Seed Cleaner
Seed Cleaner
Development Studies
Associates (DSA)
October 2008
Addis Ababa
Table of Contents
1. Executive Summary............................................................................................1
2. Product Description and Application..............................................................1
3. Market Study, Plant Capacity and Production Program..............................2
3.1 Market Study...................................................................................................................2
3.1.1 Present Demand and Supply....................................................................................2
3.1.2 Projected Demand....................................................................................................2
3.1.3 Pricing and Distribution...........................................................................................3
3.2 Plant Capacity..................................................................................................................3
3.3 Production Program.........................................................................................................3
4. Raw Materials and Utilities..............................................................................3
4.1 Availability and Source of Raw Materials.......................................................................3
4.2 Annual Requirement and Cost of Raw Materials and Utilities.......................................4
5 Location and Site...............................................................................................4
6 Technology and Engineering............................................................................4
6.1 Production Process...........................................................................................................4
6.2 Machinery and Equipment...............................................................................................5
6.3 Civil Engineering Cost....................................................................................................6
7 Human Resource and Training Requirement................................................6
7.1 Human Resource..............................................................................................................6
7.2 Training Requirement......................................................................................................6
8 Financial Analysis.............................................................................................7
8.1 Underlying Assumption...................................................................................................7
8.2 Investment........................................................................................................................8
8.3 Production Costs..............................................................................................................8
8.4 Financial Evaluation........................................................................................................9
9 Economic and Social Benefit and Justification.............................................10
ANNEXES...............................................................................................................11
1. Executive Summary
This project profile deals with the establishment of assembly and fabrication of mechanical seed
cleaner in Amhara National Regional State. The following presents the main findings of the
study
Demand projection divulges that the potential domestic demand for the equipment is substantial
and is expected to increase with time. Accordingly, the planned plant is set to produce 200 units
annually. The total investment cost of the project including working capital is estimated at birr
3.7 million and creates 14 job opportunity and birr 419.59 of income
The financial result indicates that the project will generate profit beginning from the first year of
operation. Moreover, the project will break even at 27.9% of capacity utilization and it will
payback fully the initial investment less working capital in 3 years. The result further show that
the calculated IRR of the project is 26% and NPV discounted at 18% of birr 873,783
In addition to this, the proposed project possesses wide range of economic and social benefits
such as increasing the level of investment, tax revenue and employment creation
Generally’ the project is technically feasible, financially and commercially viable as well as
socially and economically acceptable. Hence the project is worth implementing.
a) Plant parts and inert matter (stem, leave, stone, soil etc.)
b) Weed seeds (Noxious and obnoxious).
c) Other crop seeds (other cultivars).
d) Seeds of the varieties which are immature, broken, damaged and deteriorated.
Therefore, unclean seed has to be processed to remove the above mentioned contaminants to
upgrade the quality of seed.
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In general the envisaged mechanical seed cleaners are to be used for seed clearing and grading in
small scale operation. Seed cleaning and grading enhance the quality of the seeds and thereby
the value of the seeds. In rural areas farmers will get more for their grains if they use these
mechanical cleaners for cleaning and grading their marketable surplus
Seeds are the foundation of human and animal life on earth. This is because the foods we eat, the
fiber we wear, and most of the products we use in our daily life, are created from a seed. There is
no substitute for a quality seed. In Ethiopia agriculture sector contributes about 50% of the total
GDP. However, the population growth and the traditional farming system, has greatly burdened
the agriculture sector as its productivity is not able to meet the current food requirements.
The size of the farming sector in the economy of the Amhara Region and the quantity of farm
produce (grain) indicate the magnitude of the need for seed cleaning service and by extension for
seed cleaning machines. At present, with the exception of a few machines installed by grain
merchants or by grain mills operators in limited urban areas, there are no seed cleaning machines
in the whole Amhara Region. Whatever surplus grain produced and marketed from the Region,
it is sold before cleaning and grading which in turn depresses the farm get price. If seed cleaning
machines are produced and distributed in the Region, there will be added-value to the Regions
farm products and farmers will get higher prices.
The future demand for mechanical seed cleaning machines is expected to grow substantially as
awareness to the benefit of the equipment increases with time. For instance, in Amhara region
there are close to 3.33 million farming families. If we assume that one seed cleaning machine
can serve 15 families on average, the potential maximum demand for mechanical threshing
machines will be 222 thousand units. From this if we conservatively assume that only 10 percent
2
of the maximum potential demand will be realized, demand will be about 22,000 units. This
amount will be improved in the future with an increase in agricultural production and awareness
to the advantage of the machine. At the same time this suggests the relevance of establishing a
mechanical seed cleaner.
Based on the market research result and the capacity of the envisaged plant, the selling price is
set to be birr 14,058 per unit. The available sales network shall be used by the envisaged plant.
The program is scheduled based on the consideration that the envisaged plant will work 275 days
in a year in 1 shift, where the remaining days will be holidays and for maintenance. During the
first year of operation the plant will operate at 70 percent capacity and then it grows to 85
percent in the 2nd year. The capacity will grow to 100 percent starting from the 3 rd year. This
consideration is developed based on the assumption that with effective marketing and
management all barriers (market and logistics) would be eliminated within the first two years of
operation.
3
4.2 Annual Requirement and Cost of Raw Materials
and Utilities
The annual raw material and utility requirement and the associated cost for the envisaged plant is
listed in table 1 here under
Total Cost
Material and Input Quantity L.C. F.C.
Sheet Metal 10 ton 383400
MS Angle 2 ton 102240
Shafts 400 pcs 0 276048
Block Bearing 1800 pcs 0 81792
Bolts and Nuts 60 kg 0 3834
Paint 300 lit 28116 0
Total Material Cost 513756 361674
Utility
Electricity 205,000 kwh 112,750
Water 3,000m3 7,950
Total Utility Cost 120,700
Based on the above table the total cost of material and utility is estimated to be birr 996,130 per
annum.
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and finally spray painting. The alternative technology of manufacturing depends on the type of
cleaning machine desired to be produced. For instance if the interest is to fabricate gravity
separators, pneumatic separators, or magnetic separators; it needs relatively sophisticated
technique and therefore, is not selected for this profile.
The machineries and equipment required for producing seed cleaning machine is detailed in table
2 below
The, total cost of machinery and equipment including freight insurance and bank cost is
estimated to be about birr 639,000.
The following are some of the machineries suppliers’ address for the envisaged project
5
6.3 Civil Engineering Cost
The total site area for the envisaged plant is estimated to be 350m 2 where 300m2 is allocated to
the production place and the remaining space is left for stores (30m 2), office buildings and
facilities (20m2).
The list of required manpower for the envisaged plant is stated in table 3 below
Total Annual
Position No. Required Monthly Salary Salary
Manager/Skilled Technician 1 8946 107352
Accountant/Cashier 1 2556 30672
Store Keeper and Sales Clerk 1 1534 18403
Draftsman/Supervisor 1 3834 46008
Operators 6 1534 110419
Daily Laborers 2 767 18403
Guards 2 767 18403
Benefit (20%) 69932
Total 14 419593
The envisaged plant creates 14 job opportunity and about birr 419,593 thousand of income. The
professionals and support staffs for the envisaged plant shall be recruited from Amhara region
Training of key personnel shall be conducted in collaboration with the suppliers of the plant
machineries. The training should primarily focuses on the production technology and machinery
maintenance and trouble shooting. Birr 38,340 will be allocated as training expense.
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8 Financial Analysis
8.1 Underlying Assumption
The financial analysis of assembly and fabrication of mechanical seed cleaner making plant is
based on the data provided in the preceding chapters and the following assumptions.
B. Depreciation
Building 5%
Machinery and equipment 10%
Office furniture 10%
Vehicles 20%
Pre-production (amortization) 20%
Raw Material-Local 30
Raw Material-Foreign 120
Factory Supplies in Stock 30
Spare Parts in Stock and Maintenance 30
Work in Progress 10
Finished Products 15
Accounts Receivable 30
Cash in Hand 30
Accounts Payable 30
7
8.2 Investment
The total investment cost of the project including working capital is estimated at Birr 3.7 million
as shown in table 4 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.
The foreign component of the project accounts for 17.6% of the total investment cost.
8
Table 5: Production Cost
Items Cost
1. Raw materials 875,430
2. Utilities 120,700
3. Wages and Salaries 419,593
4. Spares and Maintenance 24,949
Factory costs 1,440,672
5. Depreciation 184,699
6. Financial costs 184,280
Total Production Cost 1,809,651
Investment cost and income statement projection are used in estimating the project payback
period. The projects will payback fully the initial investment less working capital in 3 years.
For the envisaged plant the simple rate of return equals to 23.4%
Based on cash flow statement described in the annex part, the calculated IRR of the project is
26% and the net present value at 18 % discount is Birr 873,783
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VI. Sensitivity Analysis
The envisaged plant is profitable even with considerable cost increment. That is the plant
maintains to be profitable starting from the first year when 10 % cost increment takes place in
the sector. This result is accompanied with payback period of 3 years and 2 months.
A. Profit Generation
The project is found to be financially viable and earns a profit of birr ….million within the
project life. Such result induces the project promoters to reinvest the profit which, therefore,
increases the investment magnitude in the region.
B. Tax Revenue
In the project life under consideration, the region will collect about birr 6.01 million from
corporate tax payment alone (i.e. excluding income tax, sales tax and VAT). Such result create
additional fund for the regional government that will be used in expanding social and other basic
services in the region
The proposed project is expected to create employment opportunity to several citizens of the
region. That is, it will provide permanent employment to 14 professionals as well as support
stuffs. Consequently the project creates income of birr 419,593 thousands per year. This would
be one of the commendable accomplishments of the project.
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ANNEXES
11
Annex 1: Total Net Working Capital Requirements (in Birr)
CONSTRUCTION PRODUCTION
Year 1 Year 2 1 2 3 4
1
Annex 1: Total Net Working Capital Requirements (in Birr) (continued)
PRODUCTION
5 6 7 8 9 10
2
Annex 2: Cash Flow Statement (in Birr)
CONSTRUCTION PRODUCTION
Year 1 Year 2 1 2 3 4
TOTAL CASH INFLOW 1309761 1761552 2338740 2576448 2842272 2811600
1. Inflow Funds 1309761 1761552 230040 46008 30672 0
Total Equity 523905 704621 0 0 0 0
Total Long Term Loan 785857 1056931 0 0 0 0
Total Short Term Finances 0 0 230040 46008 30672 0
2. Inflow Operation 0 0 2108700 2530440 2811600 2811600
Sales Revenue 0 0 2108700 2530440 2811600 2811600
Interest on Securities 0 0 0 0 0 0
3. Other Income 0 0 0 0 0 0
TOTAL CASH OUTFLOW 1309761 1309761 2300115 2127763 2453569 2351919
4. Increase In Fixed Assets 1309761 1309761 0 0 0 0
Fixed Investments 1247392 1247392 0 0 0 0
Pre-production Expenditures 62370 62370 0 0 0 0
5. Increase in Current Assets 0 0 568883 113777 75851 0
6. Operating Costs 0 0 1242471 1485720 1647887 1647887
7. Corporate Tax Paid 0 0 0 0 238421 249478
8. Interest Paid 0 0 488761 221135 184279 147423
9.Loan Repayments 0 0 0 307131 307131 307131
10.Dividends Paid 0 0 0 0 0 0
Surplus(Deficit) 0 451790 38625 448685 388703 459681
Cumulative Cash Balance 0 451790 490416 939101 1327804 1787486
3
Annex 2: Cash Flow Statement (in Birr): Continued
PRODUCTION
5 6 7 8 9 10
TOTAL CASH INFLOW 2811600 2811600 2811600 2811600 2811600 2811600
1. Inflow Funds 0 0 0 0 0 0
Total Equity 0 0 0 0 0 0
Total Long Term Loan 0 0 0 0 0 0
Total Short Term Finances 0 0 0 0 0 0
2. Inflow Operation 2811600 2811600 2811600 2811600 2811600 2811600
Sales Revenue 2811600 2811600 2811600 2811600 2811600 2811600
Interest on Securities 0 0 0 0 0 0
3. Other Income 0 0 0 0 0 0
TOTAL CASH OUTFLOW 2326120 2307805 2282006 1949076 1949076 1949076
4. Increase In Fixed Assets 0 0 0 0 0 0
Fixed Investments 0 0 0 0 0 0
Pre-production Expenditures 0 0 0 0 0 0
5. Increase in Current Assets 0 0 0 0 0 0
6. Operating Costs 1647887 1647887 1647887 1647887 1647887 1647887
7. Corporate Tax Paid 260534 279076 290132 301189 301189 301189
8. Interest Paid 110567 73712 36856 0 0 0
9. Loan Repayments 307131 307131 307131 0 0 0
10.Dividends Paid 0 0 0 0 0 0
Surplus(Deficit) 485480 503795 529594 862524 862524 862524
Cumulative Cash Balance 2272966 2776761 3306355 4168879 5031404 5893928
4
Annex 3: DISCOUNTED CASH FLOW-TOTAL CAPITAL INVESTED
CONSTRUCTION PRODUCTION
Year 1 Year 2 1 2 3 4
TOTAL CASH INFLOW 0 0 2108700 2530440 2811600 2811600
1. Inflow Operation 0 0 2108700 2530440 2811600 2811600
Sales Revenue 0 0 2108700 2530440 2811600 2811600
Interest on Securities 0 0 0 0 0 0
2. Other Income 0 0 0 0 0 0
TOTAL CASH OUTFLOW 1309761 1309761 1581313 1553489 1693066 1897364
3. Increase in Fixed Assets 1309761 1309761 0 0 0 0
Fixed Investments 1247392 1247392 0 0 0 0
Pre-production Expenditures 62370 62370 0 0 0 0
4. Increase in Net Working Capital 0 0 338843 67769 45179 0
5. Operating Costs 0 0 1242471 1485720 1647887 1647887
6. Corporate Tax Paid 0 0 0 0 238421 249478
NET CASH FLOW -1309761 -1309761 527387 976951 1118534 914236
CUMMULATIVE NET CASH FLOW -1309761 -2619523 -2092136 -1115185 3349 917585
Net Present Value (at 18%) -1309761 -1109967 378761 594603 576928 399621
Cumulative Net present Value -1309761 -2419729 -2040968 -1446365 -869438 -469817
5
Annex 3: DISCOUNTED CASH FLOW-TOTAL CAPITAL INVESTED (Continued)
PRODUCTION
5 6 7 8 9 10
TOTAL CASH INFLOW 2811600 2811600 2811600 2811600 2811600 2811600
1. Inflow Operation 2811600 2811600 2811600 2811600 2811600 2811600
Sales Revenue 2811600 2811600 2811600 2811600 2811600 2811600
Interest on Securities 0 0 0 0 0 0
2. Other Income 0 0 0 0 0 0
TOTAL CASH OUTFLOW 1908421 1926962 1938019 1949076 1949076 1949076
3. Increase in Fixed Assets 0 0 0 0 0 0
Fixed Investments 0 0 0 0 0 0
Pre-production Expenditures 0 0 0 0 0 0
4. Increase in Net Working Capital 0 0 0 0 0 0
5. Operating Costs 1647887 1647887 1647887 1647887 1647887 1647887
6. Corporate Tax Paid 260534 279076 290132 301189 301189 301189
NET CASH FLOW 903179 884638 873581 862524 862524 862524
CUMMULATIVE NET CASH FLOW 1820764 2705402 3578983 4441507 5304031 6166556
Net Present Value (at 18%) 334566 277710 232406 194461 164798 139659
Cumulative Net present Value -135251 142459 374865 569326 734124 873783
Net Present Value (at 18%) 873,783
PRODUCTION
6
6 7 8 9 10
Other Income 0 0 0 0 0
RATIOS (%)