Flour Production Project Mifita Kedere 2014
Flour Production Project Mifita Kedere 2014
Flour Production Project Mifita Kedere 2014
September- 2020
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Table of Contents
List of ANNEX.............................................................................................................................................5
List of Figure..............................................................................................................................................5
List of Table.................................................................................................................................................5
I. EXECUTIVE SUMMARY...................................................................................................................6
2. INTRODUCTION....................................................................................................................................7
2.1 RATIONAL BEHIND THE PROJECT.................................................................................................8
2.2 SOCIO-ECONOMIC JUSTIFICATIONS............................................................................................9
2.3 COMPANY / APPLICANT PROFILE..................................................................................................9
2.4 PROMOTER’S PROFILE..................................................................................................................10
3. BACKGROUND INFORMATION....................................................................................................11
3.1 ETHIOPIA FLOUR PRODUCTIONS AND MARKETING.............................................................11
3.1.1 ETHIOPIA FLOUR PRODUCTION STATUS.......................................11
4.4.2 CLIMATE.............................................................................................13
4.5.5 EDUCATION.......................................................................................15
5. THE PROJECT......................................................................................................................................16
5.1 PROJECT DESCRIPTION.................................................................................................................16
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5.7.4 ENGINEERING...................................................................................28
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List of ANNEX
Annex 1: PROJECTED INCOME STATEMENT (BIRR’000).......................................54
Annex 2: PROJECTED BALANCE SHEET (Birr’000).....................................55
Annex 3: PROJECTED CASH FLOW STATEMENT (Birr ‘000)......................56
Annex 4: PROJECTED PROJRCT WORTH MAESURE (NPV, IRR, and PB) AFTER TAX.
Birr '000).............................................................................................................57
List of Figure
Figure 1: Flour Mill Process Flow Chart..............................................................21
Figure 2: Flour milling block flow diagram.........................................................27
Figure 3 : Organizational Charts.........................................................................41
List of Table
Table 1: Flour Production Machinery...................................................................28
Table 2: Production Capacity Utilization of Flour Mill Plant................................29
Table 3: PRODUCTION PROGRAMME.....................................................................29
Table 4: Annual Requirement for Raw materials at Flour Plant...........................29
Table 5: Utilities Requirement for Factory...........................................................30
Table 6: Furniture and Fixtures Requirement for the Factory.............................31
Table 7: Transportation Vehicle Requirement for the Factory............................31
Table 8: APPARENT CONSUMPTION OF WHEAT FLOUR.......................................33
Table 9: Demand projections (tons)....................................................................34
Table 10: Demand – supply gap (Tons)...............................................................35
Table 11: Flour Plant Production Plan by years and varieties..............................35
Table 12: Annual Land Rent cost (THI.BIRR).......................................................37
Table 13: Infrastructures and Costs Related to Installations...............................37
Table 14: Land Use Plan and Related Cost..........................................................38
Table 15: Pre-Operation Plan of the project........................................................39
Table 16: PRE – OPERATING EXPENSE...........................................................40
Table 17: Human Resource Requirements..........................................................42
Table 18: Summary of Investment Costs for project (in Birr)..............................43
Table 19: Summary of Operating Costs for project (in Birr)................................43
Table 20: Project Investment and Working cost by Source of the Fund..............44
Table 21: loan repayment Schedule....................................................................50
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I. EXECUTIVE SUMMARY
This profile envisages the establishment of a plant for the production of wheat
flour with a capacity of 48,000 tons per annum at full production year. The
present demand for the proposed product is estimated at 399,710 tons per
annum. The demand is expected to reach at 799,023 tons by the year 2020 The
project is financially viable with an internal rate of return (IRR) of 94% and a net
present value (NPV) of Birr 264.3 million before tax and an internal rate of
return (IRR) of 103% and a net present value (NPV) of Birr 2681.5 million, after
government tax discounted at 10%.
This feasibility study envisages the establishment of a plant for the production
of wheat flour with a capacity of 8-150 tons per day at full production period.
The produce the best flour is one that corresponds exactly to the needs of the
customers. Is the flour which gives the maximum extraction (flour from wheat)
in the mill?
The country`s requirement of wheat flour is met through local production and
import. The present (2020) demand for flour is estimated at 399,710 tons. The
demand for the product is projected to reach 739,836 tons and 799,023 tons by
the years 2028 and 2029, respectively. The demand and supply gap is higher
due to the estimated current production of product is about 29,608 tones/year
(2021) and the demand is reached 428,921 tomes/year (2029).
The principal raw material required is wheat PP bag, electricity, water, Sewing
thread and utilities (fuel, Oil and lubricants). All are locally available while the
remaining raw materials have to be imported.
The project can create employment for 56 skilled people and 37 casual labor
and totally 93 work opportunities for the project area. The establishment of
such factory will have a foreign exchange saving effect to the country by
substituting the current imports. The project will also create backward linkage
with the agricultural sector and also generates income for the Government in
terms of tax revenue and payroll tax.
To full fill his desire after looking the gaps and opportunities Mifita Kedire
company has Proposed new investment on Flour Mill Processing Plant
establishment over 5,680 square meter area and investment of Et. Birr
44.536 Million Birr for the envisaged project
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2. INTRODUCTION
Ethiopia is one of the largest grain producers in Africa, there are still large
pockets of food insecurity, and it is a net importer of grains. The principal grain
crops grown in Ethiopia are teff, wheat, and barley, which are primarily cool-
weather crops; and corn, sorghum, and millet, which are warm weather grain
crops. All grains in Ethiopia are consumed as food, with crop residues and by-
products commonly fed to livestock. It is estimated that farmers hold about 10
percent of their grain production for planting (included in the FSI Consumption
category in the PSD). Despite Ethiopia’s large livestock population (the largest in
Africa), the commercial feed industry is just beginning, mostly located around
Addis Ababa and slightly to the south. Feed is by far the biggest constraint to
the livestock sector. There are about 20 feed millers in the country, but most of
them produce primarily for their own consumption. Only about half produce feed
solely for sale.
Flour is a food item, which is finely ground meal of cereals such as wheat,
maize, sorghum, rice, etc. obtained by milling and blending various streams of
different quality. It mainly contains endosperm and certain quantity of bran.
Wheat flour on average contains from 14% to 16.5% moisture. Based on its
baking quality and other quality indices such as gluten quality and content,
colour, moisture content, granular size of particles and others, flour is divided
into different grades. The basic application of flour is for bread making, cakes
and biscuits, and porridge at household level. Semolina, a product obtained by
milling extra hard (durum) wheat, is also used in pasta and macaroni making.
The byproduct bran is used as animal feed preparation and composite
preparation for the urban and rural agricultural inputs.
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The country`s requirement of flour product like biscuit is met through local
production and import. The present (2020) demand for flour is estimated at
399,710 tons. The demand for the product is projected to reach 739,836 tons
and 799,023 million tons by the years 2028 and 2029, respectively.
The principal raw material required is wheat PP bag, electricity, water, Sewing
thread and utilities (fuel, Oil and lubricants). Wheat flour are locally available
while the remaining raw materials have to be imported.
The proposed project is will flour production of export standard products. The
flour production manufacturing targets import substitute market after
production of the processed wheat products at the investment of flour mill
industry plantation studied by the investor at 2700 square meters. This flour
production industry project average production capacity is 48,000 tons per
annum at full production year (year three). The proposed investment area for
the envisage project found at Sidama National Peoples Reginal state, at Dara
Woreda Mechsio-Millennium town. Location of the Project area is situated
between a latitude and longitude of 7°3′N 38°28′E and 7.050°N 38.467°E, an
elevation of 1708 meters above sea level.
Policy: Government the second five years strategic plan, which promotes new
investment in agro-industrial sector and specially encourages agro processing
using high value added technology introduction for the production of high
standard flour which have a great advantage for others investment
development currency generating directly or indirectly contributes to fill full the
Ethiopia supply gape to local market ones.
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Labor: There is plenty of skilled and semi-skilled labor in Ethiopia. The country
has a good education system that churns out a number of graduates in most
key professions at all levels. Therefore for this project there is an opportunity to
employees’ cheap labor.
Availability of raw materials: The principal row materials are wheat PP bag,
electricity, water, Sewing thread and utilities (fuel, Oil and lubricants) currently
were available at domestically, at Hwassa Administrative town which processed
by this company and marketing according to Ethiopia industry product
marketing legislation at domestic levels.
Market: High market demand supply gap at the national levels and to fill full
this gape there is availability of high potential of flour supply of raw materials
for this envisage project at the local level.
The Federal as well as the Regional governments would also receive substantial
amount of revenue in the form of different taxes including profit tax. The project
will at average will generate tax revenue of 29.51 million birr per annum at the
project ten year life.
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3. BACKGROUND INFORMATION
3.1 ETHIOPIA FLOUR PRODUCTIONS AND MARKETING
3.1.1 ETHIOPIA FLOUR PRODUCTION STATUS
Processing of food grains and other agricultural products is the most important
stage in preparing them for the ultimate consumption. Almost all the
agricultural commodities have to undergo one or more stages of processing
before they reach the consumer. At present the work of processing is largely
done by middle men owning the processing units and a good chunk of the
ultimate price paid by the consumer goes to these intermediaries. This can be
eliminated if the processing activities are organized on a private sector so that
they call get better return on their produce and in some cases bring down the
sales price.
Policy attention to the sector was always considerable, and its importance has
been renewed in the latest Poverty Reduction Strategy, the Plan for Accelerated
and Sustained Development to End Poverty (PASDEP). PASDEP puts forward a
development strategy based on accelerated economic growth, part of which is
hoped to be achieved via increased private commercialisation and market
integration. On the average, farmers marketed 84% of their farm production.
Overall, industry contributed 10% to the total value of output sold. Although in
Hawassa and the surrounding town, there is high bread flour demand, flour
milling establishments in Mechiso Millennium Town and the surrounding town
immense flour supply to the surrounding community is left idle
Though flour industry in Ethiopia has been in existence since long, real fillip
came only in the later part of 20th century. The contributing factors were
urbanization, resulting in increased demand for ready to eat profiles at
reasonable costs etc. The Ethiopia flour industry can, therefore, explore this
aspect for batter food value and product quality. The use of soy flours and soy
products in bakery products not only improve nutritional quality of bakery
product, but also increase profit margins of an entrepreneur due to improved
product quality.
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Wheat imports account for roughly thirty-three percent of the wheat market.
The flour mills get the remainder of the wheat supply from the local market. In
current fiscal year, the wheat price in the local market is about forty two percent
higher than EGTE wheat prices and its quality is much better than imported
wheat (EMA, 2016).
The small and marginal farmer cannot afford to take up this aspect of
agriculture because of limited resources in terms of finance, technical skill,
knowledge and limited marketable surplus. Consequently, it is being undertaken
by the middle men in the private sector. For achieving maximum economy,
processing units may be set up close to the sources of supply. A processing unit
or society can offer a number of advantages to the rural people.
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4.4.2 CLIMATE
Dara Woreda has a tropical savanna climate (Köppen Aw) though it borders on a
subtropical highland climate. There are two seasons: a lengthy though not
intense wet season from March to October and a short dry season from
November to February. The extra cloudiness of the wet season is sufficient to
make it substantially cooler than the dry season despite a higher sun angle;
however, the coolest morning temperatures, often close to freezing, occur
during the dry season
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of kebele are interconnected by asphalt and all-weather road while the remains
are under construction.
4.5.5 EDUCATION
Hawassa University, established in 1999 through the merger of a number of
higher education institutions, is based in the city and Dilla University found near
distance to Mechiso-Millennium town.
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5. THE PROJECT
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milling involves grinding the kernel into a whole wheat flour and if desired
separating the bran and germ from the more digestible white endosperm.
Flour making is a conventional activity in many parts of the country. Despite the
advent of modern, large capacity and automatic flour making plants, large
section of people especially in semi-urban and rural areas still prefer fresh bared
and biscuits from local bakery as they are cheap and offer many varieties. These
manufacturers are able to cater to some typical local palate as well. Thus, they
are able to withstand competition from organized sector units.
Wheat flour have a good food value with substantial energy, protein,
carbohydrates and minerals apart from pleasing texture and taste. Baking
industry occupies an important position among Ethiopia food processing
industries. Wheat flour products are ready to eat and convenient to use.
Biscuits and Bread form the major baked foods accounting for over 70% of total
bakery products produced. The industry largely continues to be in the
unorganized sector contributing to over 70% of the total production. Bakery
products once considered as sick man's diet have now become an essential food
item of a sizeable segment of society.
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factor we looked at. Different articles on the production of flour were used as a
reference while writing this Business Plan.
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in hard currency and tax revenues; part of which will be reinvested in the
immediate community infrastructure
The business objectives of the envisaged industry are profitable production
of flour mill for national market
As a business firm one of objective of the Company is to earn higher income
from the demand supply gap exists in the sector at large and at the
international markets.
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2.Separator: Vibrating screens remove bits of wood and straw and almost
anything bigger or smaller than wheat
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3.Aspirator: Air currents act as a kind of vacuum to remove dust and lighter
impurities
4.De-Stoner: Using gravity, the machine separates the heavy material from
the light to remove stones that may be the same size as wheat kernels
5.Cockle Cylinder: Wheat passes through a separator that identifies the size
of the kernels even more closely. It rejects anything longer, shorter, more round,
more angular or in any way a different shape
6.Scourer: The scourer removes outer husks, crease dirt and polish the outer
surface with an intense scouring action. Currents of air pull all the loosened
material away.
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Final Product: The process is repeated over and over again, sifters to purifiers
to reducing rolls, until the maximum amount of flour is separated, consisting of
close to 75 percent of the wheat
The process engineer then designs the secondary process systems layout.
Simultaneously, the building engineer roughs out the building layout based on
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the major unit operations taking into account engineering and building code
limitations. Providing an enclosure for the unit operations and sufficient space
for access and maintenance are key for layout of the processing facility. Human
occupancy considerations, although important, are secondary and are usually a
cursory design will review for this flour milling process facilities. The general lay
out of the factory is shown below in the figure 2.
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5.7.4 ENGINEERING
Address: 412-TI AKASH RATH, B/H PARISEEMA, C.G. ROAD,
AHMEDABAD 380006, GUJARAT, INDIA Phone: 91-79-26564613/26566149
Mobile: +919824099013 Fax: 91-79-26566149
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Year y1 y2 y3-10
Capacity utilization (%) 80 90 100
Production (tons) Flour 30,720 34,56 38,400
0
Bran 7,680 8,640 9,600
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Auxiliary materials required are pp bags of different size for packing flour and
sewing thread. These can be easily obtained from local markets. The estimated
annual cost of raw and auxiliary materials is given in table 4 below. The total
annual cost of raw materials is estimated at Birr 350.849 million.
Main utilities would be electric, fuel and water. From 80-150t/D Electric Maize
Wheat Rice Corn Flour Grinding Mil is:
Distribution transformer station, loading capacity averaging total power
450 Kw annually and Power consumption 50 kw/hour, 3-phase industrial
meter is estimated to fulfill the requirement of power.
Water supply would be through ground water drilled at factory compound
and all associated works to supply 10,000 Liter/day of water qualities
which fluffiest WHO water quality requirement
The estimated annual requirement at full production capacity of the plant
and the corresponding cost are given in table 5.The total annual cost of
utilities is estimated as Birr 536.476.
The annual quantities and cost of major utilities of factories plants is as
shown at table below
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total 536.476
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In Ethiopia, the rural population used to consume flour made from cereals by
traditional means at home. Grain mills, however, are expanding deep into rural
areas reducing labour and time for women, replacing home-made flour
consumption of industrially processed flour, however, is still insignificant in rural
Ethiopia. Urban dwellers, on the other hand, consume more and more flour
produced by flour mills thus shifting to manufactured flour. Urban house-holds
also consume food items like bread, biscuits and cakes prepared at home or in
bakeries and pastries from industrially processed flour. The demand for wheat
flour is met through both local production and imports. The apparent
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Table 8 shows that both domestic production and import of wheat flour are
characterized by a fluctuating trend which is, however, erratic. The peak level of
local production, 195,437 tonnes, was registered in year 2000, and imports,
122,365 tonnes, in 2003. Given the nature of the historical apparent
consumption, it is reasonable to assume that the average of the past elven
years, i.e, about 173,518.4 tonnes, as the current effective present demand
for flour and with 6% of the average growth rate.
The demand for wheat flour is met through both local production and imports.
The apparent consumption of flour, comprising both domestic production and
import is shown in Table.8
as effective level for year 2006, 173,518 tones. As the demand on 2019 reached
370,102 tons, this is effectively supply is consisted as also effective supply and. as
the current effective demand forecast for flour milling. Therefore present
demand at the year 2019 is 173,518 tones. The apparent present demand
consumption of flour, comprising both domestic production and import is shown
in Table.8
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The production and storage hangars will have walls covered by corrugated iron
sheets on columns and beams made of metallic bars. The roofs will be of saw –
tooth type with metallic trusses and covered with metal cladding. Other
buildings will be built by hollow-block walls properly finished, but mot cement
plastered. The details breakdown and others details on floor area shown at the
supporting plan and bill of quantities.
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10.3 CONTINGENCIES
Investments costs are estimated with a certain margin of errors. To allow
physical and financial contingencies, a percentage of the initial total cost
estimate usually between 5 and 15% generally used the contingencies.
10.4 SOURCE OF FUND
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The promoter of the project has planned to finance the project through a long-
term loan from the Development Bank of Ethiopia; and, partially from own
contribution. The debt equity ratio is assumed to be 69:31. The following table
briefly summarizes the project financing by source of funds.
Table 20: Project Investment and Working cost by Source of the Fund
Source of Fund
Description
Equity Contribution Bank Loan Total
Investment Cost 7,824,432 20,119,968 27,944,400
Pre-operating cost 1,195,903 - 1,195,903
Working Capital Cost 4,772,718 10,623,146 15,395,864
Total Cost 13,793,053 30,743,114 44,536,167
% Share 31% 69%
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10.5.4.2 DEPRECIATIONS
Rate ( % ) y0 y1 y2 y3 -10
DESCRIPTIONS 1-2 3-10
Infrastructures costs 5% 5% 2,048 102 102 102
Civil works & Buildings 5% 5% 7,550 378 378 378
Machinery & equipment. 10% 12% 15,058 1,506 1,506 1,506
Furniture & Fixture 10% 10% 189 19 19 19
Motor Vehicle 10% 10% 3,100 310 310 310
Pre-production costs 20% 20% 1,196 239 239 239
Total 29,140 2,451 2,451 2,451
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working capital in the second and subsequent years. Further, adequate surplus
cash is available with the unit for promoter withdrawal, Annexure-1.
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critical stage for paying out dividends to shareholders who have invested
in the business enterprise. Nevertheless, the payment of dividend is
delayed until the enterprise fully pays out its loan (both interest and
principals).
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m m
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14. ANNEXURE
Annex 1: PROJECTED INCOME STATEMENT (BIRR’000)
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Annex 4: PROJECTED PROJRCT WORTH MAESURE (NPV, IRR, and PB) AFTER TAX. Birr '000)
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