ICE-CREAM CONES MANUFACTURING

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1 ICE-CREAM CONES MANUFACTURING 1.0 INTRODUCTION Ice-creams of many varieties, flavours and in different forms (cones, cups, slices, bulk packing, candies, etc) are served round the year and demand is going up year after year. Possibly the most popular mode of serving is in cones as it is neat & clean, easy to store and there is no disposal need. With continuous increase in sale of ice-creams, demand for cones is increasing. It is a mass consumption item. 2.0 PRODUCT Ice-cream cones are prepared from wheat & corn flour and they are eaten along with the ice-cream. Pre-determined quantity of ice-cream is automatically filled in each cone. Cones are not only convenient but there is no residual waste as well. They are of different colours and flavours. This is a very common product and can be produced all over the country. Nearness to urban market should be the main guiding factor. This note considers a suitable location in Maharashtra. 2.1 Compliance with FPO is necessary. 3.0 MARKET POTENTIAL 3.1 Demand and Supply Consumption of ice-cream has been increasing steadily over the years. With changing life styles and food habits, this trend would continue even in future. Majority of the consumers prefer ice-cream in cups or cones, and party or bulk packs or serving in glass bowls or plates is very limited. Serving in paper-cups requires a spoon to eat and disposal is a problem. But in case of cones there is no need to have a spoon and they are eaten along with the ice- 135

2 cream. Thus, this is the most convenient way of serving and also preferred by customers. Icecream candies result in waste while eating and there is consumer resistance. 3.2 Marketing Strategy Many national and regional brands are existing in the market. But local brands, ice-creams prepared by local dairies and parlours are the major players. Ideally, some marketing tie-up can be made with these local players as they are easily approachable and contemplated production capacity may not permit regular and large supplies to big manufacturers. 4.0 MANUFACTURING PROCESS Automatic ice-cream cone makers are available. Initially corn and wheat flour is mixed with water and required quantity of colour and flavours are added. Then this dough is fed to the cone making machine. The machine makes cones as per the mould they are baked-in and ready cones come out of it. 50 or 100 cones are packed in polythene bags. 5.0 CAPITAL INPUTS 5.1 Land and Building A readymade shed of around 50 sq.mtrs. can accommodate machine as well as storage and packing space. It may cost Rs.1, 25,000/ Machinery Automatic cone-making machines are available in the market with varying capacities. Capacity has to be decided by the size of the market and likely tie-ups. A machine with capacity to produce 48,000 cones per shift of 8 hours or lac cones per year considering 300 working days would cost Rs.2.00 lacs. 5.3 Miscellaneous Assets Some other support assets like SS utensils, storage racks, weighing scale, sealing machine and furniture & fixtures shall be required for which a provision of Rs. 35,000/- is enough. 5.4 Utilities Power requirement shall be 5 HP whereas per day water requirement would be around ltrs. inclusive of potable and sanitation purposes. 5.5 Raw and Packing Materials The major raw materials are wheat and corn flour and some flavours and colours. Since the overall quantities of each material shall not be much, no difficulty is envisaged in procuring them. Packing materials like plastic bags and second-hand cartons shall be required. 136

3 6.0 MANPOWER REQUIREMENTS Particulars Nos. Monthly Total Monthly Salary (Rs.) Salary (Rs.) Skilled Workers 1 2,500 2,500 Helpers 2 1,250 2,500 Salesman 1 2,500 2,500 Total 7, TENTATIVE IMPLEMENTATION SCHEDULE Activity Period (in months) Application and sanction of loan 1.5 Site selection and commencement of civil work 0.5 Completion of civil work and placement of orders for machinery 1.5 Erection, installation and trial runs DETAILS OF THE PROPOSED PROJECT 8.1 Building A readymade shed of 50 sq.mtrs. would be sufficient as discussed earlier. 8.2 Machinery The total cost of machinery would be Rs lacs as explained earlier. 8.3 Miscellaneous Assets A provision of Rs.35,000/- is adequate under this head as mentioned earlier. 8.4 Preliminary & Pre-operative Expenses There will be many pre-production expenses like registration, establishment and administrative charges, market survey expenses, interest during implementation, trial run expenses etc. for which an amount of Rs.50,000/- is provided for. 8.5 Working Capital Requirements The machine is expected to run at 60% of its rated capacity in the first year for which the following working funds shall be required: Particulars Period Margin Total Bank Promoters Stock of Raw and Packing Materials ½ Month 30% Stock of Finished Goods ½ Month 25% Receivables ½ Month 25% Working Expenses 1 Month 100% Total

4 8.6 Cost of the Project & Means of Financing Item Amount Building 1.25 Machinery 2.00 Miscellaneous Assets 0.35 P&P Expenses % on Land and Building & Plant & Machinery 0.32 Working Capital Margin 0.95 Total 5.37 Means of Finance Promoters' Contribution 1.61 Term Loan from Bank/FI 3.76 Total 5.37 Debt Equity Ratio 2.33 : 1 Promoters' Contribution 30% Financial assistance in the form of grant is available from the Ministry of Food Processing Industries, Govt. of India, towards expenditure on technical civil works and plant and machinery for eligible projects subject to certain terms and conditions. 9.0 PROFITABILITY CALCULATIONS 9.1 Production Capacity & Build-up As against the annual installed capacity of lac cones, actual capacity utilisation in the first year is envisaged to be 60% and thereafter 70%. 9.2 Sales Revenue at 100% Considering 5% wastages and selling price of 30 paise per cone, the annual sales at 100% utilisation would be Rs lacs. 9.3 Raw Material Required at 100% Cost of raw materials would be around 15 paise per cone with packing cost of 3 paise each. Hence total cost for 144 lac cones would be Rs lacs. 9.4 Utilities Annual cost of utilities at 100% utilisation is expected to be Rs. 60,000/ Selling Expenses Trade discount, transportation, replacement, free sampling etc. would account for 15% of the sales value every year. 138

5 9.6 Interest Interest on term loan of Rs lacs is 12% per annum assuming repayment in 3½ years including a moratorium period of 6 months whereas 14% per annum has been computed on bank finance for working capital. 9.7 Depreciation Depreciation has been 10% on building and 20% on machinery and miscellaneous assets on WDV basis PROJECTED PROFITABILITY No. Particulars 1st Year 2nd Year A Installed Capacity Lac Nos ---- Capacity Utilisation 60% 75% Sales Realisation B Cost of Production Raw Materials Utilities Salaries Repairs and Maintenance Selling 15% Administrative Expenses Total C Profit before Interest & Depreciation Interest on Term Loan Interest on Working Capital Depreciation Profit before Tax % Profit after Tax Cash Accruals Repayment of Term Loan

6 11.0 BREAK-EVEN ANALYSIS No Particulars Amount [A] Sales [B] Variable Costs Raw and Packing Materials Utilities (60%) 0.22 Salaries (70%) 0.63 Selling Expenses (70%) 2.58 Admn Expenses (50%) 0.18 Interest on WC [C] Contribution [A] - [B] 5.21 [D] Fixed Cost 2.88 [E] Break-Even Point [D] [C] 56% 12.0 [A] LEVERAGES Financial Leverage = EBIT/EBT = = 1.25 Operating Leverage = Contribution/EBT = = 2.24 Degree of Total Leverage = FL/OL = =

7 [B] Debt Service Coverage Ratio (DSCR) Particulars 1st Yr 2nd Yr 3rd Yr 4th Yr Cash Accruals Interest on TL Total [A] Interest on TL Repayment of TL Total [B] DSCR [A] [B] Average DSCR [C] Internal Rate of Return (IRR) Cost of the project is Rs lacs. Year Cash 24% 28% 32% Accruals The IRR is around 40%. These machines are available from 1. T Alimohammad & Co, MJ Phule Market, Mumbai S.R. Engg. Works,MIDC Satpur, Nasik 3. Sujata Enterprises,Laxmi Road, Pune 4. Techno Equipments, 31 Parekh Street, Girgaum, Mumbai

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