Pre-Feasibility Study

DETERGENT POWDER MANUFACTURING UNIT

Small and Medium Enterprises Development Authority

Ministry of Industries and Production
Government of Pakistan
www.smeda.org.pk

HEAD OFFICE
4th Floor, Building No. 3, Aiwan-e-Iqbal Complex, Egerton Road,
Lahore
Tel: (92 42) 111 111 456, Fax: (92 42) 36304926-7
[email protected]

REGIONAL OFFICE REGIONAL OFFICE REGIONAL OFFICE REGIONAL OFFICE

PUNJAB SINDH Khyber Pakhtunkhwa BALOCHISTAN

3rd Floor, Building No. 3, 5TH Floor, Bahria Ground Floor Bungalow No. 15-A
Aiwan-e-Iqbal Complex, Complex II, M.T. Khan Road, State Life Building Chaman Housing Scheme
Egerton Road Lahore, Karachi. The Mall, Peshawar. Airport Road, Quetta.
Tel: (042) 111-111-456 Tel: (021) 111-111-456 Tel: (091) 9213046-47 Tel: (081) 831623, 831702
Fax: (042) 36304926-7 Fax: (021) 5610572 Fax: (091) 286908 Fax: (081) 831922
[email protected] [email protected] [email protected] [email protected]

June 2021
Pre-Feasibility Study Detergent Powder Manufacturing Unit

TABLE OF CONTENTS
1 DISCLAIMER ...................................................................................................................2
2 EXECUTIVE SUMMARY ..................................................................................................3
3 INTRODUCTION TO SMEDA ..........................................................................................3
4 PURPOSE OF THE DOCUMENT.....................................................................................4
5 BRIEF DESCRIPTION OF PROJECT AND PRODUCT ...................................................4
5.1 Production Process Flow........................................................................................ 5
5.2 Proposed Product Mix ............................................................................................ 5
5.3 Installed and Operational Capacity......................................................................... 6
6 CRITICAL SUCCESS FACTORS.....................................................................................6
7 GEOGRAPHICAL POTENTIAL FOR INVESTMENT .......................................................7
8 POTENTIAL TARGET CUSTOMERS / MARKTETS........................................................7
9 PROJECT COST SUMMARY ..........................................................................................7
9.1 Project Economics ................................................................................................. 7
9.2 Project Cost ........................................................................................................... 9
9.3 Space Requirement ............................................................................................. 10
9.4 Machinery and Equipment Requirement............................................................... 10
9.5 Furniture and Fixtures Requirement ..................................................................... 11
9.6 Office Equipment Requirement ............................................................................ 11
9.7 Vehicles Requirement .......................................................................................... 12
9.8 Raw Material Requirement ................................................................................... 12
9.9 Human Resource Requirement ............................................................................ 13
9.10 Utilities and Other Cost ........................................................................................ 14
9.11 Revenue Generation ............................................................................................ 14
10 CONTACT DETAILS ......................................................................................................14
11 USEFUL WEB LINKS ....................................................................................................15
12 ANNEXURES .................................................................................................................17
12.1 Income Statement ................................................................................................ 17
12.2 Balance Sheet...................................................................................................... 18
12.3 Cash Flow Statement ........................................................................................... 19
12.4 Machinery Details................................................................................................. 20
13 KEY ASSUMPTIONS .....................................................................................................21
13.1 Operating Cost Assumptions ................................................................................ 21
13.2 Production Cost Assumptions .............................................................................. 21
13.3 Revenue Assumptions ......................................................................................... 22

June 2021 1
Pre-Feasibility Study Detergent Powder Manufacturing Unit

1 DISCLAIMER

The objective of this information memorandum is to introduce the subject matter and
provide a general idea and information on the said matter. Although the material
included in this document is based on data/information gathered from various reliable
sources; however, it is based upon certain assumptions, which may differ from case to
case. The information has been provided on as is where is basis without any warranties
or assertions as to the correctness or soundness thereof. Although due care and
diligence have been taken to compile this document, the contained information may
vary due to any of the concerned factors. The future is uncertain, and the actual results
may differ substantially from the presented information. SMEDA, its employees, or
agents do not assume any liability for any financial or other loss resulting from this
memorandum in consequence of undertaking this activity. The contained information
does not preclude any further professional advice to be obtained by the user. The
prospective user of this memorandum is encouraged to carry out additional diligence
and gather any information necessary for making an informed decision, including
taking professional advice from a qualified consultant/technical expert before making
any decision to act upon the information.
For more information on services offered by SMEDA, please explore our website:
www.smeda.org.pk

Document Control

Document No. PREF-NO 185

Prepared by SMEDA Punjab – OS

Revision Date June, 2021

For information [email protected]

June 2021 2
Pre-Feasibility Study Detergent Powder Manufacturing Unit

2 EXECUTIVE SUMMARY

Laundry Detergent or Washing Powder is a type of cleaning agent, used for cleaning
laundry. The detergent powder removes the dust, dirt, grease, oil, and other
environmental pollutants with ease and effectiveness. The demand for Detergent
powder is found in the market all through the year, and it is increasing day by day.
It is categorized as Fast Moving Consumer Good (FMCG).
This particular pre-feasibility study is for setting up a Detergent Powder
Manufacturing Unit. The focus of the business would be to provide quality Detergent
Powder in five different quantity packets (i.e. 5 kg, 2 kg, 1 kg, 0.5 kg, and 0.1 kg).
The produced detergent will be sold to wholesalers and retailers in major cities of
Pakistan.
The proposed unit has an installed capacity to produce 2.40 million kg of Detergent
Powder per annum, based on two shifts of 8 hours and 300 operational days.
However, starting operational capacity is assumed at 60% (i.e., 1.44 million kg) with
a gradual increase of 5% in subsequent years up to maximum capacity utilization of
95% in year 8. This production capacity is estimated to be economically viable and
justifies the capital and operational cost of the project. However, the entrepreneur’s
knowledge of the industry, competitive pricing, and strong linkage with suppliers and
wholesalers’ networks are vital factors for the success of this business.
The total cost of the proposed ‘Detergent Powder Manufacturing Unit’ is estimated
at Rs. 28.83 million out of which Rs. 17.69 million is the capital cost and Rs. 11.14
million is for working capital. The project is to be financed through 100% equity. The
project NPV is around Rs. 43.48 million, with an IRR of 37% and a Payback Period
of 3.77 years. The project will provide employment opportunities to 32 individuals,
including the owner. The legal business status of this project is proposed as ‘Sole
Proprietorship’.

3 INTRODUCTION TO SMEDA

The Small and Medium Enterprises Development Authority (SMEDA) was

established in October 1998 with an objective to provide fresh impetus to the
economy through the development of Small and Medium Enterprises (SMEs).
With a mission "to assist in employment generation and value addition to the
national income, through the development of the SME sector, by helping increase
the number, scale, and competitiveness of SMEs", SMEDA has carried out ‘sectoral
research’ to identify policy, access to finance, business development services,
strategic initiatives, and institutional collaboration and networking initiatives.

June 2021 3
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Preparation and dissemination of prefeasibility studies in key investment areas have

been a successful hallmark of SME facilitation by SMEDA.
Concurrent to the prefeasibility studies, a broad spectrum of business development
services is also offered to the SMEs by SMEDA. These services include the
identification of experts and consultants and delivery of need-based capacity
building programs of different types in addition to business guidance through help
desk services.

4 PURPOSE OF THE DOCUMENT

The objective of the pre-feasibility study is primarily to facilitate potential

entrepreneurs in project identification for investment. The project pre-feasibility may
form the basis of an important investment decision, and to serve this objective, the
document/study covers various aspects of project concept development, start-up,
production, marketing, finance, and business management.
The purpose of this document is to facilitate potential investors in the Detergent
Powder Manufacturing Unit business by providing them with a general
understanding of the business with the intention of supporting potential investors in
crucial investment decisions.
The need to come up with pre-feasibility reports for undocumented or minimally
documented sectors attains greater imminence as the research that precedes such
reports reveal specific thumb rules; best practices developed by existing enterprises
by trial and error, and certain industrial norms that become a guiding source
regarding various aspects of business set-up and it’s successful management.
Apart from carefully studying the whole document, one must consider critical
aspects provided later on, which form the basis of an informed Investment Decision.

5 BRIEF DESCRIPTION OF PROJECT AND PRODUCT

The detergent powder market is one of the key segment of the FMCG and has high
growth potential. Many varieties of detergent are available in the market, depending
upon a different percentage of active ingredients and other components. The
detergent powder manufacturing process is not complex. It involves simply mixing
different elements in the right formula.
The proposed project will make detergent by mixing Sulphonic Acid, Caustic,
Silicate, Soda, Sulphate, Minors (Color, Aroma), Salt, and Calcium in a certain
percentage. For this purpose, a fully automatic mixing machine that has the capacity
to produce 500 kg of detergent powder per hour will be used. According to proposed
business model, the unit will procure required chemicals from the local market and

June 2021 4
Pre-Feasibility Study Detergent Powder Manufacturing Unit

supply detergent powder packed in five different sizes (i.e. 5 kg, 2 kg, 1 kg, 0.5 kg,
and 0.1 kg) to wholesalers and retailers. The unit will also have an in-house packing
facility. About 2.5% of the total production is considered wastage and typical in the
detergent and soap manufacturing process. The legal business status of this project
is assumed to be ‘Sole Proprietorship.

5.1 Production Process Flow

There are three different methods of manufacturing of dry laundry detergents, i.e.
Spray Drying, Agglomeration or Dry Mixing. The combination of these methods can
also be used for manufacturing depending upon the production facility. The
proposed unit will use Blending / Mixing Process because it is very simple, cost
effective and easy to manage. This process starts with mixing of all the ingredients
(i.e. different chemicals) in the mixing machines as per the standard formulated
recipe (explained in raw material section). After adding the color and fragrance the
dry detergent powder is packed in different sized packets.
Figure 1: Production Process Flow

Ingredients

Mixing

Settling /
Drying

Packing

5.2 Proposed Product Mix

The product mix would include Detergent Powder packed in five different sizes.
Detailed production mix is given in the table below:

June 2021 5
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Table 1: Product Mix

Pack Size (kg) Production Percentage

5.0 20%
2.0 20%

1.0 25%
0.5 (500 gm) 25%

0.1 (100 gm) 10%

Total 100%

5.3 Installed and Operational Capacity

The installed and operational capacity of the Detergent Powder Manufacturing Unit
mainly depends upon the installed machinery.
The proposed business will have the capacity to produce 2.4 million kg (4.53 million
packets) of detergent powder per year and 500 kg per hour. The maximum capacity
utilization is assumed at 95%. However, during the 1st year of operation unit will
operate at 60% capacity and produce 1.44 million kg (2.72 million packets) of
detergent powder. The details of operational and installed capacity are provided in
the table below:
Table 2: Installed and Operational Capacity-(No. of Packets)

Total Operational Maximum

Pack Size (kg) Installed Capacity 60% Operational Capacity
Capacity (Year 1) 95% (Year 8)

5.0 96,000 57,600 91,200

2.0 240,000 144,000 228,000

1.0 600,000 360,000 570,000

0.5 (500 gm) 1,200,000 720,000 1,140,000

0.1 (100 gm) 2,400,000 1,440,000 2,280,000

Total 4,536,000 2,721,600 4,309,200

6 CRITICAL SUCCESS FACTORS

Following are critical success factors associated with this business:

June 2021 6
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Ø Prior knowledge and information about the Chemical Industry, especially

detergent and soap manufacturing.
Ø Selection of appropriate plant and machinery.
Ø Strong linkages with raw material suppliers for sourcing quality material on
time at economical prices.
Ø Efficient management of stock to keep inventory cost at the minimum.
Ø Induction of trained human resources for the handling of business
operations, especially in production and sales.
Ø Stringent supervision of the production process at every level.
Ø Effective marketing and distribution of the product, particularly to the
retailers.

7 GEOGRAPHICAL POTENTIAL FOR INVESTMENT

Due to the existence of the potential target customers in metropolitan cities, it is

recommended to establish the proposed venture in any major city. therefore, cities
like Lahore, Islamabad, Karachi, Rawalpindi, Peshawar, Quetta, etc., are the most
suitable locations for erecting the proposed Detergent Powder Manufacturing Unit.
It is important to find a location with adequate availability of electricity, skilled labour,
raw material and other infrastructure.

8 POTENTIAL TARGET CUSTOMERS / MARKTETS

The potential target customers of the produced Detergent Powder will be mainly
households and commercial laundry cleaners etc. The product will be sold through
wholesalers and retailers to the potential customer segments.

9 PROJECT COST SUMMARY

A detailed financial model has been developed to analyze the commercial viability
of the Detergent Powder Manufacturing Unit. Various cost and revenue-related
assumptions, along with the analysis results, are outlined in this section.
The projected Income Statement, Balance Sheet, and Cash Flow Statement are
attached as annexures.

9.1 Project Economics

All the figures in this financial model have been calculated for estimated sales of Rs.
133.4 million in year one. To financially appraise the project, a 100% Equity-Based

June 2021 7
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Business Model has been assumed. The following table shows the Internal Rate of
Return, Payback Period, and Net Present Value of the proposed venture:
Table 2: Project Economics (Equity Financed)

Description Details

Internal Rate of Return (IRR) 37%

Payback Period (Yrs.) 3.77

Net Present Value (Rs.) 43,482,809

Calculation of break-even analysis is as follows:

Table 3: Breakeven (100% Equity-Based)

Break-Even
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Analysis

Break-Even
106,131,376 105,958,313 106,118,534 102,884,874 104,933,207 114,029,828 117,014,805 120,631,764 119,752,058 125,983,073
Revenue

Break-Even
2,165,011 2,039,133 1,926,619 1,762,180 1,695,532 1,738,223 1,682,759 1,636,579 1,532,683 1,521,163
Units
Margin of 20% 31% 39% 48% 53% 55% 59% 62% 64% 65%
Safety

However, for further explanation, the Project Economics based on Debt:Equity (i.e.,
50:50) Model has also been computed. Based on the Debt:Equity model, the
Internal Rate of Return, Payback Period, and Net Present Value of the proposed
project are provided in the table below:
Table 4: Project Economics Based on Debt (50%):Equity (50%)

Description Details

Internal Rate of Return (IRR) 35%

Payback Period (Yrs.) 4.09

Net Present Value (Rs.) 52,184,408

The financial assumptions for Debt: Equity is as follows:

Table 5.1: Financial Assumptions for Debt: Equity Model

Description Details

Debt 50%

Equity 50%

June 2021 8
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Interest Rate on Debt 12%

Debt Tenure (Years) 5

Debt Payment / Year 1

The projected Income Statement, Balance Sheet, and Cash Flow Statement
enclosed as annexures are based on a 100% Equity-Based Business Model.

9.2 Project Cost

Following fixed and working capital requirements have been identified for operations
of the proposed business.
Table 5: Project Cost

Description Amount Rs.

Capital Cost
Machinery and Equipment 11,154,176
Office Vehicles 2,655,237
Pre-Operating Costs 1,286,000
Furniture and Fixtures 1,071,000
Office Equipment 928,630
Security Deposit for Rental Building 450,000
Legal, Licensing and Training Costs 150,000
Total Capital Cost 17,695,043
Working Capital
Raw Material Inventory 8,453,650
Cash 1,739,992
Upfront Insurance Payment 467,387
Upfront Building Rental 450,000
Equipment Spare Part Inventory 29,375
Total Working Capital 11,140,404
Total Project Cost 28,835,447

June 2021 9
Pre-Feasibility Study Detergent Powder Manufacturing Unit

9.3 Space Requirement

An estimated area of 5,855 sq. ft. (around 1.30 kanal) will be required for the
proposed venture. In order to reduce the initial capital expenditure, the proposed
detergent powder manufacturing unit will be established on rental premises.
Therefore, the building may be acquired in the industrial state or the outskirts of big
cities. The rent of the building will depend on the area and geographical location of
the unit.
The project's infrastructure requirement mainly comprise a production hall,
warehouses for storage of raw materials and finished goods along with an admin
block for offices of production and administration staff. However, majority of units
operating in the industry do not follow any set pattern. The following table shows the
estimated space requirement for different operations:
Table 6: Space Requirement

Description Area (Sq. Ft.)

Stores for Raw Material, Finished Goods and Spares
2,500
Warehouse
Packing Area 1,300
Production Facility 800
Management Building 500
Lab and Quality Test 450
Pavement / Driveway 225
Electric Room 80
Total 5,855

For this particular pre-feasibility, the rent amount has been determined at Rs.
150,000 per month, to be paid on a quarterly basis in advance.

9.4 Machinery and Equipment Requirement

Machinery and equipment for the proposed project are stated below:
Table 7: Machinery and Equipment

Unit Cost Total Cost

Description Quantity
(Rs.) (Rs.)

Packing Machine* 1 5,524,853

June 2021 10
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Detergent Mixer 1 784,125

Custom Dusty, Sale Tax, Clearance

- 2,785,728
Charges

Installation Cost (Fabrication cost) 1 909,471 909,471

Generator (Hyundai HDG30 30Kva / 1 800,000 800,000
24Kw Three Phase Diesel Generator)

Experts Cost 1 200,000 200,000

Lab Equipment 1 150,000 150,000

Total 11,154,177

*Details are given in Annex 12.4.

9.5 Furniture and Fixtures Requirement

Details of the furniture and fixture required for the project are given below:
Table 8: Furniture and Fixture

Unit Cost Total Cost

Description Quantity
(Rs.) (Rs.)

Electric Wiring and Lighting 750,000 750,000

Chairs 19 6,726 127,800

Table 6 18,200 109,200

CCTV 1 30,000 30,000

Guest Chairs 5 5,800 29,000

Sofa Set 1 25,000 25,000

Total 1,071,000

9.6 Office Equipment Requirement

Following office equipment will be required for Detergent powder Manufacturing
Unit:

June 2021 11
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Table 9: Office Equipment

Unit Cost Total Cost

Description Quantity
(Rs.) (Rs.)

Air Conditioners 3 83,000 249,000

Laptops 3 65,000 195,000
Industrial Exhaust Fans 3 38,610 115,830
Computers 3 30,000 90,000
Fridge 1 51,500 51,500
Fans 11 4,500 49,500
Water Cooler 1 45,000 45,000
Energy Savers 45 800 36,000
LED 1 32,500 32,500
Computer printer 2 13,200 26,400
Water Dispenser 1 16,000 16,000
Telephones 7 1,200 8,400
Microwave Oven 1 7,500 7,500
Exhaust Fans 2 3,000 6,000
Total 928,630

9.7 Vehicles Requirement

Details of the vehicles required for the project are given below:
Table 10: Vehicles

Unit Cost Total Cost

Description Quantity
(Rs.) (Rs.)
Mini Truck 1 2,500,000 2,500,000
Honda CD-70 1 77,900 77,900
Registration fee 3% 77,337
Total 2,655,237

9.8 Raw Material Requirement

Following are the details of raw material required for the proposed venture:

June 2021 12
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Table 112: Raw Material – 5 kg Detergent Powder

Description Percentage Cost (Rs)

Sulphonic Acid 12% 45

Caustic 3% 5
Silicate 7% 35
Soda 16% 80
Sulphate 12% 75
Minors (Color, Aroma) 0.8% 20
Salt 48% 6
Calcium 0.8% 15
Total 100% 281

9.9 Human Resource Requirement

In order to run the operations of Detergent Powder Manufacturing Unit smoothly,
details of human resources required along with a number of employees and monthly
salary are recommended as under:
Table 13: Human Resource

Monthly Salary per

Description No. of Employees
Person (Rs.)
CEO 1 100,000
Marketing and Sales Manager 1 75,000
Production Supervisor 2 40,000
Account Officer 1 35,000
Sales Officer 2 35,000
HSE Officer 1 35,000
Machine Operator 4 30,000
Admin / IT 1 30,000
Lab Assistant 1 30,000
Store In-charge 1 25,000
Security Guard 2 20,000

June 2021 13
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Electrician 2 20,000
Driver 1 20,000
Labour 10 18,000
Office Boys 2 18,000
32

It is assumed that the owner would have prior experience or knowledge about the
Detergent powder manufacturing business. Salaries of all employees are estimated
to increase by 10% annually.

9.10 Utilities and Other Cost

An essential cost to be borne by the business is the cost of electricity; the annual
electricity expenses is estimated as Rs. 1.53 million. This project also requires
marketing and promotional activities for which Rs. 2.67 million will be spent in year
1. The cost of maintenance of machinery is assumed as Rs. 1.41 million during first
year.

9.11 Revenue Generation

Based on the operational capacity utilization of 60%, sales revenue during the first
year of operations is provided in the table below:
Table 14: Revenue Generation (Year 1)

Rate Per Unit Quantity Sold Total Revenue

Packet Size (kg)
(Rs.) (No. of Packs) (Rs.)

5.0 410 57,600 23,616,000

2.0 175 144,000 25,200,000

1.0 95 360,000 34,200,000

0.5 50 720,000 36,000,000

0.1 10 1,440,000 14,400,000

Total 2,721,600 133,416,000

10 CONTACT DETAILS

In order to facilitate potential investors, contact details of private-sector vendors

relevant to the proposed project is given below:

June 2021 14
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Table 12: Suppliers

Name of Supplier Type of supplies Address / Phone

Zhejiang Zhonghao
[email protected]
Machinery Machinery
+ 86 0577 86818000
Technology Co.Ltd
Hyundai HDG30 30Kva /
www.shoppingum.com/pric
Shopingham 24Kw Three Phase Diesel
e/50kva-generator/
Generator
www.whatprice.com.pk/ind
HP Printer ex.php/computers/printers/
hp-printers
www.apnafurniture.pk/prod
uct/ace-office-table-or-
Woodpecker Office Furniture workstation/
0331-8999222, 0331-
7151566

11 USEFUL WEB LINKS

Small and Medium Enterprises

www.smeda.org.pk
Development Authority (SMEDA)
Government of Pakistan www.pakistan.gov.pk
Ministry of Industries and Production www.moip.gov.pk
Ministry of Education, Training, and
http://moptt.gov.pk
Standards in Higher Education
Government of Punjab www.punjab.gov.pk
Government of Sindh www.sindh.gov.pk
Government of Khyber Pakhtunkhwa www.khyberpakhtunkhwa.gov.pk
Government of Balochistan www.balochistan.gov.pk
Government of Gilgit Baltistan www.gilgitbaltistan.gov.pk
Government of Azad Jamu & Kashmir www.ajk.gov.pk
Trade Development Authority of Pakistan
www.tdap.gov.pk
(TDAP)

June 2021 15
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Security and Exchange Commission of

www.secp.gov.pk
Pakistan (SECP)
Federation of Pakistan Chambers of
www.fpcci.com.pk
Commerce and Industry (FPCCI)
State Bank of Pakistan (SBP) www.sbp.org.pk
Punjab Vocational Training Council (PVTC) www.pvtc.gop.pk
Technical Education and Vocational
www.tevta.org
Training Authority (TEVTA)
Pakistan Chemicals Manufacturers
www.pcma.org.pk
Association
Pakistan Soap Manufacturers Association www.psma.com.pk
Faisalabad Industrial Estate Development
www.fiedmc.com.pk
and Management Company (FIEDMC)
Punjab Industrial Estate Development and
www.pie.com.pk
Management Company (PIEDMC)
Punjab Small Industries Corporation www.psic.gop.pk
Sundar Industrial Estate www.sie.com.pk
Quaid-e-Azam Industrial Estate www.qie.com.pk
Sindh Small Industries Corporation www ssic.gos.pk

June 2021 16
Pre-Feasibility Study. Detergent Powder Manufacturing Unit

12 ANNEXURES

12.1 Income Statement

Calculations SMEDA
Income Statement

Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Revenue 133,416,000 153,206,040 174,890,587 198,625,738 224,579,501 252,932,664 283,879,719 317,629,863 336,687,655 356,888,914

Cost of sales
COGS-RM & Packing 101,443,800 115,392,323 130,482,088 146,792,349 164,407,431 183,417,040 203,916,591 226,007,555 237,307,933 249,173,330
Operation costs 1 (direct labor) 4,935,000 5,535,115 6,089,325 6,698,923 7,369,456 8,107,023 8,918,333 9,810,765 10,803,688 11,884,056
Operating costs 2 (machinery maintenance) 1,410,000 1,635,375 1,849,444 2,080,831 2,330,733 2,600,424 2,891,256 3,204,671 3,368,598 3,537,028
Operating costs 3 (direct electricity) 1,100,027 1,310,865 1,552,871 1,830,170 2,147,399 2,509,773 2,923,147 3,394,098 3,733,508 4,106,859
Total cost of sales 108,888,827 123,873,678 139,973,728 157,402,272 176,255,019 196,634,259 218,649,328 242,417,090 255,213,727 268,701,273
Gross Profit 24,527,173 29,332,362 34,916,860 41,223,466 48,324,483 56,298,404 65,230,391 75,212,773 81,473,928 88,187,641

General administration & selling expenses

Administration expense 5,952,000 6,547,200 7,201,920 7,922,112 8,714,323 9,585,756 10,544,331 11,598,764 12,758,641 14,034,505
Administration benefits expense 595,200 654,720 720,192 792,211 871,432 958,576 1,054,433 1,159,876 1,275,864 1,403,450
Building rental expense 1,800,000 1,980,000 2,178,000 2,395,800 2,635,380 2,898,918 3,188,810 3,507,691 3,858,460 4,244,306
Electricity expense 428,106 470,917 518,008 569,809 626,790 689,469 758,416 834,257 917,683 1,009,452
Water expense 66,000 69,300 72,765 76,403 80,223 84,235 88,446 92,869 97,512 102,388
Gas expense 60,000 63,000 66,150 69,458 72,930 76,577 80,406 84,426 88,647 93,080
Travelling expense 1,190,400 1,309,440 1,440,384 1,584,422 1,742,865 1,917,151 2,108,866 2,319,753 2,551,728 2,806,901
Communications expense (phone, fax, mail, internet, etc.) 297,600 327,360 360,096 396,106 435,716 479,288 527,217 579,938 637,932 701,725
Office vehicles running expense 79,657 87,623 96,385 106,024 116,626 128,289 141,117 155,229 170,752 187,827
Office expenses (stationary, entertainment, janitorial services, etc.) 297,600 327,360 360,096 396,106 435,716 479,288 527,217 579,938 637,932 701,725
Promotional expense 2,668,320 2,534,904 2,408,159 2,287,751 2,173,363 2,064,695 1,961,460 1,863,387 1,770,218 1,681,707
Insurance expense 467,387 389,671 311,954 234,238 200,775 381,127 276,393 171,659 66,925 33,463
Professional fees (legal, audit, consultants, etc.) 333,540 383,015 437,226 496,564 561,449 632,332 709,699 794,075 841,719 892,222
Depreciation expense 2,334,843 2,334,843 2,334,843 1,466,125 1,466,125 2,925,660 2,944,600 2,944,600 1,519,171 1,541,097
Amortization of pre-operating costs 257,200 257,200 257,200 257,200 257,200 - - - - -
Amortization of legal, licensing, and training costs 15,000 15,000 15,000 15,000 15,000 15,000 15,000 15,000 15,000 15,000
Property tax expense
Bad debt expense 2,668,320 2,534,904 2,408,159 2,287,751 2,173,363 2,064,695 1,961,460 1,863,387 1,770,218 1,681,707
Subtotal 19,511,173 20,286,456 21,186,537 21,353,079 22,579,278 25,381,053 26,887,872 28,564,850 28,978,403 31,130,555
Operating Income 5,016,000 9,045,906 13,730,322 19,870,387 25,745,205 30,917,351 38,342,519 46,647,923 52,495,525 57,057,086

Other income (interest on cash) 54,216 135,248 281,043 443,987 574,314 732,701 983,791 1,290,753 1,611,747 2,348,511
Gain / (loss) on sale of office equipment (IT) - - - - 246,892 - - - -
Gain / (loss) on sale of office equipment - - 186,840 - - 309,711 - - 405,239
Gain / (loss) on sale of office vehicles - - - - 1,062,095 - - - -
Earnings Before Interest & Taxes 5,070,216 9,181,154 14,198,205 20,314,374 27,628,506 31,959,763 39,326,311 47,938,676 54,512,510 59,405,597

Earnings Before Tax 5,070,216 9,181,154 14,198,205 20,314,374 27,628,506 31,959,763 39,326,311 47,938,676 54,512,510 59,405,597

Tax 941,065 2,333,404 4,089,371 6,230,031 8,789,977 10,305,917 12,884,208 15,898,536 18,199,378 19,911,959
NET PROFIT/(LOSS) AFTER TAX 4,129,151 6,847,750 10,108,834 14,084,343 18,838,529 21,653,846 26,442,102 32,040,140 36,313,132 39,493,638

June 2021 17
Pre-Feasibility Study. Detergent Powder Manufacturing Unit

12.2 Balance Sheet

Calculations SMEDA
Balance Sheet

Year 0 Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Assets
Current assets
Cash & Bank 1,739,992 2,597,282 8,222,552 14,260,872 21,258,094 24,687,017 33,929,041 44,774,275 58,485,981 70,453,745 117,427,121
Accounts receivable 7,310,466 7,852,659 8,988,949 10,233,324 11,594,664 13,082,525 14,707,189 16,479,715 17,926,507 19,002,098
Finished goods inventory 2,316,784 2,584,844 2,920,465 3,283,775 3,676,767 4,101,574 4,560,473 5,055,900 5,316,953 5,597,943
Equipment spare part inventory 29,375 35,774 42,479 50,184 59,021 69,143 80,720 93,944 103,687 114,314 -
Raw material inventory 8,453,650 10,096,828 11,988,042 14,160,874 16,653,188 19,507,649 22,772,311 26,501,277 29,217,658 32,212,468 -
Pre-paid building rent 450,000 495,000 544,500 598,950 658,845 724,730 797,202 876,923 964,615 1,061,076 -
Pre-paid insurance 467,387 389,671 311,954 234,238 200,775 381,127 276,393 171,659 66,925 33,463 -
Total Current Assets 11,140,405 23,241,804 31,547,030 41,214,532 52,347,022 60,641,097 75,039,766 91,685,739 110,374,480 127,118,526 142,027,162

Fixed assets
Security Deposit for Rental Building 450,000 450,000 450,000 450,000 450,000 450,000 450,000 450,000 450,000 450,000 450,000
Machinery & equipment 11,154,176 10,038,759 8,923,341 7,807,923 6,692,506 5,577,088 4,461,671 3,346,253 2,230,835 1,115,418 -
Furniture & fixtures 1,071,000 963,900 856,800 749,700 642,600 535,500 428,400 321,300 214,200 107,100 -
Office vehicles 2,655,237 1,770,158 885,079 - - 4,276,286 2,850,857 1,425,429 - - -
Office equipment (IT) 311,400 207,600 103,800 360,484 240,323 120,161 417,306 278,204 139,102 483,084 322,056
Office equipment 617,230 493,784 370,338 246,892 123,446 787,759 630,207 472,656 315,104 157,552 -
Total Fixed Assets 16,259,043 13,924,201 11,589,358 9,615,000 8,148,875 11,746,795 9,238,441 6,293,841 3,349,241 2,313,153 772,056

Intangible assets
Pre-operation costs 1,286,000 1,028,800 771,600 514,400 257,200 - - - - - -
Legal, licensing, & training costs 150,000 135,000 120,000 105,000 90,000 75,000 60,000 45,000 30,000 15,000 -
Total Intangible Assets 1,436,000 1,163,800 891,600 619,400 347,200 75,000 60,000 45,000 30,000 15,000 -
TOTAL ASSETS 28,835,448 38,329,805 44,027,988 51,448,932 60,843,097 72,462,891 84,338,207 98,024,580 113,753,721 129,446,679 142,799,218

Liabilities & Shareholders' Equity

Current liabilities
Accounts payable 6,191,036 7,071,683 8,029,731 9,073,172 10,209,039 11,444,959 12,789,209 14,166,223 14,959,086 13,847,143
Total Current Liabilities - 6,191,036 7,071,683 8,029,731 9,073,172 10,209,039 11,444,959 12,789,209 14,166,223 14,959,086 13,847,143

Shareholders' equity
Paid-up capital 28,835,448 28,835,448 28,835,448 28,835,448 28,835,448 28,835,448 28,835,448 28,835,448 28,835,448 28,835,448 28,835,448
Retained earnings 3,303,321 8,120,857 14,583,753 22,934,477 33,418,405 44,057,801 56,399,922 70,752,050 85,652,145 100,116,627
Total Equity 28,835,448 32,138,769 36,956,305 43,419,201 51,769,925 62,253,853 72,893,249 85,235,370 99,587,498 114,487,593 128,952,075
TOTAL CAPITAL AND LIABILITIES 28,835,448 38,329,805 44,027,988 51,448,932 60,843,097 72,462,891 84,338,207 98,024,580 113,753,721 129,446,679 142,799,218

June 2021 18
Pre-Feasibility Study. Detergent Powder Manufacturing Unit

12.3 Cash Flow Statement

Calculations SMEDA
Cash Flow Statement

Year 0 Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Operating activities
Net profit 4,129,151 6,847,750 10,108,834 14,084,343 18,838,529 21,653,846 26,442,102 32,040,140 36,313,132 39,493,638
Add: depreciation expense 2,334,843 2,334,843 2,334,843 1,466,125 1,466,125 2,925,660 2,944,600 2,944,600 1,519,171 1,541,097
amortization of pre-operating costs 257,200 257,200 257,200 257,200 257,200 - - - - -
amortization of training costs 15,000 15,000 15,000 15,000 15,000 15,000 15,000 15,000 15,000 15,000
Accounts receivable (7,310,466) (542,193) (1,136,290) (1,244,375) (1,361,340) (1,487,861) (1,624,663) (1,772,526) (1,446,793) (1,075,590)
Finished goods inventory (2,316,784) (268,060) (335,621) (363,310) (392,992) (424,806) (458,899) (495,427) (261,053) (280,991)
Equipment inventory (29,375) (6,399) (6,706) (7,704) (8,837) (10,122) (11,577) (13,224) (9,743) (10,628) 114,314
Raw material inventory (8,453,650) (1,643,178) (1,891,214) (2,172,833) (2,492,314) (2,854,461) (3,264,662) (3,728,966) (2,716,381) (2,994,810) 32,212,468
Pre-paid building rent (450,000) (45,000) (49,500) (54,450) (59,895) (65,885) (72,473) (79,720) (87,692) (96,461) 1,061,076
Advance insurance premium (467,387) 77,716 77,716 77,716 33,463 (180,352) 104,734 104,734 104,734 33,463 33,463
Accounts payable 6,191,036 880,647 958,048 1,043,441 1,135,867 1,235,920 1,344,251 1,377,014 792,863 (1,111,943)
Cash provided by operations (9,400,412) 1,683,120 7,655,485 10,044,742 12,730,841 16,847,570 20,673,780 24,945,214 31,399,718 33,863,884 72,002,533

Financing activities
Issuance of shares 28,835,448 - - - - - - - - - -
Cash provided by / (used for) financing activities 28,835,448 - - - - - - - - - -

Investing activities
Capital expenditure (17,695,043) - - (360,484) - (5,064,045) (417,306) - - (483,084) -
Cash (used for) / provided by investing activities (17,695,043) - - (360,484) - (5,064,045) (417,306) - - (483,084) -

NET CASH 1,739,992 1,683,120 7,655,485 9,684,258 12,730,841 11,783,525 20,256,474 24,945,214 31,399,718 33,380,800 72,002,533

June 2021 19
Pre-Feasibility Study. Detergent Powder Manufacturing Unit

12.4 Machinery Details

Sr.
Machine Parts Quantity Price
No.
Vertical Packer-Forming,
1 Vertical Packer 1 2,939,700
Sealing, Cutting
Ribbon Date Printer-
1 70,725
Printing Date-
Two Head 2 Head Weigher-Filling,
2 1 849,315
Weigher Weighing
Bucket Conveyor-
3 Z Type Elevator 1 870,225
Feeding-
Output Output Conveyor-
4 1 167,280
Conveyor Conveying -
Supporting Supporting Platform
5 1 488,464
Platform Support Weigher
Sub Total 7 5,385,709
Freight (Karachi, Pakistan) 139,144
Total 5,524,853

June 2021 20
Pre-Feasibility Study Detergent Powder Manufacturing Unit

13 KEY ASSUMPTIONS

13.1 Operating Cost Assumptions

Description Details

Operating Costs Growth Rate 5%

Administration Benefits Expense 10% Admin Expense
Traveling Expense 20% Admin Expense
Communication Expense 5% Admin Expense
Office Vehicles Running Expense 3% of Vehicles Cost
Office Expenses (Stationary, Entertainment,
5% Admin Expense
Janitorial Services, Etc.)
Promotional Expense 2% of Revenue
Professional Fees (Legal, Audit, Consultants,
0.3% of Revenue
Etc.)
Bad Debt Expense 2% of Revenue
Machinery and Equipment Insurance Rate 3%
Office Vehicles Insurance Rate 5%
Security Deposit for Rental Building Rs.450,000
Licenses Obtained Rs. 50,000
Depreciation Method Straight Line
Inflation Rate 10%
Electricity Price Growth Rate 10%
Water Price Growth Rate 5%
Gas Price Growth Rate 5%
Wage Growth Rate 10%

13.2 Production Cost Assumptions

Description Details

Detergent Powder Packing 5 kg 2 kg 1 kg 0.5 kg 0.1 kg

June 2021 21
Pre-Feasibility Study Detergent Powder Manufacturing Unit

Raw Material (Rs.) 281 112 56 28 6

Packing (Rs.) 12 10 8 6 4
Cost of Goods Sold Growth Rate 5%
Industrial Electricity Connection
Rs. 20 /KWH
Rate
Machinery Maintenance Rs 1 (Per kg of Production)
Production Wastage 2.5%
Cost of Goods Sale Price Growth
5%
Rate

13.3 Revenue Assumptions

Description Details

Detergent Packing 5 kg 2 kg 1 kg 0.5 kg 0.1 kg

Sale Price in Year 1 (Rs.) 410 175 95 55 10

Sale Price Growth Rate 6%
Production Capacity Utilization
60%
Year 1
Production Capacity Utilization
5%
Growth Rate
Maximum Capacity Utilization 95%
Hours Operational / Day 16
Shift Length (Hours) 8
No. of Shifts 2
Days Operational / Year 300

June 2021 22