Project Profile on
BAKING POWDER PRODUCTION
Development Studies
Associates (DSA)
October 2008
Addis Ababa
Table of Contents
1.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..................................................................................................2
3.2.Plant Capacity........................................................................................................................3
3.3.Production Program...............................................................................................................3
8Financial Analysis..................................................................................................6
8.1Underlying Assumption .........................................................................................................6
8.2Investment...............................................................................................................................8
8.3Production Costs.....................................................................................................................9
8.4Financial Evaluation.............................................................................................................10
1. Summary
This project profile deals with the establishment of baking powder producing plant in Amhara
National Regional State. The following presents the main findings of the study
Demand projection divulges that the domestic demand for baking powder is substantial and is
increasing with time. The planned plant is set to produce 60 tons on baking powder annually.
The total investment requirement is estimated at Birr 1 million, out of which Birr 132,275 is for
machinery and equipment.
The plant will create employment opportunities for 19 persons. The project is financially viable
with an internal rate of return (IRR) of 35.78% and a net present value (NPV) of Birr 597,142
discounted at 18%.
Year
Projected Demand
for Baking Powder
(in tons)
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
138
146
153
161
169
176
184
192
199
207
215
The raw materials are partially imported and. Seventy percent of the raw material is expected to
be imported.
4.2
The Major raw materials consist of sodium Acid pyro-phosphate, sodium bicarbonate, and starch
(filler). Auxiliary materials include packaging materials, which might include polyethylene
packages, tin and glass packages.
The list and costs of required raw materials are shown in Table 2 below.
No.
1
2
3
4
Material
Sodium Acid Pyro-Phosphate
Sodium Bicarbonate
Starch (Filler)
Packaging materials
Total
Qty
30
15
15
Lump sum
60
The inputs required by the plant are electricity and water. The annual energy consumption will
be 60000 kwh, the cost of which is estimated at Birr 33,000. Annual water consumption is
estimated to be 1000 m3, the cost of which is estimated at Birr 2,650. Thus, the total annual
expenditure on utilities will be Birr 35,650.
Production Process
The production of baking powder mainly involves the physical mixing of various components in
a long-scale batch mixer. Sodium acid pyro-phosphate sodium bicarbonate and starch are the
major ingredients to be mixed in certain proportions.
The characteristics of the various components have an influence on product uniformity. The
order in which mixing occurs may have influence on the stability of the product. Rigid
specifications for purity, granulation and moisture content of the components, must be adhered to
if a uniform, stable and reliable is to be obtained.
Variations in ingredient purity can later the proper balance of acids to soda. Granulation is very
critical, not only in terms of stability and uniformity of distribution of particles during blending,
but also in the appearance of baked products. The proper kind and speed of blending are essential
4
to attain and maintain proper distribution of particles. The baking powder is usually packaged in
air-tight metal or fibre cans.
Alternative technology
Proportioning the ingredients, mixing and granulating the mixed components can be automated;
but this will be capital intensive.
6.2
The list of machinery and equipment required by the plant is presented in Table 3. The total cost
of machinery and equipment is estimated at Birr 132,275.
Table 3: Required Machineries and Equipments
Item
Description
Qty.
Sifter
5
6
7
1
Many
Supplier Address
The machineries and equipments listed above are available in Addis Ababa Market.
6.3
The total land required is 500 m2 while the built-up area for plant is 250 m2. The cost of plant
building is estimated at Birr 500,000. The land lease is estimated at Birr 30,000.
Human Resource
The required human resource and associated costs are shown in Table 4.
Table 4: Human Resource Requirements
Salary/Wage (Birr)
Job Title
1
2
3
4
5
6
7
9
1
0
1
1
1
2
No.
Monthly
Annual
3500
42,000
2500
30,000
1,500
18,000
1,200
14,400
850
10,200
850
10,200
1200
14,400
1200
43,200
General Manger
Production Supervisor
Personnel Head
Accountant
Secretary
Casher
Chemist
Operators & technicians
1
1
1
1
1
1
1
3
700
25,200
Security
350
12,600
Genitors
3
19
350
12,600
232,800
Total
Employment Benefits 20% of Annual
Salary
46,560
279,360
B. Training Requirement
The production supervisor, the chemist and the skilled workers will receive short term training
on the operation of the plant for a total of four to six weeks. The cost of training is estimated at
Birr 30,000.
8 Financial Analysis
8.1
Underlying Assumption
The financial analysis of this plant is based on the data provided in the preceding sections and
the following assumptions.
2 years
Source of finance
Tax holidays
2 years
12%
18%
Value of land
3% of fixed investment
B. Depreciation
Building
5%
10%
Office furniture
10%
Vehicles
20%
Pre-production (amortization)
20%
30 days
Raw Material-Foreign
120 days
30 days
30 days
Work in Progress
Finished Products
Accounts Receivable
Cash in Hand
Accounts Payable
10 days
15 days
30 days
30 days
30 days
8.2
Investment
The total investment cost of the project including working capital is estimated at Birr one 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.
Cost
1,500.00
500,000.00
50,000.00
132,275.00
683,775.00
Total
34,188.75
717,963.75
290,944.61
1,008,908.36
*Pre-production capital expenditure includes - all expenses for preinvestment studies, consultancy fee during construction and expenses for
companys establishment, project administration expenses, commission
expenses, preproduction marketing and interest expenses during
construction.
8.3
Production Costs
The total production cost at full capacity is estimated at Birr one million. The details are shown
in Table 6.
Table 6: Total Production Cost at Full Capacity
542,084.38
35,650.00
279,360.00
20,513.25
877,607.63
50,065.25
72,641.40
1,000,314.28
8.4
I.
Financial Evaluation
Profitability
The income statement shows that the proposed project generates profit starting from the first year
of operation. Profit starts at undiscounted Birr 196,888 in first year and reaches about Birr
302,996 in the eight year of the project life. Gross Profit to Sales ratio starts at 17.16% and
reaches 32.06% at eight year. The total profit earned during the whole ten years of operation
amounts Birr to 2.83 million. These and other indicators prove that the project is profitable.
II.
Breakeven Analysis
The breakeven analysis shows that the Total Revenue equals the Total Cost at 28.45% of
capacity which is achieved in the first year of operation.
III.
Payback Period
The project pays back its initial investment in the second year of operation.
IV.
The Internal Rate of Return is 28.45% and the Net Present Value at 18% discount rate per annum
is Birr 597,142.
VI.
Sensitivity Analysis
A 10% reduction in sales reduces the total profit to Birr 1.83; it still remains viable. A 10%
increase in price of raw materials reduces the total profit to Birr 2.27; the impact is not serious.
A. Profit Generation
The project is found to be financially viable and earns a total profit of Birr 2.83 million within
the project life.
B. Tax Revenue
In the project life under consideration, the government will collect about Birr 978,207 from
corporate tax payment alone (i.e. excluding income tax, sales tax and VAT).
11
ANNEXES
12
PRODUCTION
Year 1
Year 2
85%
100%
100%
100%
368,908
434,009
434,009
434,009
150,815
177,430
177,430
177,430
Raw Material-Local
16,750
19,705
19,705
19,705
Raw Material-Foreign
134,065
157,724
157,724
157,724
860
1,012
1,012
1,012
1,902
2,238
2,238
2,238
Work in Progress
21,505
25,300
25,300
25,300
Finished Products
43,010
50,600
50,600
50,600
2. Accounts Receivable
125,182
147,273
147,273
147,273
3. Cash in Hand
29,210
34,365
34,365
34,365
372,485
438,217
438,217
438,217
4. Current Liabilities
125,182
147,273
147,273
147,273
Accounts Payable
125,182
147,273
147,273
147,273
247,303
290,945
290,945
290,945
247,303
43,642
CURRENT ASSETS
(continued)
PRODUCTION
5
10
100%
100%
100%
100%
100%
100%
434,009
434,009
434,009
434,009
434,009
434,009
177,430
177,430
177,430
177,430
177,430
177,430
19,705
19,705
19,705
19,705
19,705
19,705
157,724
157,724
157,724
157,724
157,724
157,724
1,012
1,012
1,012
1,012
1,012
1,012
2,238
2,238
2,238
2,238
2,238
2,238
Work in Progress
25,300
25,300
25,300
25,300
25,300
25,300
Finished Products
50,600
50,600
50,600
50,600
50,600
50,600
2. Accounts Receivable
147,273
147,273
147,273
147,273
147,273
147,273
34,365
34,365
34,365
34,365
34,365
34,365
438,217
438,217
438,217
438,217
438,217
438,217
4. Current Liabilities
147,273
147,273
147,273
147,273
147,273
147,273
Accounts Payable
147,273
147,273
147,273
147,273
147,273
147,273
290,945
290,945
290,945
290,945
290,945
290,945
3. Cash in Hand
CURRENT ASSETS
PRODUCTION
Year 1
Year 2
358,982
649,926
1,272,682
1,372,091
1,350,000
1,350,000
358,982
649,926
125,182
22,091
Total Equity
143,593
259,971
215,389
389,956
125,182
22,091
2. Inflow Operation
1,147,500
1,350,000
1,350,000
1,350,000
Sales Revenue
1,147,500
1,350,000
1,350,000
1,350,000
Interest on Securities
358,982
358,982
1,273,032
1,113,186
1,144,990
1,136,516
358,982
358,982
341,888
341,888
17,094
17,094
372,485
65,733
6. Operating Costs
743,966
873,921
873,921
873,921
109,644
113,276
8. Interest Paid
156,582
72,641
60,535
48,428
9.Loan Repayments
100,891
100,891
100,891
10.Dividends Paid
Surplus (Deficit)
290,945
-350
258,905
205,010
213,484
290,945
290,594
549,499
754,509
967,993
3. Other Income
Fixed Investments
Pre-production Expenditures
6
1,350,000
7
1,350,000
8
1,350,000
9
1,350,000
10
1,350,000
Total Equity
2. Inflow Operation
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
Sales Revenue
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,128,041
1,121,617
1,113,142
1,003,777
1,003,777
1,003,777
Fixed Investments
Pre-production Expenditures
6. Operating Costs
873,921
873,921
873,921
873,921
873,921
873,921
116,908
122,591
126,223
129,855
129,855
129,855
36,321
24,214
12,107
100,891
100,891
100,891
221,959
228,383
236,858
346,223
346,223
346,223
1,189,953
1,418,335
1,655,193
2,001,416
2,347,640
2,693,863
Interest on Securities
3. Other Income
8. Interest Paid
9. Loan Repayments
10.Dividends Paid
Surplus (Deficit)
Cumulative Cash Balance
PRODUCTION
Year 2
1,147,500
1,350,000
1,350,000
1,350,000
1. Inflow Operation
1,147,500
1,350,000
1,350,000
1,350,000
Sales Revenue
1,147,500
1,350,000
1,350,000
1,350,000
Interest on Securities
358,982
358,982
991,269
917,563
983,565
987,197
358,982
358,982
Fixed Investments
341,888
341,888
17,094
17,094
247,303
43,642
5. Operating Costs
743,966
873,921
873,921
873,921
109,644
113,276
-358,982
-358,982
156,231
432,437
366,435
362,803
-358,982
-717,964
-561,732
-129,295
237,140
599,942
-358,982
-304,222
112,203
263,194
189,003
158,584
-358,982
-663,204
-551,001
-287,806
-98,803
59,781
2. Other Income
Pre-production Expenditures
(Continued)
PRODUCTION
5
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1. Inflow Operation
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
Sales Revenue
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
990,829
996,513
1,000,145
1,003,777
1,003,777
1,003,777
Fixed Investments
Pre-production Expenditures
5. Operating Costs
873,921
873,921
873,921
873,921
873,921
873,921
116,908
122,591
126,223
129,855
129,855
129,855
359,171
353,487
349,855
346,223
346,223
346,223
959,113
1,312,601
1,662,456
2,008,679
2,354,903
2,701,126
133,048
110,969
93,075
78,058
66,151
56,060
192,829
303,798
396,873
474,931
541,082
597,142
Interest on Securities
2. Other Income
TOTAL CASH OUTFLOW
10
597,142.12
35.8%
85%
100%
100%
100%
100%
1,147,500
1,350,000
1,350,000
1,350,000
1,350,000
1,147,500
1,350,000
1,350,000
1,350,000
1,350,000
641,433
754,627
754,627
754,627
754,627
VARIABLE MARGIN
506,067
595,373
595,373
595,373
595,373
44.10
44.10
44.10
44.10
44.10
152,598
169,360
169,360
169,360
169,360
OPERATIONAL MARGIN
353,469
426,013
426,013
426,013
426,013
30.80
31.56
31.56
31.56
31.56
Sales Revenue
Other Income
2. Less Variable Cost
156,582
72,641
60,535
48,428
36,321
5. GROSS PROFIT
196,888
353,372
365,479
377,586
389,693
109,644
113,276
116,908
196,888
353,372
255,835
264,310
272,785
17.16%
26.18%
27.07%
27.97%
28.87%
17.16%
26.18%
18.95%
19.58%
20.21%
Return on Investment
36.62%
42.23%
31.36%
31.00%
30.64%
Return on Equity
48.79%
87.56%
63.39%
65.49%
67.59%
10
100%
100%
100%
100%
100%
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
1,350,000
754,627
754,627
754,627
754,627
754,627
VARIABLE MARGIN
595,373
595,373
595,373
595,373
595,373
44.10
44.10
44.10
44.10
44.10
162,522
162,522
162,522
162,522
162,522
OPERATIONAL MARGIN
432,851
432,851
432,851
432,851
432,851
32.06
32.06
32.06
32.06
32.06
24,214
12,107
5. GROSS PROFIT
408,637
420,744
432,851
432,851
432,851
122,591
126,223
129,855
129,855
129,855
7. NET PROFIT
286,046
294,521
302,996
302,996
302,996
Gross Profit/Sales
30.27%
31.17%
32.06%
32.06%
32.06%
21.19%
21.82%
22.44%
22.44%
22.44%
Return on Investment
30.75%
30.39%
30.03%
30.03%
30.03%
Return on Equity
70.88%
72.98%
75.08%
75.08%
75.08%
Sales Revenue
Other Income
2. Less Variable Cost
RATIOS (%)
Year 1
358,982
0
0
0
0
0
0
0
0
358,982
0
341,888
17,094
0
0
0
358,982
0
0
0
215,389
215,389
0
143,593
143,593
0
0
0
0
0
0
Year 2
1,008,908
290,945
0
0
0
0
0
290,945
0
717,964
341,888
341,888
34,189
0
0
0
1,008,908
0
0
0
605,345
605,345
0
403,563
403,563
0
0
0
0
0
0
PRODUCTION
1
1,330,978
663,079
153,577
21,505
43,010
125,182
29,210
290,594
0
667,899
683,775
0
34,189
50,065
0
0
1,330,978
125,182
125,182
0
605,345
605,345
0
403,563
403,563
0
0
0
196,888
0
196,888
2
1,605,550
987,717
180,679
25,300
50,600
147,273
34,365
549,499
0
617,833
683,775
0
34,189
100,131
0
0
1,605,550
147,273
147,273
0
504,454
504,454
0
403,563
403,563
0
0
196,888
353,372
0
353,372
3
1,760,494
1,192,726
180,679
25,300
50,600
147,273
34,365
754,509
0
567,768
683,775
0
34,189
150,196
0
0
1,760,494
147,273
147,273
0
403,563
403,563
0
403,563
403,563
0
0
550,260
255,835
0
255,835
4
1,923,913
1,406,211
180,679
25,300
50,600
147,273
34,365
967,993
0
517,703
683,775
0
34,189
200,261
0
0
1,923,913
147,273
147,273
0
302,673
302,673
0
403,563
403,563
0
0
806,095
264,310
0
264,310
Continued
PRODUCTION
TOTAL ASSETS
1. Total Current Assets
Inventory on Materials and Supplies
Work in Progress
Finished Products in Stock
Accounts Receivable
Cash in Hand
Cash Surplus, Finance Available
Securities
2. Total Fixed Assets, Net of Depreciation
Fixed Investment
Construction in Progress
Pre-Production Expenditure
Less Accumulated Depreciation
3. Accumulated Losses Brought Forward
4. Loss in Current Year
TOTAL LIABILITIES
5. Total Current Liabilities
Accounts Payable
Bank Overdraft
6. Total Long-term Debt
Loan A
Loan B
7. Total Equity Capital
Ordinary Capital
Preference Capital
Subsidies
8. Reserves, Retained Profits Brought Forward
9. Net Profit After Tax
Dividends Payable
Retained Profits
5
2,095,807
1,628,170
180,679
25,300
50,600
147,273
34,365
1,189,953
0
467,638
683,775
0
34,189
250,326
0
0
2,095,807
147,273
147,273
0
201,782
201,782
0
403,563
403,563
0
0
1,070,405
272,785
0
272,785
6
2,280,963
1,856,553
180,679
25,300
50,600
147,273
34,365
1,418,335
0
424,410
683,775
0
34,189
293,554
0
0
2,280,963
147,273
147,273
0
100,891
100,891
0
403,563
403,563
0
0
1,343,190
286,046
0
286,046
7
2,474,593
2,093,410
180,679
25,300
50,600
147,273
34,365
1,655,193
0
381,183
683,775
0
34,189
336,781
0
0
2,474,593
147,273
147,273
0
0
0
0
403,563
403,563
0
0
1,629,236
294,521
0
294,521
8
2,777,589
2,439,634
180,679
25,300
50,600
147,273
34,365
2,001,416
0
337,955
683,775
0
34,189
380,009
0
0
2,777,589
147,273
147,273
0
0
0
0
403,563
403,563
0
0
1,923,757
302,996
0
302,996
9
3,080,584
2,785,857
180,679
25,300
50,600
147,273
34,365
2,347,640
0
294,728
683,775
0
34,189
423,236
0
0
3,080,584
147,273
147,273
0
0
0
0
403,563
403,563
0
0
2,226,753
302,996
0
302,996
10
3,383,580
3,132,080
180,679
25,300
50,600
147,273
34,365
2,693,863
0
251,500
683,775
0
34,189
466,464
0
0
3,383,580
147,273
147,273
0
0
0
0
403,563
403,563
0
0
2,529,748
302,996
0
302,996
10