water Turbines
Strategic Objectives
The strategy proposed to develop the water turbine manufacturing sector is based
on 3 main objectives:
Domestically-
produced
water turbine,
Bamyan
49
Water Turbines
Strategic Objective 1
Strategic Objective 1: Support the efforts made to upgrade the standards of
domestically-produced turbines.
• Contribute to the definition of quality standards, adapted to the Afghan context.
– A certification, based on regular quality checks, would be granted
to companies complying with standards defined by the Afghan
Electrical Engineer Association (AEEA), in cooperation with
the Ministries of Water and Energy (MEW) and Rural Rehabilitation
and Development (MRRD) and other actors of the sector like
Remote Hydro Light, Engineering Associates, etc.
The AEEA has recently been set up and has submitted a grant Afghan Quality
request to ASMED in order to structure and expand the association. Turbine
They should become one of the main actors working on the standardization Certification
of the sector.
– A testing facility should also be set up to be able to guarantee turbine performance
levels.
• Build capacity of domestic manufacturers to help them improve the quality of their
production and reach standards set up for this industry in Afghanistan.
– The AEEA should accompany turbine producers in complying with these standards
(E.g.: organize trainings on quality processes, share information on spare parts suppliers, etc.).
– The improvement of production standards should also focus on the capacity of local
manufacturers to produce larger turbines (>25 kW).
50
Water Turbines
Strategic Objective 2
Strategic Objective 2: Promote the creation of manufacturing units in provinces
with high micro-hydro potential but no current local turbine production.
• Expand training programs on high quality standard turbine manufacturing to other
provinces (Nangarhar, Badakhshan, etc.).
– A GDA could be set up with IAM as well as AKF who are willing to train local metal
workers to be able to procure the equipment needed for the manufacturing of their own
turbines locally (E.g.: in Badakhshan) and manufacture high-quality units in their respective
provinces.
– The development of local turbine manufacturing industries would support the development
of the micro-hydro power sector in provinces with hydro power potential.
51
Water Turbines
Strategic Objective 3
Strategic Objective 3: Craft a communication strategy to promote local turbine
manufacturers.
• Support the development by the Afghanistan Energy Information Center (AEIC)1 of
a website similar to the Procurement Directory2. A description of product range
offered by each company would be useful to international agencies seeking to procure
engineering expertise to design micro-hydro projects.
• Make this information available at the offices of the Department of MEW and
MRRD in the provincial centers, for local customers willing to set up their own micro-
hydro power plant.
• Invite local turbine manufacturers to energy fairs (E.g.: WEPEX, Water, Energy and
Power Exhibition) as a way to advertise their products and promote the micro-hydro
power sector.
53
Reinforcement Bars
Sub-sector Overview
Construction will account for between $4 Bn and $4.5 Bn in 20071. The high usage of
concrete in Afghanistan’s construction boom is fuelling the importation of large quantities of
reinforcement bars (rebar).
Scrap is melted in The scrap is molded When a billet is used The billet is passed Large shears cut the
furnaces to a into a billet that as a raw material, it through a series of rebar to the desired
temperature of at feeds directly into should be heated to machines with length. The rebar is
least 1,538º C the rolling stands 900º C (1,620º F) in grooved rollers bundled with other
(2,800º F)1. High while still hot. a furnace2. The fuel known as “stands” rebar to be
carbon scrap, such source is oil (old that progressively transported to the
as cast iron or some motor oil in shape the billet into buyer.
armored vehicles is Afghanistan). a cylindrical, ridged
not suitable for bar, or rebar.
rebar. Billet
Rebar is
Scrap Metal is Billet is Billet is Billet is
Cut and
Baking
Melted Produced Heated Rolled
Bundled
Overview
Description The value chain on the left is for a theoretical Pakistani plant of the same size as
the Toulid-e-Shoeb Sobhan mill under construction in Kabul, producing the type
of rebar currently being sold in Afghanistan. The chain on the right is for the Abdurahman
Baba mill currently operating in Kandahar.
High Energy Costs The process of rolling reinforcement bars involves heating steel billets, then running them
through “stands” that roll them into rebar. The heating and rolling are both energy
intensive processes. The Kandahar plant produces its own billets.
1: Rebar would have a factory wholesale price of $688 in Kabul. 58 Note: Transport costs are included in raw material costs.
Reinforcement Bars
Projected Value Chain, Kabul Mill
Reinforcement bar manufacturing is a relatively capital-intensive industry (~$500,000
initial investment), but the high volumes produced reduce the proportion of fixed costs to
minimal levels. Energy and transport costs are the major expenses after raw materials.
The value chain below is based on a capacity of 25 MT of daily output. The price per MT
will be $670, to be the lowest-priced high-quality product on the market.
This new mill should be more efficient than the theoretical Pakistani one, and will not
produce its own billets. Its production costs are projected to be $49 more per MT, but its transport
costs will be $84 less per MT (price of Kabul-Lahore round trip of 1 MT of Kazakh steel), therefore
the Kabul mill will be able to sell rebar in Kabul at a lower price than Pakistani rebar.
7 25
600 55
123
3
400 117
670
200 340
0
Raw Material Transport & Machines & Energy Labor Others Producer Final Price
Customs Factory Margin
59
Reinforcement Bars
Importers and Retailers
Steel importation for the Afghan wholesale and retail market is based on a few
companies, of which Rahim Gardezy Co. is the largest by far. Importers focus more on rebar
of a CIS origin, as can be seen by the number of importers in Mazar-e-Sharif.
Importers:
• The largest steel importer in Afghanistan is Rahim Gardezy (Kabul), with around
200,000 MT of steel being imported annually. He is the only major importer to specialize
exclusively in metals.
• Other large importers include the Barakat and Brotheran Safi companies. All are
national companies that are importing metal primarily through their Mazar-e-Sharif offices. The
second tier of metal importing companies combined account for up to 50,000 MT of metal
imports to Afghanistan.
• There is a recently enacted 25% regulatory duty on steel products leaving Pakistan1,
but its unclear enforcement causes confusion amongst traders. This, and the better quality of CIS
products, encourages importers to import fewer Pakistani steel products.
Retailers:
• There are numerous retailers selling small quantities of rebar along with other steel.
Many import small quantities directly from neighboring countries.
• Retailers cluster together with other retailers selling the same products, often selling
out of small shop fronts or cargo containers. They usually sell a variety of rebar, beams and
profile steel.
1: SRO. 482 (I)/2007. Revision to Customs Act, 1969, Pakistan.
60
Reinforcement Bars
Contractors and Donors
Most construction projects are funded by international donor agencies which request
that their contractors respect international standards.
Contractors:
• Large donor-funded projects rely on international construction companies which
bypass Afghan businesses in their procurement altogether (E.g.: Contrack
International).
• Afghan contractors use the material specifications of their clients, for both public and
private sector clients, and those implementing projects for international donors comply with
standards.
• Private projects involving Afghan planning and implementation often use informal
contractors or none at all (E.g.: using engineers for the design, then informally hiring
workers).
Donors:
• Construction in Afghanistan is donor-driven, with only an estimated 13% of the
sector based on private investment. The market for rebar not meeting international
standards is at best between $40 Mn and $55 Mn annually.
• The US Army Corps of Engineers (53% of the construction in Afghanistan by value) and
USAID (13% of construction in Afghanistan) are the two largest donors for construction
projects.
• Standards (E.g.: ASTM) are not used or understood by all local contractors, but are
important for international donors.
61
Reinforcement Bars
SWOT Analysis
Strengths Weaknesses
Rebar is an integral part of modern concrete The rolling industry is dependent on imported
construction which represents a significant market in billets due to the lack of Afghan steel processing.
today’s Afghanistan.
There is little Afghan experience in steel rolling.
Afghanistan borders the CIS, providing a source of Foreign knowledge is the source of industry growth,
high-quality raw materials. and probably for another several years.
Given the high costs of transportation of finished The market for rebar not meeting standards is
products, Afghan production has a comparative limited due to the prevalence of donor-funded
advantage over its foreign competitors. projects.
With technical assistance, rebar sub-sector is ready Capital-intensive industry which is a significant
for knowledge transfer to other sub-sectors. barrier to entry for potential Afghan producers.
Opportunities Threats
Afghan rebar production has room to grow from its Supply shortage from CIS countries would require
low base in the booming construction market. the use of steel from Pakistan or other countries,
damaging the reputation of a product whose
The development of an Afghan rebar manufacturing
reputation is in part based on the source of its raw
capacity is by its nature also a development of other
materials.
rolling capacities (E.g.: angle iron, profile steel, etc.).
When the military and security infrastructure of
The growth of Afghan steel rolling may be the
Afghanistan, such as bases and police stations, will
impetus needed to revive the Afghan mining sector.
be completed, the market will lose its largest
The increased use of CIS steel will enhance the source of funding.
reputation of Afghan rebar.
62
Reinforcement Bars
Strategic Objectives
The strategy proposed to develop the rebar sub-sector is based on 3 main objectives:
A rebar
structure
ready for
the pouring
of concrete
63
Reinforcement Bars
Strategic Objectives (1/2)
Strategic Objective 1: Increase the amount and quality of rebar produced in
Afghanistan.
• Arrange partnerships with financial institutions to provide loans or offer grants to
assist:
- Toulid-e-Shoeb Sobhan upgrade or add to its machinery to increase its production capacity
and range of products quickly.
- Abdurahman Baba Mill expand its activity by modernizing its productive machinery.
• Arrange financial support, including for at least 2 years of risk insurance (E.g.: with
MIGA) for foreign companies willing to open re-rolling mills in Afghanistan.
Companies producing rebar meeting international standards should be priorities once Afghan
producers gain a foothold in the market.
Strategic Objective 2: Increase the use of Afghan rebar in private and donor-
funded projects as Afghan rebar production increases.
• Assist Afghan rebar companies in effectively marketing their products to contractors
and their clients in the private sector. Specify “Afghan rebar encouraged” where possible in
USAID projects.
• Organize negotiations between rebar manufacturers in Afghanistan and
international donors to increase the use of Afghan rebar in other donor-funded projects.
64
Reinforcement Bars
Strategic Objectives (2/2)
Strategic Objective 3: Lobby for the establishment of internationally-recognized
standards for construction materials and ready Afghan access to laboratories to
test for adherence to them.
• Encourage the prioritization of standards such as the ones developed by ISO
(International Organization for Standardization) or ASTM as a focal point of Afghan
regulations developed in cooperation with the Afghanistan National Standard Authority.
• Organize awareness workshops and trainings about materials standards through
ASMED’s Business Development Centers (make participation in this program a requisite part of
receiving ASMED support).
- For construction material buyers: provide information on why standards exist, how they are
established and how to understand the markings on materials by communicating to which
standards they adhere.
- For construction material manufacturers: provide information on why standards exist and
how to implement them in the manufacturing process. A GDA with the Afghan Builders’
Association (ABA) should be considered as the ABA could play a leading role in accompanying
companies towards compliance with these standards.
• Initiate the creation of a laboratory in Afghanistan to test samples of Afghan products
for compliance with established standards.
65
Metalworking
Summary of Key Recommendations
Upgrade technology: Stimulate growth:
Support efforts to improve the Create linkages between
technical capacity of the Afghan companies both within
metalworking sector, via better Afghanistan and
access to productive technology between Afghan and
and quality facilities. foreign companies to
increase production
volumes and
Stimulate national knowledge transfers.
expansion: Main
recommendations
Assist key leaders in the for development
industry in expanding of Metalworking
their production and sector
distribution outreach to Improve access to
other untapped finance:
provinces of the
country. Encourage the growth of
the metalworking
sector through the use
Promote standardization: of financial
Support the creation of instruments, targeting
standards and accompany both producers and
Afghan companies customers.
towards compliance with
such standards.
66
METALWORKING
Project Overview
Sector Overview
Farm Machinery
Rickshaws
Water Turbines
Reinforcement Bars
Bibliography
Units and Acronyms
67
Bibliography
Reports and Websites (1/3)
Abbas, A., A Case Study on SMEDA Pakistan, n.d.
Albu, M., Technological Learning and Innovation in Industrial Clusters in the South, Masters Thesis, University of
Sussex, September 1997.
American Iron and Steel Institute, Auto Steel Partnership, Automotive Steel Design Manual, Chapter 2.4, August 2002.
Cleaner Production Program, Cleaner Production Opportunities: Steel Melting Sector in Pakistan, www.cpp.org.pk,
2001.
Commodity Price Bulleting Update, United Nations Conference on Trade and Development, July 2007.
Customs Act, 1969 and Rules, Significant Amendments, KPMG, 2007.
Davies, T., Enhancing Competitiveness in the Manufacturing Sector: Key Opportunities Provided by Inter Firm
Clustering, Competitiveness Review, June 2001.
Engineering Development Board, Government of Pakistan, Road Freight Strategy Paper, April 2006.
Engineers Without Borders, Concrete Mixes Guideline, Draft, 2005.
FAO, Afghanistan: Survey of the Horticulture Sector, 2003.
Humphrey, J., Opportunities for SMEs in Developing Countries to Upgrade in a Global Economy, ILO’s In Focus
Programme on Small Enterprise Development. December 2001.
International Monetary Fund, Islamic Republic of Afghanistan: Selected Issues and Statistical Appendix. IMF Country
Report No. 06/114, March 2006.
Khawaja, S., Unleashing the Potential of the SME Sector with a Focus on Productivity Improvements, Pakistan
Development Forum, 2006.
Lahore Chamber of Commerce & Industry, Steel Industry in Pakistan, n.d.
68
Bibliography
Reports and Websites (2/3)
Lister, S., Karaev, Z., Understanding Markets in Afghanistan: A Case Study of the Market in Construction Materials,
AREU, June 2004.
Mead, D.C., Linkages within the Private Sector: A Review of Current Thinking, FIT Program of the International Labor
Organization, March 1994.
Nadvi, K., Facing the New Competition: Business Associations in Developing Country Industrial Clusters, International
Institute of Labor Studies, 1999.
Rey, J.A., Global Market / Macroeconomic Situation, presented at the 57th Irepas Meeting, Warsaw, Poland,
September 9th to 11th, 2007.
Romijn, H., Technology Support for Small Industries in Developing Countries: From ‘Supply Push’ to ‘Eightfold-C,’
Development Studies Working Papers, Centro Studi Luca D’Agliano, June 1999.
Schmitz, H., Collective Efficiency: Growth Path for Small-Scale Industry, Journal of Development Studies, April 1995.
Schmitz, H., Collective Efficiency and Increasing Returns, IDS Working Paper 50, March 1997.
Schmitz, H., Lessons from the JICA Project ‘Strengthening the Capacity of SME Clusters in Indonesia’ , Report
Prepared for KRI International Corp, June 2003.
Singh, B., Kaushik, S.K., Influence of Steel-Making Processes on the Quality of Reinforcement, The Indian Concrete
Journal, July 2002.
SMEDA, Cluster Diagnostic Study: Auto Parts Cluster, n.d.
Steelworker, Volume 02, Chapter 7, Nonresident Training Course, US Navy, 1996.
Tanburn, J. et al., Strengthening Informal Sector Networks in Kenya Through Exchange Visits, FIT Synthesis Paper,
March 1995.
69
Bibliography
Reports and Websites (3/3)
Tambunan, T., Development of Small-and Medium-Scale Industry Clusters in Indonesia, Kadin Indonesia, Indonesian
Chamber of Commerce and Industry, n.d.
Tambunan, T., Promoting Small and Medium Enterprises with a Clustering Approach: A Policy Experience from
Indonesia, Journal of Small Business Management, April 2005.
Tewari, M., Intersectoral Linkages and the Role of the State in Shaping the Conditions of Industrial Accumulation: A
Study of Ludhiana’s Manufacturing Industry, World Development, 1998.
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Web Sites:
www.meps.co.uk
www.lme.co.uk
70
METALWORKING
Project Overview
Sector Overview
Farm Machinery
Rickshaws
Water Turbines
Reinforcement Bars
Bibliography
Units and Acronyms
71
Units & Acronyms (1/2)
ABA – Afghan Builders’ Association IFC – International Financial Corporation
ADB – Asian Development Bank IMF – International Monetary Fund
AEEA – Afghanistan Electrical Engineer Association ISO – International Organization for Standardization
AEIC – Afghanistan Energy Information Center KII – Key Informant Interview
AEP – Ansary Engineering Products and Services MEW – Ministry of Energy and Water
AFMI – Afghan Farm Machinery Institute MHP – Micro-hydro Power
AKF – Aga Khan Foundation MIGA – Multilateral Investment Guarantee Agency (World
Bank)
ASMED – Afghanistan Small and Medium Enterprise Development
MRRD – Ministry of Rural Rehabilitation and Development
ASTM – American Society for Testing and Materials
NABDP – National Area Based Development Program
BOP – Bottom Of the Pyramid
NGO – Non-Governmental Organization
CIS – Commonwealth of Independent States (Armenia,
Azerbaijan, Belarus, Georgia, Kazakhstan, Kyrgyzstan, Moldova, NSP – National Solidarity Program
Russia, Tajikistan, Ukraine, Uzbekistan and Turkmenistan) PRT – Provincial Reconstruction Team
CSO – Central Statistical Office, Government of Afghanistan PT – Pamir Turbine
DACCAR - Danish Committee for Aid to Afghan Refugees RHL – Remote Hydro Light
DAI – Development Alternatives, Inc. SME – Small and Medium Enterprise
DFID – Department for International Development SMEDA – Small and Medium Enterprise Development Authority
FAO – Food and Agriculture Organization SWOT – Strengths, Weaknesses, Opportunities and Threats
FPI – Frontier Power International (Analysis)
GDA – Global Development Alliance TMT – Traditional Mill Turbine
GDP – Gross Domestic Product UNIDO – United Nations Industrial Development Organization
GTZ - Gesellschaft für technische Zusammenarbeit USAID – United States Agency for International Development
HKT – Hindu Kush Turbine WEPEX – Water, Energy and Power Exhibition
IAM – International Assistance Mission
72
Units & Acronyms (2/2)
• $ - US Dollar (1 Dollar = 50 • K – Thousands
Afghanis) • Kg – Kilograms
• Af/Afs – Afghani/Afghanis (1 • kW – Kilowatt
Afghani = 0.02 US Dollars)
• m – Meter
• PKR – Pakistani Rupee (1 PKR
• m2 – Square meter
= 0.016 US Dollar
• Mn – Million
• Bn – Billion
• MT – Metric Ton
• ºC – Degree Celsius
• MW – Megawatt
• Cc – cm cube
• Psi – Pounds per square inch
• ºF – Degree Fahrenheit
• Ha - Hectare
73
Main Authors
74
Contact Information
Contact
Mobile + 93 (0) 799 888 111
rbaudeau@altaiconsulting.com
Altai Consulting
Qala-e-Fatullah, Street 4,
Kabul, Afghanistan
www.altaiconsulting.com
75