KUNAP'S Final Feasibility Study
KUNAP'S Final Feasibility Study
KUNAP'S Final Feasibility Study
FEASIBILITY STUDY
FOR
January, 2013
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
TABLE OF CONTENTS
EXECUTIVE SUMMARY..............................................................................................................................5
1. PROJECT DESCRIPTION....................................................................................................................7
1.1 Benefits and Advantages of Soya Bean foods and Soya Bean Oil......................................................7
2. PROJECT DESCRIPTION...................................................................................................................11
3. MARKET ANALYSIS...........................................................................................................................15
4. OPERATIONAL ANALYSIS...............................................................................................................21
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
4.4 Utilities.............................................................................................................................................26
6. SWOT ANALYSIS................................................................................................................................35
7. FINANCIAL PLAN...............................................................................................................................36
7.4 Vehicles............................................................................................................................................40
8. FINANCIAL ANALYSIS......................................................................................................................42
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
10.1 Profitability......................................................................................................................................49
10.2 Viability...........................................................................................................................................49
10.5 Conclusion.......................................................................................................................................49
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
EXECUTIVE SUMMARY
This feasibility study report is prepared by KUNIFIRA Agro-Processing PLC (KUNAP) to complete
a project for establishment of edible soya bean oil processing factory with a capacity of processing
6,600 tons of soybeans for production of 860,000 liters of soy oil and 5,214 tons of defatted
soybeans annually, in Oromiya national regional state, Gelan town.
The Promoters of the project, KUNAP’s founders, have an extensive business background and have
developed a variety of businesses with long years of experience and intimate knowledge of the oil
and food processing sector. Currently in desiring to expand their business, they wishes to implement
this edible soya oil and defatted soya bean processing plant.
Ethiopia with almost 80 million inhabitants is a large market for edible oil. The combination of a
growing GDP with an annually population growth of 2.6% makes it even more relevant that the
availability of good quality oil, such as soybean oil is required.
According to the data obtained from ministry of industry (FAO and ITC in 1997/8 – 1999/2000 E.C)
the annual consumption of edible oil for the country is estimated 174, 000 tons out of this 80,000 ton
(46%) is from own production and 94,000 (54%) was imported. Taking the population in the same
period per capita Production was 1 k.g and per capita consumption was 2.2 k,g. Thus the per capita
supply is lower than per capita supply by 54.5%
There is also a strong demand for defatted soybeans from the supplementary food industries;
factories that supply to the World Food Program alone have a total annual demand of 60,000 tons to
cater for soy blends for the food insecure and malnutrition affected areas.
Thus, the project’s overall objective is to establish modern plant for edible soya bean oil processing
to supply quality edible soya bean oil and defatted soy bean products mainly for local market.
The project major activities are therefore completing construction of building for oil processing plant
and warehouse, procurement and installation of the required machinery and equipment as well as
infrastructure facilities, procurement of vehicles to transport raw material and factory products,
recruitment of the required employees to deliver customers quality edible soy oil and defatted
soybeans products.
The foundation for the project is a preliminary survey, upon which the operating and marketing
strategies are built. Discussions and interviews were held with a variety of individuals involved in
other similar businesses to develop the Performa data, review the market potential, and competitive
situation.
After the project become operational, it will create additional permanent job opportunity for about
49 persons, and other contractual employees required on seasonal basis.
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
The project is environmentally friendly and the social and economic benefits are immense as it is
geared to notably substitute the huge imports of edible oil. In addition, it will generate Birr 73.5
million income to the government in the form of taxes.
The market assessment for this project justifies the implementation of the intended project. The plan
shows annual sales of Birr 52,932,436 for the first year of operation and Birr 168,145,433 by the end
of year ten with net profits of Birr 3,987,722.97 and Birr 20,133,895.50 respectively.
The total project cost is Birr 23,456,453.06 before bank interest, out of the total Birr 6,923,867.34
(30%) will be covered by the owners and the remaining amount Birr 16,532,585.72 (70%) will be
covered through bank financing.
The project has positive cash flow throughout the assumed project life; it starts with 2,746,937.63 in
the first year and reached to Birr 24,556,065.99 at the end of year ten. The IRR of the project is 32%
as shown in the detail financial analysis of the project.
In conclusion, this feasibility study shows in detail that the project is financially viable, technically
feasible, and economically sound and will have no market problems.
Bringing the new facility to maximum production within three years of operation.
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
1. PROJECT DESCRIPTION
1.1 Benefits and Advantages of Soya Bean foods and Soya Bean Oil
Several nutritional advantages could be obtained by incorporating soybean based foods in the
diet. Soybean represents an excellent source of high quality protein with a low content in
saturated fat, with no cholesterol, and a great amount of dietary fiber. Therefore, the possible
use of soybean in functional food design is very promising, since the consumption of soybean
protein and dietary fiber seems to reduce the risk of cardiovascular diseases and to improve
glycemic control.
Furthermore, soybean and several of its components have shown in various in vitro, in vivo,
and human clinical studies their effectiveness and potential role in the prevention and treatment
of different diseases. The use of soybean in food form for several centuries assures us of its
safety and nutritive value for human health. Consequently, it is imperative for all the conscious
societies to incorporate this abundantly available ‘treasure of functionality’ in their daily diet
and harness the complete benefit of this yellow ‘miracle’ seed.
Soybean oil is a vegetable oil extracted from the seeds of the soybean (Glycine max). It is one
of the world’s most widely used edible oils. The following are the major advantages of soy oil.
1.1 Versatile
Soybean oil’s clean, natural taste and nearly imperceptible aroma support and enhance the
natural flavors of prepared foods. Whether used as a shortening for an old-fashioned pie crust
or blended with flavored vinegar for a new dressing, soybean oil’s neutral flavor lets the real
taste of the food product come through.
Adaptable to nearly every fat or oil application in the food industry, soybean oil works well
with other ingredients including other fats and oils, making it very suitable for use in salad
dressings, sauces and baked foods. Soybean oil is available with OSI (Oil Stability Index)
stability levels ranging from 7 to over 60 hours, and it is a proven performer in the wide range
of applications required by snack food manufacturers, bakeries, foodservice providers and
more.
Liquid soybean oil is used in 100% formulations for cooking oil and to create mayonnaise,
salad dressings and sauces. Soybean oil can turn 2 ounces of olive oil into a whole pint of
flavored oil for dressings. The distinctive olive oil aroma will be evident, even though the bulk
of the dressing’s oil component comes from inexpensive soybean oil. Oils that are flavorful,
such as olive, peanut and walnut, are generally expensive and it only takes a small amount in a
blend with soybean oil to make a large quantity of flavored oil. Chefs and food companies have
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
long practiced oil blending to gain the benefits of flavored oils and save money on ingredient
costs.
Soybean oil also is found in breads, crackers, and barbecue sauce and non-dairy creamers.
Soybean oil is used in prepared foods such as whipped toppings, potato chips and battered and
breaded snacks and vegetables.
Compared to other vegetable oils, soybean oil has good emulsifying ability. This makes it an
appropriate ingredient in mayonnaise, and the first choice of the general food industry.
Liquid soybean oil is among the healthiest of all edible oils and has a very favorable fatty acid
profile. It is relatively low in saturated fat, high in polyunsaturated fat and contains
monounsaturated fat. The Institute of Medicine’s Dietary Reference Intakes (DRI)
acknowledges that unsaturated fatty acids reduce blood cholesterol and lower the risk of heart
disease when they replace saturated fats in the diet, and recommends intakes for both linoleic
and alpha-linoleic acid (ALA).
1.3 Rich Source of omega-3 and omega-6 fatty acids for heart health
Soybean oil is one of the few non-fish sources of omega-3 polyunsaturated fatty acids, which
have various physiological benefits including cardio protective effects.
While fish oil is the preferred source of omega-3s because of the bioavailability of
eicosapentaenoic (EPA) and docosahexaenoic acid (DHA), the ALA in soybean oil is the
principal source of omega-3s.
Omega-6 fatty acids, found naturally in soybean oil, may also decrease risk of heart disease,
according to a science advisory published by the American Heart Association in January 2009.
Containing about 50% omega-6s, conventional soybean oil is one of the most concentrated
sources of this polyunsaturated fat.
Soybean oil is the primary commercial source of alphatocopherol, also known as vitamin E.
Vitamin E is the body’s primary lipid-soluble antioxidant defense against free radical induced
cell damage, which has been linked to a number of cancers, heart disease, cataracts, premature
aging and arthritis.
population of about 3 million with an annual growth rate of well over 5%. (CSA 2010) This
population constitutes 4% of the country’s total and about 28% the urban population. The daily
food requirements of the city will increase substantially in the coming years.
Hence soybean is a multipurpose crop, which can be used for a variety of purposes including
preparation of different kinds of soybean foods, soybean oil, animal feed, soy milk, raw
material for the processing industry
As it is mentioned above, using soy bean foods and soybean oil is advantageous for its
versatility, availability and competitive pricing, neutral flavor and well-balanced fatty acid
profile. In addition it is a desirable ingredient for a variety of applications ranging from baked
foods to salad dressings.
1- Import substitution
Ethiopia imports large quantities of soybean and palm oil. The value of imported edible oil is
40 to 50% of the export earnings of oilseeds. Oil seed crushers produce around 20% of the
domestic consumption of edible oil: 80% is imported mainly as palm oil and soybean oil.
Increased domestic edible oil production can substitute these imports and improve the trade
balance. In addition to edible oil, a significant amount of soy blended food is imported to
Ethiopia; implying a further potential for import substitution.
Ethiopia with almost 80 million inhabitants is a large market for edible oil. The combination of
a growing GDP with an annually population growth of 2.6% makes it even more relevant that
the availability of good quality oil, such as soybean and sunflower oil, is improved. There is
also a large scarcity in high protein animal feed for the booming dairy, export beef and poultry
sectors. Similarly, there is strong demand from the nutritious food industries; factories that
supply to the World Food Program alone have a total annual demand of 60,000 tons to cater for
soy blends for the food insecure and malnutrition affected areas.
Soybean is a multipurpose crop, which can be used for a variety of purposes including
preparation of different kinds of soybean foods, animal feed, soy milk, raw material for the
processing industry, and it counter effects depletion of plant nutrients in the soil resulting from
continuous mono-cropping of cereals, especially maize and sorghum, thereby contributing to
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
increasing soy fertility. There is also a potential to intercrop soybean with long stem crops such
as maize and sugarcane.
Food insecurity and malnutrition are among the urgent challenges that developing countries
face these days. The major staple food crop of most developing Sub-Saharan African
Countries, maize, contains low protein (5.2-13.7 %). The challenges are especially acute in
Ethiopia and relatively more serious in the rural than urban areas, mainly because of a low
level of understanding of a balanced diet and lack of capacity to purchase animal source
proteins. Producing and consuming more soy would improve the situation as soy provides a
nutritious combination of both calorie and protein intake: it is the most nutritionally rich crop,
as its dry seed contains the highest protein and oil content among grain legumes (40 to 42%
protein) with a good balance of the essential amino acids and has 18-20% oil on a dry seed
weight basis. It is cheap and rich source of protein for poor farmers, who have less access to
animal source protein, because of their low purchasing capacity.
There are favorable climatic and soil conditions for production in South and Western Ethiopia;
therefore, soybean can be easily produced both for commercial purposes as well as for
subsistence farming.
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2. PROJECT DESCRIPTION
2.1 Location and Address
Plant location is a compromise between the availability of market, raw materials, labor, energy
and water. KUNIFIRA Agro-processing PLC (KUNAP) is located in Oromiya national
regional state at Gelan Town which is situated at a distance of about 30 kilometers from Addis
Ababa along the main road to Adama Town and the Port of Djibouti. The specific address of
the factory is as follows:
Region Oromiya
P. O. Box 10332
Email: [email protected]
The demand for soy oil products has been growing continuously over the past several years.
Now it has reached a point that the already existing factories are unable to meet orders with
their existing production capacity. As a result, the management of KUNAP is now in the
process of undertaking investment to establish a new factory to fill the widening demand and
supply gap.
Specifically:
Provide excellent soy edible oil products with particular emphasis on quality and
customer satisfaction,
Maximize profit of the company by using large market opportunity and competitive
price advantage.
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
To increase its contribution of the revenue generation of the state in the form of
taxation and significant amount of foreign currency saving by import substitution and
to contribute in the growth of the country as a whole and the region and town in
particular.
The oil will be clean, natural taste and enhance the natural flavors of prepared foods
Works well with other ingredients including other fats and oils
The Soybean oil can be used for wide range of applications required by snack food
manufacturers, bakeries, foodservice providers and more. It can be also used in breads,
crackers, and barbecue sauce and non-dairy creamers. It can also be used in prepared foods
such as whipped toppings, potato chips and battered and breaded snacks and vegetables.
The huge and ever growing demand for edible oil mainly Soy oil that goes with the
growing population and living standard of the country.
The future intention of the Government to put the manufacturing industry as a lead in
the overall macroeconomic structure of the country which will bring complementary
growth to the edible oil industry.
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It is anticipated that the edible oil and defatted soya bean production will start operation in a
year’s time.
The main activities to be undertaken before the commencing of edible soy oil production are
completing the factory building, procurement and installation of machinery and equipment’s,
procurement of vehicles to transport raw material to the factory and factory products to market
and recruitment of the required skilled and unskilled man power.
The refined edible soy oil production process involves several distinct operations, drying and
cleaning, decorticated, cooking and conditioning and screw presses. Each process is briefly
described in operational plan section of this document.
The attainment of the project capacity will depend upon the factors like involvement of the
management to facilitate production, marketing and quality of the product, and the skills and
motivation of the labor force involved in the production of products. As described in this
document the company management and staff have vast experience in this regard. The detailed
production program and capacity utilization assumptions are mentioned in the operational
analysis section of this document.
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
1 2 3 4 5 6 7 8 9 10 11 12
Securing additional fund
Building Completion
Activities
Procurement and
installation (Machinery,
Vehicle)
Manpower Recruitment
Project operations
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3. MARKET ANALYSIS
3.1 Past Supply and Present demand of Edible Oil
Various studies indicate that the demand for edible oil products is increasing as a result of
increase in number of population in Ethiopia mainly in urban areas and as a result of fast
urbanization in Ethiopia.
Thus the demand for edible oil is also expected to grow as Ethiopia’s population expands and
demographic changes result in an increasingly urbanized population. Ethiopia, the fastest-
urbanizing country in Africa with 4.3 percent growth per year, has unmet demand for edible oil
products. The combination of a growing GDP with an annually population growth of 2.6% and
fast urbanization in the country makes it even more relevant that the availability of good
quality oil, such as soybean oil, is improved.
According to the data obtained from ministry of trade and industry (FAO and ITC in 1997/8 –
1999/2000 E.C) the annual consumption of edible oil for the country is estimated 174, 000 tons
out of this 80,000 ton (46%) is from own production and 90,000 (54%) was imported. Taking
the population in the same period per capita Production was 1 k.g and per capita consumption
was 2.3 k,g. Thus the per capita supply is lower than per capita supply by 130%
Furthermore, when comparing the per capita consumption in of Ethiopia for edible oil with
other countries of Africa and the world, it is very low and indicates consumption in Ethiopia
will be increased significantly in the coming years as a result of economic development (GDP
growth), population growth, and urbanization. The following table (3.1) shows per capita
comparison with other countries:
Table 3.1 – Ethiopia Edible oil Per capita consumption Comparison with other countries:
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
According to the information obtained from the Ethiopian Revenue and Customs Authority’s
trade statistical database department, over the period 1997-2010, Ethiopia's import of edible oil
has been showing an increasing trend with an average annual growth rate of 6.8% and 21.1%
in volume and value terms respectively. Ethiopia's import of edible oil has shown an increasing
trend over the 1997-2010 periods. Accordingly, import volume increased from 13,000 MT in
1997 to 252,000 MT in 2010. Similarly, the foreign exchange cost of the import has in general
been showing an increasing trend from 7.6 million USD in 1997 to 255 million USD in
2010. /See Table 3.2 and Figure 1 for details/
Annual Average
Annual Average
Yea growth Rate in growth Rate in
r Quantity (in Kg) Value in ETB Value in USD Quantity (%) Value (%)
1997 13,048,522 51,165,708.45 7,623,246.90
1998 9,683,917 68,184,183.94 9,582,082.68 -34.7 25
1999 43,461,168 157,660,657.01 19,852,255.45 77.7 56.8
2000 31,766,180 173,466,826.02 21,109,954.11 -36.8 9.1
2001 38,431,041 259,961,718.05 30,733,784.72 17.3 33.3
2002 25,939,010 161,265,733.00 18,822,303.68 -48.2 -61.2
2003 135,761,783 546,932,811.68 63,597,578.05 80.9 70.5
2004 82,375,819 512,234,355.70 59,311,094.41 -64.8 -6.8
2005 92,102,380 677,364,271.50 77,388,295.35 10.6 24.4
2006 89,084,343 590,998,387.64 67,275,875.98 -3.4 -14.6
2007 115,254,493 949,633,243.58 104,958,524.67 22.7 37.8
2008 173,033,103 2,403,787,060.55 248,140,542.13 33.4 60.5
2009 244,465,602 2,826,760,865.27 238,085,123.69 22.9 15
2010 252,517,466 3,726,478,398.52 255,860,372.72 11.1 24.1
88.7 273.8
Average Annual Growth Rate, % 6.8 21.1
Source: Ethiopian Revenue and Customs Authority, Trade Statistical Database Department,
2010
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This shows the major foreign exchange that the country has to allocate for the import of edible
oil in to the country. Though no reliable data could be obtained, there is said to be large of
informal import of edible oil into the country in addition to what is obtained from official
sources.
Therefore, increased domestic edible oil production can substitute these imports and improve
the trade balance.
As it shown above there is a large demand supply variance for edible oil products in Ethiopia
indicating the untapped potential for development of edible oil production plants. Edible oil
production factories have tremendous potential for development and play a significant role in
minimizing the acute shortage of edible oil products in Ethiopia.
The ideal location of the company (assessed in section 1.1), the quality of products to be
delivered and the demand- supply gap in Ethiopia assessed above will enable our company to
have a significant market share from Ethiopia mainly from the capital Addis Ababa and the
surrounding area.
Furthermore, aware of the fact that operating in such a market is largely dependent on good
marketing; the company intends to establish networks and strategic relationships with various
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
edible oil products consumers such as hotels, distributers such as supermarkets, shops, etc to
ensure a steady stream of clients. However in so doing we intend to ensure that the product will
deliver is of extremely high quality.
According to the United Soybean Board’s (USB) 2012 Consumer Attitudes about Nutrition
survey, soybean oil was among the top three oils ranked “very healthy” by consumers, along
with olive and flaxseed oils.
In Ethiopia also Soya oil is the second largest edible oil type imported for a number of years
next to palm oil. According to the data obtained from ministry of industry from a total of
102,000 tons of Edible oil produced about 8,218 ton was soya oil. Thus KUNAP total
production will substitute 10.5 of annual import soy oil.
In addition to edible oil, a significant amount of soy blended food is imported to Ethiopia;
implying a further potential for import substitution. According to Royal Netherlands Embassy
in Ethiopia commissioned study in 2009, there is also strong demand from the nutritious food
industries; factories that supply to the World Food Program alone have a total annual demand
of 60,000 tons to cater for soy blends for the food insecure and malnutrition affected areas.
The drought and famine in the horn of Africa has created a huge market for the local nutritious
food processors; World Food Program is buying a big volume of soy for the food-insecure
people in Somalia and Darfur.
For this plant output, refined edible oil has increasing demand due to increase in population,
urbanization and standard of living.
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In contrast to the highly growing demand of edible oil products, currently much of the country
consumption for such products is covered through import. Hence due to, the ever increase in
price of imported edible oil products and due to the limited production in the country there is
untouched market for this product due to greater tax saving and price competiveness
advantage.
Therefore, investing in this sector is not only to fill the gap between demand and supply of
edible oil products for local consumption but also needs to play a significant role as import
substitution to save foreign currency and keeps the trade balance healthy. In order to do this,
Ethiopia, needs to further establish numerous edible oil products and processing plants.
Conclusion
In summary there is no significant competition for Soy edible oil and defatted soya bean
products in Ethiopia mainly due to increase in number of population in Ethiopia mainly in
urban areas and the higher price of the imported products while there is uncompromised
quality of products mentioned on the product description of this study.
Moreover our assessment shows there is a higher and ever increasing demand for these
products due the wide social and macro-economic changes in Ethiopia.
Thus marketing strategies will build on these facts, taking advantage of precipitating events,
fostering word-of-mouth recommendations, and creating satisfaction through supply of quality
soy oil and defatted soybeans products.
Supermarkets
Hence the need to professionally market ourselves and the products we will make available are
uncompromised nature.
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
Our competitive edge comes from the advantage of having wide and superior experience in
edible oil products. Our marketing strategy will be based mainly on making the right products
available to the right target customer.
We will ensure that our products' prices take into consideration peoples' budgets and very
lower than imported edible oil, and that these people know that we exist, appreciate the value
of our products, and how to contact us. The marketing will convey the sense of quality in every
picture, every promotion, and every publication.
We realize the need to focus our marketing message and our product offerings. We need to
develop our message, communicate it, and make good on it. The decision to establish strategic
alliances with several edible oil products consumers, hotels, restaurants and edible oil
distribution channels (supermarkets and food items retail shops and distributers) are aimed at
tapping our target market effectively and efficiently. The marketing strategy is also subject to
change upon customer’s feedback and surveys.
Pro-active selling which will include employing a suitable sales persons and visits to
the large customers.
Selected direct consumers, institutions, individuals, and Kiosks will be given our
products for free on a limited basis to aid referrals.
The recommended price for the envisaged project for soy oil per liter is Birr 42.00, and
defatted soya bean Birr 940 per quintal. Hence edible oil should be available in the nearest
retail shop for households; to the consumer's convenience, intensive distribution through
delivery to the retailers as well as its own shops in selected centers is recommended.
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
4. OPERATIONAL ANALYSIS
4.1 Plant Capacity and Capacity Utilization
Based on the market study, minimum economies of scale and availability of raw material, the
envisaged plant is proposed to have a capacity of processing 6,600 tons of soybeans for
production of 860,000 liters of soy oil and 5,214 tons of defatted soybeans based on 300
working days per annum and three shifts of 8 hours per day.
The maximum attainable capacity which is 90% will be reached in the third year and onwards.
It is assumed that the plant will achieve 70% and 80% capacity utilization rate in the first,
second year, respectively. Table 4.1 summarizes plant capacity and capacity utilization.
Year
Description Year 1 Year 2 Year 3 Year 4 & Onwards
Capacity Utilization % 70% 80% 90% 90% 90%
Soya Bean Crushing Capacity Per 5,2 5,94 5
annum (tons) 4,620 80 0 ,940 5,940
Refined Soya oil Production Capacity 60 688, 774,78 774 7
per annum (Liters) 2,609 696 3 ,783 74,783
Defatted Soybean Flour Production 3,9 4,39 4
Capacity per annum (tones) 3,419 07 6 ,396 4,396
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
De-gumming: The crude oil undergoes de-gumming process to remove gummy matter such as
phospholipids and lipoproteins. It is accomplished by exposing the oil to water and adding the
phosphoric acid at 50oC.As a result precipitate of gum and soap is generated and removed by
centrifugation.
Bleaching: The purpose of oil bleaching is to eliminate its coloring pigments through the
adsorption on bleaching earth. Fuller’s earth is used for bleaching because of its excellent
adsorption power. The bleached oil containing fuller’s earth is passed through a series of filter
presses to remove the spent earth.
Hydrogenation: Hydrogen process is the hardening of oil to reduce its un-saturation. At the
same time, it improves the stability of the product against its oxidation, Chemically, the degree
of un-saturation decreases by passing hydrogen gas through oil in the presence of nickel
catalyst at 1500C. The objective of the hydrogenation process is not only to raise the melting
point but to greatly improve the keeping quality, taste and odor for many oils.
Deodorization: Most of the odorous substances along with FFA, sterols, tocopherols, saturated
and un-saturated hydrocarbons are stripped out by injecting dry steam into oil at 235-245 0C.
Citric acid is also added to remove the odor. After deodorization, the deodorized oil is cooled
in the de cooler to about 850C. The remaining odorous substances are removed during the de
cooling under vacuum.
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – Feasibility Study
Expelled Cake
Pressing Solvent extraction Extracted Meal
Filtration
Removes Bleaching
Bleaching Earth
Color
Ghee Hydrogenation
Refined oil
Packaging
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
Table 4.4 Summary of Annual Direct Raw materials Requirement and Cost.
No Description Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
1 Soya bean
40,656,000.00 51,110,400.00 63,249,120.00 69,574,032.00 76,531,435.20 84,184,578.72 92,603,036.59 101,863,340.25 112,049,674.28 123,254,641.70
2 Packing material
1,712,179.69 2,152,454.46 2,663,662.40 2,930,028.64 3,223,031.50 3,545,334.65 3,899,868.11 4,289,854.92 4,718,840.42 5,190,724.46
Total 42,368,179.69 53,262,854.46 65,912,782.40 72,504,060.64 79,754,466.70 87,729,913.37 96,502,904.71 106,153,195.18 116,768,514.69 128,445,366.16
4.4 Utilities
Electricity, furnace oil and water are utilities of the proposed project. Table 3.5 indicates the
annual utility requirements and cost at the assumed initial capacity for utilities and other
expenses. The summary of all annual costs and expenses is depicted in cost and expenses
section of this document.
Currently the company is intended to implement an oil processing plant with 6,600 tons of soybeans
producing 860,000 liters of soy oil and 5,214 tons of defatted soybeans.
The missions and operating philosophy of the company are summarized as follows:
It requires that the entire organization be continuously customer oriented as the company’s future
success is dependent on meeting the customers’ needs better than its competitors.
It maintains a marketing concept and distribution capability to identify the needs of the market and
undertakes effective promotions of its products.
It strives to provide its customers with continuous offerings of quality health food products,
competitively priced—stressing value for money.
It plans to constantly maintain and upgrade its facilities as modern and clean to make them
conducive for supply of products of high standard quality appropriate for consumption for health.
It will maintain a sound financial plan that provides capital for growth of the business and provides
optimum return for its owners.
27
management, marketing, and processing of food products. Brief background of the management and
senior staff of the company are given below:
Ato Deresse has M.Sc degree and a B.Sc degree (Distinction) in Agricultural Economics from Alemaya
University. He has also taken, locally and abroad, several management skill development training
courses. His experience adds up to more than 20 years working at senior managerial posts in different
business organizations. The list of senior positions he held include:
Planning and Policy Advisor of Ministry of State Farms Coffee and Tea Development
Ato Deresse has travelled extensively on business trips to different countries including to UK, Italy,
Spain, Japan, Russia, Germany, Kuwait, Kenya, Djibouti, Lesotho and China.
Ato Tilahun is a food processing technologist specialising in weaning food processing, supplementary
food processing, ready–to use therapeutic food processing, food safety and quality management and
food and nutrition training.
He is educated in food science with Mphil in Food Technology from Dept. of Food Science,
Humberside College of Higher Education, England. He has also obtained Postgraduate Diploma from
the same college. His first degree is B.Sc in Biology from Addis Ababa University. He has also taken
several training courses related to food processing including in:
Environmental Economics
Food Management
28
Quality system, Traceability, HACCP and Production of Plumpy nut
He has gained extensive experience in food processing working for different business establishments as
senior technical staff. He has worked in senior positions including as:
Lecturer, Addis Ababa University, Faculty of Science, Food Science and Nutrition Program
Production, Quality and Technical Manager, Hilina Enriched Foods Processing Center PLC
Senior Expert, Industrial Development Promotion Department, Ministry of Trade and Industry
Food Technologist, Research Department, Food Research and Development Centre (FRDC)
Training for food industry technicians, quality control personnel and production supervisors
Food Technology Expert, Food Science and Nutrition Department, Ethiopian Nutrition
Institute (ENI)
Ato Kumsa is one of the major shareholders of the company. He has completed secondary education.
He has also taken entrepreneurship Course. He has more than 17 years of experience working for one
of the major food processing enterprise. The specific assignments that he has undertaken include:
As Production head
As Accountant
As Assistant administrator
As Purchaser
Production Forman
Ato Abiy Admassu is a chemical engineer with a B.Sc Degree from Addis Ababa University. Having
completed required courses for M. Sc in Chemical Engineering (Food Engineering), he is preparing his
theses in fulfillment of the M. Sc degree. He has also taken training in Food Safety Management
System (ISO 22000:2005) and Food Safety Management System Audit Training (ISO 22000:2005).
29
His previous experiences include:
As Safety Chairman
Ato Tinkishu is a graduate of Addis Ababa University, Technology Faculty, with B.Sc. degree in
Mechanical Engineering. He has also obtained additional training in Electro Mechanical Systems,
Production and technical management of various machineries in France by International Development
Department of NU triset in December 2008.
He has considerable experience in technical and production operations, which includes the following:
One and half year as sales representative on various Agricultural and construction materials.
Planning the preventive maintenance Annual Program and managing the activities to be
performed.
Ato Hussien has a Diploma in Book Keeping and Accounting from Entoto Vocational Technical School
as well as Advanced Diploma from Admas University College in Accounting. Currently, he is
attending his final year in Addis Ababa University to complete the requirement for B. Sc degree
program in accounting. He has comprehensive working skill in Peachtree Accounting as well as
application of Microsoft Word and Excel.
30
He has more than 20 years of experience at job positions ranging from Junior Accountant to Deputy
Manager in different organizations. The organization he served includes Ethiopian Retail Trade
Corporation and Arsi Agricultural Mechanization Service. His specific experience includes positions:
As a Junior Accountant
As a Senior Accountant
As a Deputy Manager
As a Project Coordinator
31
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
General Manager
Personnel Administration
Finance Technic Sales & Distribution Logistics
& General service
32
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
Having a general manger at the top, different additional professional and non-professional
staff will be hired for the successful implementation of the proposed project.
List of the required man power with expected salary expense is summarized in table 4.1.
Periodically external auditors shall be employed to audit the company’s account.
33
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
Table 5.1- List of Project man power and expected salary expense
Monthly
S/N Position Title No of Pos. Yearly Salary
Salary
1 General Manager's Office
1.1 General Manager 1 15000 180,000
1.2 Secretary 1 2500 30,000
1.3 Quality Assurance Officer 1 4000 48,000
Sub total 3 21500 258,000
Production and Technical
2
Department
2.1 Production & Technical Head 1 6000 72,000
2.2 Mechanical Engineer 1 5500 66,000
2.3 Shift Supervisor 2 2500 60,000
2.4 Mechanics 2 2200 52,800
2.5 Milling Operator 3 2200 79,200
2.6 Electrician 2 2500 60,000
2.7 Packing Operator 6 1500 108,000
2.8 Laborers--Oil Filling 6 1200 86,400
2.9 Press Machine Operator 2 1200 28,800
Sub total 25 23600 613,200
3 Finance and Administration
3.1 Head, Administration & Finance 1 6000 72,000
3.3 Senior Accountant 1 3500 42,000
3.4 Accountants 1 2800 33,600
3.5 Personnel Officer 1 3500 42,000
3.6 Clerical Staff 1 1550 18,600
3.7 Drivers 3 1300 46,800
3.8 Guards 6 950 68,400
3.9 Cleaners 3 900 32,400
Sub total 17 20500 355,800
4 Marketing and Sales
4.1 Head, Marketing and Sales 1 6000 72,000
4.2 Salesmen 2 2500 60,000
4.3 Storekeepers 1 1600 19,200
Sub total 4 10100 484,800
75,700 1,711,8
Total 49
.00 00.00
Employee Benefits (25%) 427,950.00
Grand Total 49 85800 2,139,750.00
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
6. SWOT ANALYSIS
Strengths Weaknesses
Advanced Soy edible oil Production and Shortage sufficient working capital for
packing technology and plant facilities long term sustainability
capable of producing high quality
products.
Dedicated Management and staff running
the business
Excellent marketing strategies,
Opportunities Threats
35
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
7. FINANCIAL PLAN
7.1 Pre Operating Costs
Pre operating Costs includes Bank interest during grace period, other costs which are
expected to be incurred before the factory starts operation. The following table shows the list
of estimated pre operating costs of the factory.
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
37
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
38
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
CONVEYOR
INSTA-PRO MODEL 850 OIL
24 SCREENING TANK W/PUMP 0.75 1 39,760.00 39,760.00 725,620.00
INSTA-PRO MODEL 900 DRUM
25 COOLER W/ AIR SYSTEM 4 1 22,837.00 22,837.00 416,775.25
6" X 10' COOLER DISCHARGE
26 SCREW CONVEYOR 1 1 4,434.00 4,434.00 80,920.50
MIX-MILL SENTRY 1000
27 HAMMER MILL 5 1 6,579.00 6,579.00 120,066.75
SPARE PARTS PACKAGE FOR
28 EXTRUDER 1 4,202.00 4,202.00 76,686.50
SPARE PARTS PACKAGE FOR
29 OIL PRESS 1 5,711.00 5,711.00 104,225.75
30 INSTA-PRO SCREW PULLER 1 1 7,237.00 7,237.00 132,075.25
TOTAL Hammer Mill EXPRESS: 176.75 231,376.00 4,757,658.20
31 Fright and Transport 1 15,856.00 15,856.00 289,372.03
START-UP & TRAINING
32 SERVICE 1 3,500.00 3,500.00 63,875.01
Total Charges TBH Express 19,356.00 5,110,905.23
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
7.4 Vehicles
The project intends to buy the following three vehicles at a total cost of about Birr 1,247,000.00 as
shown below:
40
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
The total project cost is Birr 23,456,453.09 out of the total Birr 6,923,867.34 (30%) will be
covered by the owners and the remaining amount Birr 16,532,585.75 (70%) will be covered
through bank financing.
41
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
8. FINANCIAL ANALYSIS
8.1 Financial Projections and Assumptions
These Financial Projections are based on estimates and assumptions set forth therein, and
have been delivered for the information and convenience of persons who wish to evaluate the
feasibility of the project and goals. Anyone who has received the feasibility study realizes
that financial projections are inherently speculative.
The financial analysis of the project is based on the data presented in the previous chapters
and the following underlying assumptions:-
4. Bank loan is estimated to be paid within 5 years’ time at 9.5% on Monthly basis for
each year and 1 year grace period.
5. Straight line method of depreciation has been used to calculate depreciation expense
as per the following details:
Depreciation/Year
Description Useful
Life Cost
Building and Civil Works 20 6,311,390.00 315,569.50
Machinery and Equipment 5 years 9,550,155.40 1,910,031.08
Vehicle 5 Years 1,247,000.00 249,400.00
Furniture and Fixtures 10 years 172,900.00 34,580.00
Other Equipment 5 Years 65,000.00 13,000.00
Pre Operating Costs 10 years 885,500.00 88,550.00
Total 11,920,555.40 2,611,130.58
8.2 Sales revenue
The company will generate revenue mainly from sales of soy edible oil and defatted soya
bean. The price of is assumed to be increased by 10% annually. The revenue over the
assumed project life is illustrated in the following table:
42
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
Description Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Beginning
Inventory 0 60,261 68,870 77,478 77,478 77,478.30 77478.3 77478.3 77478.3 77478.3
Soya Bean oil
Production
(tons) 602,609 688,696 774,783 774,783 774,783 774,783.00 774,783.00 774,783.00 774,783.00 774,783.00
Ending
Inventory 60,261 68,870 77,478 77,478 77,478 77,478.30 77,478.30 77,478.30 77,478.30 77,478.30
Annual Sales
(QTY) 542,348.10 680,087.30 766,174.30 774,783.00 774,783.00 774,783.00 774,783.00 774,783.00 774,783.00 774,783.00
Soya Bean oil
Unit Price
Liter 42.00 46.20 50.82 55.90 61.49 67.64 74.41 81.85 90.03 99.03
Annual Sales
(ETB) 22,778,620.20 31,420,033.26 38,936,977.93 43,311,919.27 47,643,111.19 52,407,422.31 57,648,164.54 63,412,981.00 69,754,279.10 76,729,707.01
Description Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Beginning
Inventory 0 342 391 440 440 440
Defatted
Soybean flour
(tons) 3,419 3,907 4,396 4,396 4,396 4,396 4,395.60 4,395.60 4,395.60 4,395.60
Ending
Inventory 341.88 391 440 440 440 440 440 440 440 440
Annual Sales 3,076.92 3,858.36 4,346.76 4,395.60 4,395.60 4,395.60 3,956.04 3,956.04 3,956.04 3,956.04
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
Defatted Soya
Per Unit Price 9,800.00 10,780.00 11,858.00 13,043.80 14,348.18 15,783.00 17,361.30 19,097.43 21,007.17 23,107.89
Annual Sales
(ETB) 30,153,816.00 41,593,120.80 51,543,880.08 57,335,327.28 63,068,860.01 69,375,746.01 68,681,988.55 75,550,187.40 83,105,206.14 91,415,726.76
Description
Year
1 2 3 4 5 6 7 8 9 10
Production Cost
96,502,904.7 106,153,195.1
Raw Material Cost 42,368,179.69 53,262,854.46 65,912,782.40 72,504,060.64 79,754,466.70 87,729,913.37 1 8 116,768,514.69 128,445,366.16
1,357,901.5 1,493,691.6
Direct Labor 766,500.00 843,150.00 927,465.00 1,020,211.50 1,122,232.65 1,234,455.92 1 6 1,643,060.82 1,807,366.91
Utility (electricity, 375,570.9 413,128.0
water etc.) 212,000.00 233,200.00 256,520.00 282,172.00 310,389.20 341,428.12 3 3 454,440.83 499,884.91
106,293.6 116,923.0
Repair & Maintenance 60,000.00 66,000.00 72,600.00 79,860.00 87,846.00 96,630.60 6 3 128,615.33 141,476.86
Total 43,406,679.69 54,405,204.46 67,169,367.40 73,886,304.14 81,274,934.55 89,402,428.00 98,342,670.80 108,176,937.88 118,994,631.67 130,894,094.84
GENERAL & ADMIN
EXPENSE
General and Amin Staff 2,432,796.1 2,676,075.7
Salary 1,373,250.00 1,510,575.00 1,661,632.50 1,827,795.75 2,010,575.33 2,211,632.86 4 6 2,943,683.33 3,238,051.67
Communication
Expense (Telephone, 116,923.0 128,615.3
fax, Postal etc.) 66,000.00 72,600.00 79,860.00 87,846.00 96,630.60 106,293.66 3 3 141,476.86 155,624.55
Fuel, Grease, car
Maintenance 61.20 67.32 74.05 81.46 89.60 98.56 108.42 119.26 131.19 144.31
Professional Fee (Legal, 115,151.4 126,666.6
Audits, etc.) 65,000.00 71,500.00 78,650.00 86,515.00 95,166.50 104,683.15 7 1 139,333.27 153,266.60
Sales and Promotion 88,578.0 97,435.8
Expense 50,000.00 55,000.00 60,500.00 66,550.00 73,205.00 80,525.50 5 6 107,179.44 117,897.38
Other General and 322,424.1 354,666.5
Admin. Expenses 182,000.00 200,200.00 220,220.00 242,242.00 266,466.20 293,112.82 0 1 390,133.16 429,146.48
Sub Total 1,736,311.20 1,909,942.32 2,100,936.55 2,311,030.21 2,542,133.23 2,796,346.55 3,075,981.21 3,383,579.33 3,721,937.26 4,094,130.98
2,611,130.5 2,611,130.5
Depreciation expense 2,611,130.58 2,611,130.58 2,611,130.58 2,611,130.58 2,611,130.58 2,611,130.58 8 8 2,611,130.58 2,611,130.58
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KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
Grand Total
47,754,121.47 58,926,277.36 71,881,434.53 78,808,464.92 86,428,198.36 94,809,905.13 104,029,782.59 114,171,647.79 125,327,699.51 137,599,356.41
45
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
50,00 55,00 60,5 66,55 73,205 80,52 88,578. 97,435. 107,17 117,897.
Sales Expense 0.00 0.00 00.00 0.00 .00 5.50 05 86 9.44 38
Other General and 182,00 200,20 220,2 242,24 266,466 293,11 322,424. 354,666. 390,13 429,146.
admin. Expenses 0.00 0.00 20.00 2.00 .20 2.82 10 51 3.16 48
1,554,31 1,709,74 1,880,7 2,068,78 2,275,667 2,503,23 2,753,557. 3,028,912. 3,331,80 3,664,984.
Total 1.20 2.32 16.55 8.21 .03 3.73 10 81 4.10 51
Profit before
interest and 7,971,44 16,898,20 21,430,7 24,692,15 27,161,369 29,877,50 25,233,925. 27,757,317. 30,533,04 33,586,354.
depreciation 5.31 7.28 74.06 4.20 .62 6.59 18 70 9.47 42
2,611,13 2,611,13 2,611,1 2,611,13 2,611,130 2,611,13 2,611,130. 2,611,130. 2,611,13 2,611,130.
Deprecation 0.58 0.58 30.58 0.58 .58 0.58 58 58 0.58 58
Profit before 5,360,31 14,287,07 18,819,6 22,081,02 24,550,239 27,266,37 22,622,794. 25,146,187. 27,921,91 30,975,223.
interest expense 4.73 6.70 43.48 3.62 .04 6.01 60 12 8.89 84
1,462,59 1,346,45 1,019,1 659,63 264,717
Interest expense 1.78 6.70 53.45 1.04 .86
3,897,72 12,940,62 17,800,4 21,421,39 24,285,521 27,266,37 22,622,794. 25,146,187. 27,921,91 30,975,223.
Profit before tax 2.96 0.00 90.02 2.58 .19 6.01 60 12 8.89 84
4,529,21 6,230,1 7,497,48 8,499,932 9,543,23 7,917,978. 8,801,165. 9,772,67 10,841,328.
Tax expense - 7.00 71.51 7.40 .42 1.60 11 49 1.61 34
3,897,72 8,411,40 11,570,3 13,923,90 15,785,588 17,723,14 14,704,816. 16,345,021. 18,149,24 20,133,895.
Profit after tax 2.96 3.00 18.52 5.18 .77 4.40 49 63 7.28 50
46
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
Pv of cash flow 59,144,901.57 2,508,618.84 10,824,774.06 9,888,189.79 10,115,702.27 10,001,564.72 402,506.51 8,711,325.67 9,962,761.40 9,934,629.25 9,912,756.14
NPV 59,943,258.39
IRR 32%
47
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
48
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
49
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
Important ratios such as profit to total sales, net profit to equity (Return on equity) and net
profit plus interest on total investment (return on total investment) show an increasing trend
during the life-time of the project. The income statement and the other indicators of
profitability show that the project is viable.
10.2 Viability
The project is profitable and worthwhile. The NPV is positive, 59,943,258.43 within ten
years and The IRR is 32%. Furthermore it has positive cash flow throughout the project life
as shown on the forecasted cash flow statement of the project.
10.5 Conclusion
The market assessment carried out shows that there is a promising market opportunity for
the project output owing to the rapid growth of demand for Soy edible oil products. Also
the project will generate Birr 73.6 million in terms of tax revenue over the assumed project
life of 10 years.
The planned manpower of the project is 49; In addition casual labor will be required.
These will create job opportunities for citizens that will contribute to reducing
unemployment in the country and the project employees will acquire experience in the
production and processing which contributes to the development of skills in the country.
50
KUNIFIRA AGRO-PROCESSING PLC (KUNAP) – FEASIBILITY STUDY
The loan is assumed to be paid quarterly in 5 years at 9.5% of interest rate. A cash flow
projection shows the project earns positive cash inflow throughout its operational life, it
will have a net cash inflow of Birr 2,746,937 and 24,556,065 at the end of year one and
year ten respectively.
In general the analysis reported in this document shows that the project under consideration
is financially feasible, economically beneficial and socially desirable.
51