110. PROFILE ON PRODUCTION OF GLASS BOTTLES AND TUMBLERS

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1 0. PROFILE ON PRODUCTION OF GLASS BOTTLES AND TUMBLERS

2 0-2 TABLE OF CONTENTS PAGE I. SUMMARY 0-3 II. PRODUCT DESCRIPTION & APPLICATION 0-3 III. MARKET STUDY AND PLANT CAPACITY 0-4 A. MARKET STUDY 0-4 B. PLANT CAPACITY & PRODUCTION PROGRAMME 0-7 IV. RAW MATERIALS AND INPUTS 0-8 A. RAW & AUXILIARY MATERIALS 0-8 B. UTILITIES 0-9 V. TECHNOLOGY & ENGINEERING 0-0 A. TECHNOLOGY 0-0 B. ENGINEERING 0- VI. MANPOWER & TRAINING REQUIREMENT 0-3 A. MANPOWER REQUIREMENT 0-3 B. TRAINING REQUIREMENT 0-5 VII. FINANCIAL ANALYSIS 0-5 A. TOTAL INITIAL INVESTMENT COST 0-5 B. PRODUCTION COST 0-6 C. FINANCIAL EVALUATION 0-7 D. ECONOMIC BENEFITS 0-8

3 0-3 I. SUMMARY This profile envisages the establishment of a plant for the production of glass bottles and tumblers with a capacity of 5 million bottles and 6 million tumblers per annum. The present demand for the proposed product is estimated at 2 million bottles and 8.75 million tumblers per annum. The demand is expected to reach at 43.8 million bottles and 8.9 million tumblers by the year The plant will create employment opportunities for 76 persons. The total investment requirement is estimated at about Birr million, out of which Birr 9.06 million is required for plant and machinery. The project is financially viable with an internal rate of return (IRR) of 23 % and a net present value (NPV) of Birr 6.4 million discounted at 8.5%. II. PRODUCT DESCRIPTION & APPLICATION Glass bottles and tumblers are vitreous silica compounds produced in a suction fed type blowing machine. Glass bottles are used for handling liquid, paste or powder products from beverage, cosmetic or pharmaceutical industries. Shape, color and size of glass bottles may vary according to clients demand, architecture and strength. Almost all glass bottles are flat bottom, straight with a neck for corking or sealing. Glass bottles are produced either clear, brown or in green color. Standard sizes for glass bottles may range from 50 cc to,000 cc. Typical sizes are 50,00,250,330,500,630,750 and,000 ccs. Tumblers are flat bottom, straight clear drinking glass without handles. They are usually produced as 250 cc glasses.

4 0-4 III. MARKET STUDY AND PLANT CAPACITY A. MARKET STUDY. Past Supply and Present Demand The demand for glass bottles and tumblers is met through both domestic production and imports. However, data on imports of the products is not readily available since the external statistics of the customs authority does not show the products separately. The volume of domestic production of bottles and tumblers during is shown in Tables 3.. Apparently, the quantity of glass bottles and tumblers produced in the country fluctuated from year to year but, on the average, bottles and tumblers are produced during the period under consideration. Table 3. DOMESTIC PRODUCTION OF GLASS BOTTLES AND TUMBLERS ('000 PIECES) Year Glass Tumblers Bottles Average Source: CSA, Statistical Abstract, Various Issues

5 0-5 A survey conducted on some retailers and wholesalers reveals that the market share of domestically produced glass bottles and tumblers roughly stood at 75% and 25% of the total supply, respectively. Assuming the average annual domestic production for the period under reference represents the domestic production capacity for the products and making use of the above stated market share of domestic production of the products, the effective demand for glass bottles and tumblers for the year 2006 is estimated at and 7940 pieces, respectively. The demand for bottles comes from the beverage industry, the catering industry and other commercial users of glass packing materials. Household, the catering industry and other institutions like hospitals and boarding schools constitute the major users of tumblers. The demand for the products is therefore estimated to grow at the rate of 5% annually. Thus the present demand for glass bottles and tumblers (i.e. for 2007) is estimated at and pieces, respectively. 2. Demand Projection For the reasons stated above, a 5% rate of growth is applied in projecting the demand for glass bottles and tumblers. As stated above, the market share of domestically produced bottles and tumblers is estimated at 75% and 25%, respectively. Assuming domestic producers will maintain their share, the projected demand and the market share of the envisaged is shown in Tables 3.2.

6 0-6 Table 3.2 PROJECTED DEMAND FOR GLASS BOTTLES AND TUMBLERS (PIECES) Bottles Tumblers Market Share Market Year of Share Projected Envisaged Projected of Envisaged Demand Plant Demand Plant Pricing and Distribution The prices of glass bottles and tumblers vary depending on size and quality. On the average, the unit prices of a bottle and a tumbler are Birr 5 and Birr 3, respectively. Allowing margin for

7 0-7 whole sale and retail, the unit factory gate prices of a bottle and a tumbler for the envisaged plant are estimated at Birr 3.50 and Birr.5, respectively. The envisaged plant is expected to distribute its product directly to users in the case of bottles. Tumblers can be marketed through the existing wholesale and retail network. B. PLANT CAPACITY AND PRODUCTION PROGRAMME. Plant Capacity Based on demand projection shown is Table 3.2, and capital requirement, the envisaged glass bottles and tumblers plant will have a capacity of producing 5 million pieces of glass bottles and 6 million pieces of tumblers per annum. The proposed plant is an energy intensive unit where large quantity of fuel oil is required in order to operate the glass melting furnace. Such a plant is required to operate continuously for 24 hours a day and for 350 days a year. Therefore, the proposed plant operates three shifts a day. 2. Production Programme In order to provide adequate time for developing the skill of producing glass bottles and tumblers, and develop market outlets at different locations of the country, it would be advisable to start production at a lower level and gradually build up the scale of production. Accordingly, the envisaged plant will start operation at 70% of its production capacity, during the first year of operation, and then raise up production to 80%, 90% and lastly to 00% during the next succeeding years. Table 3.3 below shows production programme.

8 0-8 Table 3.3 PRODUCTION PROGRAMME Description Unit Production Year Glass Bottles (' 000) Pcs 3,000 4,000 4,500 5,000 Tumblers ('000) Pcs 4,200 4,800 5,400 6,000 Capacity Utilization % IV. RAW MATERIALS AND INPUTS A. RAW & AUXILIARY MATERIALS The major raw materials required for manufacturing of glass bottles and tumblers are silica, limestone, soda ash and cullet. In addition to raw materials, auxiliary materials like include dolomite, ceramic colours (enamel), and packaging materials are required. Annual consumption of these materials at full production capacity of the plant and their estimated cost is given in Table 4. below. Thus, the total annual cost of raw and auxiliary materials at full capacity production will be Birr 5,293,0 of which Birr 78,865 is required in foreign currency, and the remaining Birr 5,24,46 is in local currency.

9 0-9 Table 4. RAW AND AUXILIARY MATERIALS No. Description Qty. Cost in Birr ( 000) FC LC TC A. RAW MATERIAL Silica sand Limestone Soda Ash Cullet 9,90 2,50 2,796 2, Sub total - - 5, , B. AUXILIARY MATERIAL 2 3 Dolomite Ceramic Color ( Enamel) Packing Materials As req Sub-total Total Cost , ,293.0 B. UTILITIES The major utilities required by the envisaged project are electricity, water and furnace fuel. The annual requirement of utilities and associated cost is shown in Table 4.2. The total cost of utilities is estimated at Birr 2,363,036.

10 0-0 Table 4.2 UTILITIES REQUIREMENT No. Utilities Unit Qty. Total Cost (Birr). Electric power KWh 3,00,000,425, Water M 3 80, , Furnace oil lit,750,000 9,947,500 Grand Total 2,363,036 VI TECHNOLOGY AND ENGINEERING A. TECHNOLOGY. Production Process Production of glass bottles and tumblers mainly involves cleaning, mixing, molding and packing. These processes are discussed in brief as follows. Cleaning and mixing: - The foreign matter and pieces of iron contained in the raw material will be removed and weighed in proportion to the mixing ratio with auxiliary material. Then, the mixture is proposed into molten, refined glass in the furnace at the temperature of approximately,500 0 c. Molding: - The molten mixture is molded by bottle forming and tumbler forming machines and cooled slowly in the annealing lehr. Packing: - Going through inspection, the annealed product is packed and delivered. When necessary, the bottle as well as the tumbler will be printed in ceramic colors by multi-color decorating machine. After glazing, final inspection will be conducted for delivery.

11 0-2. Source of Technology The technology required for bottles & tumblers is simple and widely applied for many years in countries such as Western Europe, China, India & Korea. It would be possible to obtain the latest technology for the manufacturing of bottles & tumblers from these countries. Please find here below the machinery supplier address:- A. ITTFLYGT, Srl Fax: ittlypt. Country of orgin: Italy B. Muhak Co., LTD Add: 4G9-6,Pong-amdong, Hoewon-gu,masan- Kyongnam Tel: Fax: Home page: B. ENGINEERING. Machinery and Equipment The required machinery and equipment for the production of glass and tumblers plant will be acquired through import. The total machinery and equipment cost is estimated at Birr 9.06 million, out of which about Birr million will be required in foreign currency. The detailed list of machinery and equipment is given in Table 5..

12 0-2 Table 5. MACHINERY AND EQUIPMENT REQUIREMENT & COST Description A. Machinery. Raw material preparation plant 2. Melting furnace 3. Forming Machine 4. Annealing lehr 5. Decorating and packing machine 6. Compressor 7. Boiler 8. Generator 9. Pumps B. Installation costs. Oil system 2. LPG system 3. Electrical System 4. Cooling system C. Equipments. Office furniture 2. Vehicles Unit Set Pcs Pcs Pcs Set Pcs Pcs Pcs Pcs Set Set Set Set Set Pcs Qty Land, Building and Civil Works The envisaged plant will require a total land area of 4,000 m 2, out of which 2,000 m 2 will be covered by factory and office buildings, stores, etc. The total cost of building and civil works, estimated at a rate of Birr 2300 per m 2, will be Birr 4.6 million. Cost for holding of land at a lease rate of 0. Birr per square meter for 80 years of

13 0-3 lease is estimated at Birr 32,000. Therefore, the total cost for land holding, building and civil works will be Birr million. 3. Proposed Location Konso s/ woreda and Surma woreda which are found in Konso s/ woreda and Benchmaji zone respectively are considered as the potential woredas for the envisaged project due to their access to raw materials. From the above woredas, Karat town, the center of Konso s/ woreda, is selected to be the location of the envisaged plant. Moreover, the location of the plant should be at a place where the workers conveniently commute or take up their lodgings in view of the fact that the plant is operated for 24 hours a day. VI. MANPOWER AND TRAINING REQUIREMENT A. MANPOWER REQUIREMENT The total manpower requirement of the envisaged project is 76 persons. The proposed manpower and the estimated annual labour cost are indicated in Table 6..

14 0-4 Table 6. MANPOWER REQUIREMENT AND LABOUR COST) Sr. Req. Monthly Annual Salary Description No. Qty. Salary (Birr) (Birr). General Manager 3,000 36, Executive Secretary,000 2, Plan and Statistics Head,800 2, Production and Technical Manager 2,500 30, Commercial and Marketing Manager 2,300 27, Finance Manager 2,300 27, Administration Manager 2,500 30, Personnel,500 8, Secretary , Glass Technologist,800 2,600. Production Workers , Technicians , Sales man , Store Head 500 6, General Accountant , Finance and Budget Accountant , General Service ,000 Sub-Total ,800 Employees Benefit (25% BS) 36,950 Training Cost 30,000 Total 74,750

15 B. TRAINING REQUIREMENT 0-5 Training is required for technical staff and operators for a period of at least one month. It is recommended that machinery supplier will provide on-job training or arrangements can be made with Addis Ababa Glass and Bottle Factory. A total of Birr 30,000 is allotted to execute the training programme. VII. FINANCIAL ANALYSIS The financial analysis of the glass bottle and tumblers project is based on the data presented in the previous chapters and the following assumptions:- Construction period year Source of finance 30 % equity 70 % loan Tax holidays 3 years Bank interest 8% Discount cash flow 8.5% Accounts receivable 30 days Raw material local 30 days Work in progress 2 days Finished products 30 days Cash in hand 5 days Accounts payable 30 days A. TOTAL INITIAL INVESTMENT COST The total investment cost of the project including working capital is estimated at Birr million, of which 32 per cent will be required in foreign currency. The major breakdown of the total initial investment cost is shown in Table 7..

16 0-6 Table 7. INITIAL INVESTMENT COST Sr. Total Cost No. Cost Items ( 000 Birr) Land lease value Building and Civil Work 4, Plant Machinery and Equipment 9, Office Furniture and Equipment Vehicle Pre-production Expenditure*, Working Capital,953.4 Total Investment cost 27,629.0 Foreign Share 32 * N.B Pre-production expenditure includes interest during construction ( Birr.65 thousand ) training (Birr 30 thousand ) and Birr 20 thousand costs of registration, licensing and formation of the company including legal fees, commissioning expenses, etc. B. PRODUCTION COST The annual production cost at full operation capacity is estimated at Birr 22 million (see Table 7.2). The material and utility cost accounts for per cent, while repair and maintenance take.27 per cent of the production cost.

17 0-7 Table 7.2 ANNUAL PRODUCTION COST AT FULL CAPACITY ('000 BIRR) Items Cost % Raw Material and Inputs 5, Utilities Maintenance and repair Labour direct Factory overheads Administration Costs Total Operating Costs 8, Depreciation Cost of Finance Total Production Cost 22, C. FINANCIAL EVALUATION. Profitability According to the projected income statement, the project will start generating profit in the first year of operation. 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.

18 Break-even Analysis The break-even point of the project including cost of finance when it starts to operate at full capacity ( year 3) is estimated by using income statement projection. BE = Fixed Cost = 42 % Sales Variable Cost 3. Pay Back Period The investment cost and income statement projection are used to project the pay-back period. The project s initial investment will be fully recovered within 4 years. 4. Internal Rate of Return and Net Present Value Based on the cash flow statement, the calculated IRR of the project is 23 % and the net present value at 8.5% discount rate is Birr 6.4 million. D. ECONOMIC BENEFITS The project can create employment for 76 persons. In addition to supply of the domestic needs, the project will generate Birr 0.78 million in terms of tax revenue. The establishment of such factory will have a foreign exchange saving effect to the country by substituting the current imports.

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