Pre-Feasibility Study

UPVC PIPE MANUFACTURING UNIT

Small and Medium Enterprises Development Authority

Ministry of Industries & 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 KPK 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 2016
Pre-Feasibility Study UPVC Pipe Manufacturing Unit

Table of Contents
1 DISCLAIMER .................................................................................................... 3
2 EXECUTIVE SUMMARY ................................................................................... 4
3 INTRODUCTION TO SMEDA ........................................................................... 4
4 PURPOSE OF THE DOCUMENT ..................................................................... 5
5 BRIEF DESCRIPTION OF PROJECT & PRODUCT ........................................ 5
5.1 PRODUCTION PROCESS FLOW ........................................................................ 6
5.2 INSTALLED AND OPERATIONAL CAPACITIES ...................................................... 7
6 CRITICAL FACTORS ....................................................................................... 8
7 GEOGRAPHICAL POTENTIAL FOR INVESTMENT ....................................... 9
8 POTENTIAL TARGET CUSTOMERS / MARKETS .......................................... 9
9 PROJECT COST SUMMARY ........................................................................... 9
9.1 PROJECT ECONOMICS .................................................................................... 9
9.2 PROJECT FINANCING .................................................................................... 10
9.3 PROJECT COST............................................................................................ 10
9.4 SPACE REQUIREMENT .................................................................................. 11
9.5 MACHINERY & EQUIPMENT REQUIREMENT ..................................................... 11
9.6 FURNITURE & FIXTURES REQUIREMENT ......................................................... 12
9.7 OFFICE EQUIPMENT REQUIREMENT ............................................................... 12
9.8 RAW MATERIAL REQUIREMENT ..................................................................... 13
9.9 HUMAN RESOURCE REQUIREMENT ................................................................ 13
9.10 UTILITIES AND OTHER COSTS ....................................................................... 14
9.11 REVENUE GENERATION .............................................................................. 14
10 CONTACT DETAILS....................................................................................... 14
10.1 MACHINERY SUPPLIERS .............................................................................. 14
10.2 RAW MATERIAL SUPPLIERS ......................................................................... 15
11 USEFUL WEB LINKS ..................................................................................... 15
12 ANNEXURES .................................................................................................. 17
12.1 INCOME STATEMENT ................................................................................... 17
12.2 BALANCE SHEET ........................................................................................ 18
12.3 CASH FLOW STATEMENT ............................................................................ 19
13 KEY ASSUMPTIONS ...................................................................................... 20
13.1 OPERATING COST ASSUMPTIONS ................................................................ 20
13.2 PRODUCTION COST ASSUMPTIONS .............................................................. 20
13.3 REVENUE ASSUMPTIONS ............................................................................ 20
13.4 FINANCIAL ASSUMPTIONS ........................................................................... 21

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1 DISCLAIMER

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 has been taken to compile this document, the contained
information may vary due to any change in any of the concerned factors, 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. The
prospective user of this memorandum is encouraged to carry out additional
diligence and gather any information which is necessary for making an informed
decision, including taking professional advice from a qualified consultant /
technical expert before taking any decision to act upon the information.

For more information on services offered by SMEDA, please contact our website:
www.smeda.org.pk

Document Control
Document No. PREF-113
Revision No. 1
Prepared by SMEDA-Punjab
Revision Date June, 2016
Provincial Chief – Punjab
For information
[email protected]

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2 EXECUTIVE SUMMARY

The Un Plasticized Polyvinyl Chloride (abbreviated as UPVC) Pipes Manufacturing

is a project of plastic sector. UPVC pipes are generally recognized as pressure
pipelines and are most commonly used in agriculture, chemical and construction
industry. It is available in a variety of colors and finishes, especially for use in
construction of housing / buildings as cable protector, drainage and window
frames / sills as a substitute for painted wood.

This pre-feasibility study is for setting up a semi-mechanized UPVC Pipe

Manufacturing Unit. The proposed unit comprises of production facility for
manufacturing of UPVC pipes in three different diametric ranges of 3”, 4” and 6”.
The proposed unit is based on 02 extrusion lines having Twin Screw Extruders
Machines, each with a capacity of approximate production of 1,840 kgs / day. The
maximum production capacity of the unit is assumed to be 270,913 pipes annually
on 8 hours single shift basis and 300 operational days. The business will provide
employment opportunity to 22 individuals including the owner manager.

Most of the UPVC Pipes manufacturing units are part of small-scale industry and
operating in major cities like Lahore, Gujranwala, Karachi, Multan and Faisalabad.
The market for UPVC pipes exists in almost every part of the country. Ability to
generate work orders through industrial networking, direct marketing and
negotiating long term contracts is key aspect for the success of the proposed
business.

The total project cost for setting up this unit is estimated at Rs. 43.06 million out of
which Rs. 33.87 million is capital cost and Rs. 9.18 million as working capital. The
project is financed through 50% debt and 50% equity. The project NPV is around
Rs. 30.75 million, with an IRR of 35% and payback period of 3.38 years. The legal
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 development of Small and Medium Enterprises (SMEs).

With a mission "to assist in employment generation and value addition to the
national income, through 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.

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Preparation and dissemination of prefeasibility studies in key areas of investment

has 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 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 in order to serve this
objective, the document / study covers various aspects of project concept
development, start-up, and production, marketing, finance and business
management.

The purpose of this document is to facilitate potential investors in UPVC Pipe

Manufacturing Unit 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 certain 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 basis of any Investment Decision.

5 BRIEF DESCRIPTION OF PROJECT & PRODUCT

The proposed project entails setting up of a UPVC Pipe manufacturing Unit, which
has a product range of 3”, 4” and 6” pipes. UPVC, which stands for ‘Un Plasticized
Polyvinyl Chloride’ is a thermoplastic polymer composition with high rigidity and
high modulus of elasticity. This raw material is made by the chemical industry and
used for a wide variety of applications, including Underground Water Supply,
Chemical Industries, Ventilation, Sewerage Systems, and Cable Conduits.

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The sizes vary from range ½ to 16 inch diameter and PS. 3051 Standard.
Accordingly, UPVC can be divided in two major categories, i.e. Pressure Pipes
(used for Water Distribution and in Tube wells) and Non-Pressure pipes (used for
Drainage / Sewerage and as Conduits)

This Industry is playing an important role in the construction and agriculture sector,
particularly for transportation of portable drinking water. It has 95% penetration in
the conduit sector, 65% in tube well sector, 15% in drainage and 20% in water
supply sector.

Currently the most basic UPVC applications are being made in Pakistan with the
low material quality. The absence of information about UPVC processing and lack
of exposure in international markets are the reasons behind low quality pipes.
Promoting UPVC in agriculture sector would help in utilizing far flung areas for
cultivation through drip irrigation, salinity control and land reclamation. Therefore,
market for PPRC pipes exists in almost every part of the country.

For the purpose of this project, the two extruder machines with total capacity of
460 Kgs / hour will be used for the production of UPVC Pipes.

5.1 Production Process Flow

UPVC Pipes manufacturing process mainly involves the following key steps:

Extrusion Process: To get blended compound in predetermined ratio with UPVC

resin along with adding color; mixing is done in a high-speed mixer at high
temperature. The melted compound is passed through a warm dye fixed to the
extruder to get a specific size and quality of pipe.

Haul Off: Extruder is pulled by a machine that is called Haul Off. This machine is
also called take up machine / unit. Haul off is used to give proper shape to pipe.
This machine works under a fixed command / time. Haul off machine basically
consist of rollers.

Cooling: After Extruder and Haul Off the next process is to cool down the hot
pipe. Putting water in cooling tank cools down this soft pipe. After cooling the
pipes, UPVC pipe transforms an unbending form.

Cutting: After maturing pre decided / desired lengths an automatic machine

comes into force and cuts the pipes as per the standard length.

Final Inspection & Packing: This is the last process of production. Finished
products are inspected and only those complying with the standards are

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considered passed. Passed products are carefully packed and then sent to the
customers.

Figure: Process Flow Diagram of UPVC Pipes Manufacturing

Extrusion
Raw Material Haul Off
Process

Final Inspection
Cutting Cooloing
& Packing

Markets
(Wholesalers /
Retailers)

5.2 Installed and Operational Capacities

The maximum installed capacity of producing UPVC Pipes is 270,913 pipes
(around 1,104 tons in terms of weight) per year. While percentage share of 3”, 4”
and 6” diameter pipes in total production capacity are assumed as 50%, 35% and
15% respectively. These percentages are assumed on the basis of market
demands.

The physical dimensions of different diametric sizes of pipes produced by the

proposed unit are illustrated below:

Table 1: Physical Dimensions of UPVC Pipes Produced

Diametric Size Length Net Weight (Kgs)
3” 13 ft 3.19
4” 13 ft 4.12
6” 13 ft 9.50

The starting production capacity of the project is worked out at 55% and
accordingly 149,002 pipes will be produced in year one on an 8-hour single shift

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basis. Capacity utilization growth rate of 5% is considered for subsequent years,

while maximum capacity utilization is 257,367 pipes at 95% that will be attained in
9th year of operations.

The details of installed and operational capacities are provided in the table below:

Table 2: Installed and Operational Capacities

Product Mix Production Daily Annual Starting
(Pipes Process Production Production Production
Diameter) Contribution (No of Pipes) (No Pipes) (No of Pipes)
3” 50% 550 164,904 90,697
4” 35% 298 89,407 49,174
6” 15% 55 16,602 9,131
Total
100% 903 270,913 149,002
Production

6 CRITICAL FACTORS

The most critical considerations / factors for the success of this project are as
follows:

 Technical know-how and relevant experience of entrepreneur.

 Availability of skilled labor having technical knowledge.

 Ability to generate work orders through industrial networking, direct

marketing and negotiating long term contracts.

 Higher return on investment and a steady growth of business is closely

associated with regular training and capacity building of the entrepreneur
and employees.

 Stringent supervision of the production process at every level.

 Strong linkages with wholesaler / retailers for selling of product.

 Knowledge about local environmental regulations and compliance

requirements.

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7 GEOGRAPHICAL POTENTIAL FOR INVESTMENT

The major UPVC pipe-manufacturing units are established in Gujranwala, Lahore,

Karachi, Faisalabad and Multan. Therefore, any of the above cities would be
suitable for setting up a UPVC pipe-manufacturing unit. Raw material and labor is
also easily accessible in these cities. The ideal location for the project may be
outside municipal and cantonment limits, preferably in a small industrial cluster /
estate.

8 POTENTIAL TARGET CUSTOMERS / MARKETS

In Pakistan, the UPVC Pipes are being used in four major areas: Water supply,
drainage, conduits and tube wells. The main products produced in Pakistan
constitute of Polyvinyl Chloride and UPVC (Un-plasticized Polyvinyl Chloride).
UPVC is used in the drinking water supply system, especially in agriculture,
drainage and sanitation. These pipes usually fall in four categories as per their
composition are scrap based, resin based, scrap resin mix and compact type.

Therefore, the market for UPVC pipes exists in almost every part of the country.

9 PROJECT COST SUMMARY

A detailed financial model has been developed to analyze the commercial viability
of UPVC Pipe Manufacturing Unit. Various cost and revenue related assumptions
along with results of the analysis are outlined in this section.

The projected Income Statement, Cash Flow Statement and Balance Sheet are
attached as appendices.

9.1 Project Economics

All the figures in this financial model have been calculated for estimated sales of
145,898 pipes with net revenue of Rs. 111.98 million in the year one. The capacity
utilization during year one is worked out at 55% with 5 % increase in subsequent
years up to the maximum capacity utilization of 95%.

The following table shows Internal Rate of Return, Payback Period and Net
Present Value of the proposed venture.

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Table 3: Project Economics

Description Details

Internal Rate of Return (IRR) 35%

Payback Period (Yrs.) 3.38

Net Present Value (Rs.) 30,753,983

9.2 Project Financing

Following table provides details of the equity required and variables related to
bank loan:

Table 4: Project Financing

Description Details
Total Equity (50%) Rs. 21,532,215
Bank Loan (50%) Rs. 21,532,215
Markup to the Borrower (%age / annum) 14%
Tenure of the Loan (Years) 5

9.3 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
Land 4,555,555
Building and Infrastructure 13,010,000
Plant and Machinery 13,125,000
Furniture and Fixture 380,000
Office Vehicle 1,040,000
Office Equipment 216,500
Pre-operating Cost 1,551,599
Total Capital Cost 33,878,654

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Working Capital
Equipment Spare Parts Inventory 27,344
Raw Material Inventory 7,036,944
Upfront Insurance Payment 708,250
Cash 1,413,237
Total Working Capital 9,185,775
Total Project Cost 43,064,430

9.4 Space Requirement

The space requirement for the proposed UPVC Pipe Manufacturing Unit is
estimated considering various facilities including production hall, management
office, storage, open space, and etc.

Total land requirement for proposed project is around 2 kanal. It is suggested to

purchase land instead of getting on rent or lease as the project life is very high and
Plant & Machinery used in the project is expensive. Total estimated land cost is
taken at Rs. 4.55 million. Details of space requirements along with cost of building
and infrastructural requirements is given below:

Table 6: Space Requirment

Description Estimated Area Unit Cost Total Cost
(Sq.ft) (Rs.) (Rs.)
Management Office 1,000 2,500 2,500,000
Production Hall 3,700 1,800 6,660,000
Warehouse 2,000 1,800 3,600,000
Loading & Unloading 500 500 250,000
Total 13,010,000

9.5 Machinery & Equipment Requirement

Plant, machinery and equipment required for the proposed project are stated
below:
Table 7: Machinery & Equipment Requirement
Unit Cost Total Cost
Description Quantity
(Rs.) (Rs.)
UPVC Production Line
2 3,500,000 7,000,000
1) Powder Auto-Loader

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2) Twin Screw Extruder

3) Mould
4) Calibration tank
5) Haul-Off Machine
6) Automatic cutting machine
7) Stacker
Oil Ink Printer 1 500,000 500,000
Compressor 2 250,000 500,000
Mixer 1 1,000,000 1,000,000
Generator (300 KVA) 1 3,500,000 3,500,000
Contingences 5% 625,000 625,000
Total 13,125,000

9.6 Furniture & Fixtures Requirement

Details of the furniture and fixture required for the project are given below:

Table 8: Furniture & Fixture Requirement

Unit Cost Total Cost
Description Quantity
(Rs.) (Rs.)
Furniture Lump sum 250,000 250,000
Office Furnishing Lump sum 20,000 20,000
Air Conditioners 2 55,000 110,000
Total 380,000

9.7 Office Equipment Requirement

Following office equipment will be required for the proposed unit:

Table 9: Office Equipment Requirement

Unit Cost Total Cost
Description Quantity
(Rs.) (Rs.)
Computer with LCD 5 25,000 125,000
Printer 1 15,000 15,000
Telephone Set 2 2,000 4,000
Scanner 1 10,000 10,000
UPS 5 12,500 62,500

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Total 216,500

9.8 Raw Material Requirement

Following raw material required for UPVC pipes manufacturing.

Table 10: Raw Material Requirement

Description Composition Per Kg Rate Per Kg Raw Material Cost
UPVC Resin 96.62% 130 125.60
Stabilizer 1.93% 250 4.83
Filler 0.97% 200 1.93
Color 0.48% 2,000 9.66
Total 100% 142.02

9.9 Human Resource Requirement

In order to run operations of UPVC Pipe Manufacturing Unit smoothly, details of
human resources required along with monthly salary are recommended as under:

Table 11: Human Resource Requirement

Description No. of Employees Monthly Salary
Per Person (Rs.)
Owner Manager 1 60,000
Extruder Operator 2 40,000
Mixer Operator 1 25,000
Accountant 1 25,000
Marketing officers 2 25,000
Purchaser 1 20,000
Staking man 2 18,000
Office Assistant 1 15,000
Store keeper 1 15,000
Helper 6 14,000
Color Operator 1 14,000
Electrician 1 14,000

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Sweeper 1 14,000
Guard 1 14,000
Total 22

9.10 Utilities and Other Costs

An essential cost to be borne by the project is the cost of electricity. The direct
electricity (including generator) expenses are estimated to be around Rs. 475,508
per month. Furthermore, promotional expense being essential for marketing of
UPVC Pipe is estimated as 2% of revenue.

9.11 Revenue Generation

Based on the 55% capacity utilization, sales revenue during the first year of
operations is estimated as under:

Table 12: Revenue Generation – Year 1 (Ex-factory Price)*

Year 1
Product Mix Production Year 1 Sale Sales Revenue
Production
(Pipes Diameter) Percentages Price / Pipe (Rs.)
(No of Pipes)
3” 50% 90,697 635.83 57,667,874
4” 35% 49,174 810.03 39,832,415
6” 15% 9,131 1,846.52 16,860,574
Total 100% 149,002 114,360,863
Finished Goods (3,104) 768 (2,382,514)
Inventory (25
Days)
Total 111,976,991
* Variation in figures is due to rounding off factor.

10 CONTACT DETAILS

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

Providers relevant to the proposed project be given.

10.1 Machinery Suppliers

Name of Supplier Address Phone Website / E-mail

Speedup Shahdara, www.speedup.com.pk
042-37933110
Engineering Lahore [email protected]

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m
10 / 3 Modern H
021-4548132,
S Shahed E
Blowmatic 5416167
Millat Road,
Corporation Mobile: 0300
Karachi
2014380

6-Rana Tel: 042-

37323798
Azfar & Company Chambers, Lake
Fax: 042-
Road, Lahore 37235352

10.2 Raw Material Suppliers

Name of
Address Phone Website
Supplier
First Floor, 38 Z
Block, Commercial Tel:042 -
Engroplymer &
Area, Phase III, 35743690-3 www.engropolymer.com
Chemicals
DHA, Lahore, Fax:042-35743689
Pakistan.

11 USEFUL WEB LINKS

Small & Medium Enterprises Development

www.smeda.org.pk
Authority (SMEDA)
Government of Pakistan www.pakistan.gov.pk
Ministry of Industries & Production www.moip.gov.pk
Government of Punjab www.punjab.gov.pk
Government of Sindh www.sindh.gov.pk
www.khyberpakhtunkhwa.gov.
Government of Khyber Pakhtunkhwa
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 (TDAP) www.tdap.gov.pk
Security Commission of Pakistan (SECP) www.secp.gov.pk
Federation of Pakistan Chambers of Commerce
www.fpcci.com.pk
and Industry (FPCCI)

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State Bank of Pakistan (SBP) www.sbp.org.pk

Punjab Small Industries Corporation www.psic.gop.pk
Sindh Small Industries Corporation www.ssic.gos.pk
Punjab Vocational Training Council (PVTC) www.pvtc.gop.pk
Technical Education and Vocational Training
www.tevta.org
Authority (TEVTA)
Punjab Industrial Estates (PIE) www.pie.com.pk
Faisalabad Industrial Estate Development and
www.fiedmc.com.pk
Management Company (FIEDMC)
Gujranwala Tools Dies and Molds Center
www.gtdmc.org.pk
(GTDMC)
Pakistan Industrial and Technical Assistance
www.pitac.gov.pk
(PITAC)

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12 ANNEXURES

12.1 Income Statement

Income Statement
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Revenue 111,978,157 133,881,041 155,936,488 180,547,170 207,972,312 238,495,648 272,427,639 310,107,892 351,907,776 378,716,118
Cost of sales
Raw Material 84,443,333 100,960,417 117,592,548 136,151,597 156,833,044 179,850,857 205,439,155 233,854,037 265,375,556 285,591,871
Direct Labor 2,868,000 3,147,233 3,453,652 3,789,904 4,158,894 4,563,810 5,008,149 5,495,750 6,030,824 6,617,993
Machinery Manintenance 656,250 1,345,313 2,068,828 2,828,520 3,626,196 4,463,755 5,343,193 6,266,603 7,236,183 8,254,242
Direct Electricity & Generator 5,706,098 6,847,317 8,159,720 9,666,129 11,392,224 13,366,876 15,622,536 18,195,660 21,127,183 23,239,901
Total cost of sales 93,673,681 112,300,279 131,274,747 152,436,149 176,010,358 202,245,298 231,413,033 263,812,049 299,769,745 323,704,008
Gross Profit 18,304,476 21,580,762 24,661,740 28,111,021 31,961,954 36,250,350 41,014,606 46,295,843 52,138,031 55,012,111
General administration & selling expenses
Administration expense 2,724,000 2,989,212 3,280,246 3,599,616 3,950,080 4,334,665 4,756,694 5,219,812 5,728,021 6,285,709
Administration benefits expense 136,200 149,461 164,012 179,981 197,504 216,733 237,835 260,991 286,401 314,285
Electricity expense 403,495 484,195 576,998 683,521 805,579 945,212 1,104,717 1,286,670 1,493,967 1,643,364
Travelling expense 272,400 298,921 328,025 359,962 395,008 433,466 475,669 521,981 572,802 628,571
Communications expense (phone, fax, mail, internet, etc.) 272,400 298,921 328,025 359,962 395,008 433,466 475,669 521,981 572,802 628,571
Office vehicles running expense 208,000 228,800 251,680 276,848 304,533 334,986 368,485 405,333 445,866 490,453
Office expenses (stationary, entertainment, janitorial services, etc.) 204,300 224,191 246,018 269,971 296,256 325,100 356,752 391,486 429,602 471,428
Promotional expense 2,239,563 2,015,607 1,814,046 1,632,642 1,469,377 1,322,440 1,190,196 1,071,176 964,058 867,653
Insurance expense 708,250 632,225 556,200 480,175 404,150 411,872 329,497 247,123 164,749 82,374
Professional fees (legal, audit, consultants, etc.) 559,891 669,405 779,682 902,736 1,039,862 1,192,478 1,362,138 1,550,539 1,759,539 1,893,581
Depreciation expense 2,281,167 2,281,167 2,281,167 2,292,542 2,292,542 2,419,528 2,432,696 2,432,696 2,432,696 2,447,940
Amortization of pre-operating costs 310,320 310,320 310,320 310,320 310,320 - - - - -
Subtotal 10,319,986 10,582,425 10,916,420 11,348,274 11,860,218 12,369,947 13,090,348 13,909,790 14,850,503 15,753,929
Operating Income 7,984,490 10,998,338 13,745,320 16,762,746 20,101,736 23,880,403 27,924,257 32,386,053 37,287,528 39,258,182
Other income (interest on cash) - - - - - - - - - -
Gain / (loss) on sale of office vehicles - - - - 416,000 - - - -
Earnings Before Interest & Taxes 7,984,490 10,998,338 13,875,220 16,762,746 20,517,736 24,095,728 27,924,257 32,386,053 37,569,269 39,258,182
Interest on short term debt - - - - - - - - - -
Interest expense on long term debt (Project Loan) 2,214,141 1,838,450 1,406,653 910,370 339,971 - - - - -
Interest expense on long term debt (Working Capital Loan) 381,668 - - - - - - - - -
Subtotal 2,595,809 1,838,450 1,406,653 910,370 339,971 - - - - -
Earnings Before Tax 5,388,682 9,159,888 12,468,568 15,852,377 20,177,766 24,095,728 27,924,257 32,386,053 37,569,269 39,258,182
Tax 1,139,104 2,428,460 3,586,498 4,770,831 6,284,717 7,656,004 8,995,989 10,557,618 12,371,743 12,962,863
NET PROFIT/(LOSS) AFTER TAX 4,249,577 6,731,428 8,882,070 11,081,546 13,893,048 16,439,724 18,928,268 21,828,435 25,197,526 26,295,319

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Pre-Feasibility Study UPVC Pipe Manufacturing Unit

12.2 Balance Sheet

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 1,413,237 1,662,806 9,371,331 18,884,272 31,215,096 45,102,735 68,076,807 94,584,814 124,858,381 160,915,664 236,923,602
Accounts receivable 4,601,842 5,051,901 5,955,155 6,914,048 7,983,277 9,173,999 10,498,424 11,969,908 13,603,062 15,012,820
Finished goods inventory 1,993,057 2,343,658 2,739,280 3,180,486 3,671,982 4,218,937 4,827,020 5,502,453 6,252,058 6,743,833
Equipment spare part inventory 27,344 58,857 95,037 136,432 183,653 237,375 298,350 367,406 445,464 533,543 -
Raw material inventory 7,036,944 8,834,036 10,803,815 13,134,374 15,885,962 19,128,361 22,942,343 27,421,343 32,673,380 36,920,561 -
Pre-paid insurance 708,250 632,225 556,200 480,175 404,150 411,872 329,497 247,123 164,749 82,374 -
Total Current Assets 9,185,775 17,782,824 28,221,943 41,329,688 57,783,395 76,535,602 105,039,933 137,946,130 175,614,335 218,307,262 258,680,255
Fixed assets
Land 4,555,555 4,555,555 4,555,555 4,555,555 4,555,555 4,555,555 4,555,555 4,555,555 4,555,555 4,555,555 4,555,555
Building/Infrastructure 13,010,000 12,359,500 11,709,000 11,058,500 10,408,000 9,757,500 9,107,000 8,456,500 7,806,000 7,155,500 6,505,000
Machinery & equipment 13,125,000 11,812,500 10,500,000 9,187,500 7,875,000 6,562,500 5,250,000 3,937,500 2,625,000 1,312,500 -
Furniture & fixtures 380,000 342,000 304,000 266,000 228,000 190,000 152,000 114,000 76,000 38,000 -
Office vehicles 1,040,000 832,000 624,000 416,000 208,000 1,674,930 1,339,944 1,004,958 669,972 334,986 -
Office equipment 216,500 144,333 72,167 250,626 167,084 83,542 290,131 193,420 96,710 335,863 223,908
Total Fixed Assets 32,327,055 30,045,888 27,764,722 25,734,181 23,441,639 22,824,027 20,694,630 18,261,934 15,829,237 13,732,404 11,284,463
Intangible assets
Pre-operation costs 1,551,599 1,241,279 930,960 620,640 310,320 - - - - - -
Total Intangible Assets 1,551,599 1,241,279 930,960 620,640 310,320 - - - - - -
TOTAL ASSETS 43,064,430 49,069,991 56,917,624 67,684,509 81,535,354 99,359,630 125,734,563 156,208,063 191,443,573 232,039,666 269,964,719
Liabilities & Shareholders' Equity
Current liabilities
Accounts payable 7,725,409 9,304,486 10,925,933 12,743,813 14,780,135 17,059,340 19,608,583 22,458,040 25,484,864 24,151,735
Short term debt - - - - - - - - - - -
Total Current Liabilities - 7,725,409 9,304,486 10,925,933 12,743,813 14,780,135 17,059,340 19,608,583 22,458,040 25,484,864 24,151,735
Other liabilities
Deferred tax 1,139,104 3,567,564 7,154,062 11,924,893 18,209,611 25,865,615 34,861,604 45,419,222 57,790,965 70,753,828
Long term debt (Project Loan) 16,939,327 14,423,686 11,532,354 8,209,224 4,389,811 - - - - - -
Long term debt (Working Capital Loan) 4,592,888 - - - - - - - - - -
Total Long Term Liabilities 21,532,215 15,562,790 15,099,918 15,363,286 16,314,705 18,209,611 25,865,615 34,861,604 45,419,222 57,790,965 70,753,828
Shareholders' equity
Paid-up capital 21,532,215 21,532,215 21,532,215 21,532,215 21,532,215 21,532,215 21,532,215 21,532,215 21,532,215 21,532,215 21,532,215
Retained earnings 4,249,577 10,981,005 19,863,075 30,944,621 44,837,669 61,277,393 80,205,661 102,034,096 127,231,622 153,526,940
Total Equity 21,532,215 25,781,792 32,513,220 41,395,290 52,476,835 66,369,884 82,809,608 101,737,876 123,566,311 148,763,836 175,059,155
TOTAL CAPITAL AND LIABILITIES 43,064,430 49,069,991 56,917,624 67,684,509 81,535,354 99,359,630 125,734,563 156,208,063 191,443,573 232,039,666 269,964,719

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Pre-Feasibility Study UPVC Pipe Manufacturing Unit

12.3 Cash Flow Statement

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 4,249,577 6,731,428 8,882,070 11,081,546 13,893,048 16,439,724 18,928,268 21,828,435 25,197,526 26,295,319
Add: depreciation expense 2,281,167 2,281,167 2,281,167 2,292,542 2,292,542 2,419,528 2,432,696 2,432,696 2,432,696 2,447,940
amortization of pre-operating costs 310,320 310,320 310,320 310,320 310,320 - - - - -
amortization of training costs - - - - - - - - - -
Deferred income tax 1,139,104 2,428,460 3,586,498 4,770,831 6,284,717 7,656,004 8,995,989 10,557,618 12,371,743 12,962,863
Accounts receivable (4,601,842) (450,059) (903,253) (958,893) (1,069,229) (1,190,722) (1,324,425) (1,471,484) (1,633,153) (1,409,758)
Finished goods inventory (1,993,057) (350,601) (395,622) (441,206) (491,496) (546,955) (608,083) (675,433) (749,605) (491,775)
Equipment inventory (27,344) (31,514) (36,179) (41,395) (47,221) (53,723) (60,974) (69,056) (78,058) (88,079) 533,543
Raw material inventory (7,036,944) (1,797,092) (1,969,779) (2,330,559) (2,751,588) (3,242,399) (3,813,982) (4,479,000) (5,252,037) (4,247,181) 36,920,561
Advance insurance premium (708,250) 76,025 76,025 76,025 76,025 (7,722) 82,374 82,374 82,374 82,374 82,374
Accounts payable 7,725,409 1,579,077 1,621,447 1,817,881 2,036,322 2,279,205 2,549,243 2,849,456 3,026,824 (1,333,128)
Cash provided by operations (7,772,538) 7,358,097 10,599,858 13,086,696 16,150,237 19,952,380 23,264,203 26,508,007 30,273,567 36,393,145 76,007,938
Financing activities
Project Loan - principal repayment (2,515,641) (2,891,332) (3,323,130) (3,819,413) (4,389,811) - - - - -
Working Capital Loan - principal repayment (4,592,888) - - - - - - - - -
Short term debt principal repayment - - - - - - - - - -
Additions to Project Loan 16,939,327 - - - - - - - - - -
Additions to Working Capital Loan 4,592,888 - - - - - - - - - -
Issuance of shares 21,532,215 - - - - - - - - - -
Cash provided by / (used for) financing activities 43,064,430 (7,108,529) (2,891,332) (3,323,130) (3,819,413) (4,389,811) - - - - -
Investing activities
Capital expenditure (33,878,654) - - (250,626) - (1,674,930) (290,131) - - (335,863) -
Cash (used for) / provided by investing activities (33,878,654) - - (250,626) - (1,674,930) (290,131) - - (335,863) -
NET CASH 1,413,237 249,568 7,708,526 9,512,941 12,330,824 13,887,638 22,974,072 26,508,007 30,273,567 36,057,282 76,007,938

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Pre-Feasibility Study UPVC Pipe Manufacturing Unit

13 KEY ASSUMPTIONS

13.1 Operating Cost Assumptions

Description Details
Office Expenses (Stationery, Entertainment, 7.5% of Administrative
Janitorial services, etc.) Expense
Machinery & Equipment Maintenance 5% of Machinery Cost
Promotional Expenses 2% of Revenue
Professional Fee 0.5% of Revenue
Depreciation Method Straight Line
Depreciation Rate
Building & infrastructure 5%
Machinery & Equipment 10%
Furniture & Fixtures 10%
Office Equipment 33%
Inflation Growth Rate 10%
Electricity Price Growth Rate 10%
Salaries Growth Rate 10%

13.2 Production Cost Assumptions

Description Details
Cost of Goods Sold Growth Rate 7.5%
Raw Material Wastage 5%
UPVC Resin (25 Kg Bag) Rs. 3,250
Stabilizer (25 Kg Bag) Rs. 6,250
Filler (25 Kg Bag) Rs. 5,000
Color (1 Kg) Rs. 2,000

13.3 Revenue Assumptions

Description Details
Sales Price Growth Rate 8%
Starting Capacity Utilization 55%
Growth in Capacity 5%
Maximum Capacity Utilization 95%

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Pre-Feasibility Study UPVC Pipe Manufacturing Unit

Sales Price (Year 1)

3” Pipe (13 ft. Length) Rs. 636
4” Pipe (13 ft. Length) Rs. 810
6” mm Pipe (13 ft. Length) Rs. 1,847

13.4 Financial Assumptions

Description Details
Project Life (Years) 10
Debt: Equity 50:50
Interest rate on long term debt 14%
Discount rate for calculation of NPV 20%

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