Auto Brick Business Plan (Business Plan)

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100 k production capacity of Auto Brick Factory Business Plan. Detailed Business Plan to get financing.

Transcript of Auto Brick Business Plan (Business Plan)

Page 1: Auto Brick Business Plan (Business Plan)

TABLE OF CONTENTS

SL NO. SUBJECT PAGE NO

01. SUMMARY OF THE PROJECT 1-4

02. MANAGEMENT ASPECT 5-19

03. TECHNICAL ASPECT 20-41

04. FINANCIAL SUMMARY 42-43

05. SOCIO ECONOMIC ASPECT 44

06. MARKETING ASPECT 45-56

07. FINANCIIAL ANALYSIS 1-31

Page 2: Auto Brick Business Plan (Business Plan)

EXECUTIVE SUMMARY

1. Name of the project :

(Fully Automated Bricks Manufacturing)

2. Location of the project :

3. Registered Office :

4. Main Partner :

5. Nature of the project :

6. Brief Description of the Project:

The project envisages setting up of an automatic brick-making factory of Tunnel Kiln

technology to manufacture high quality, technically sound and marketable solid bricks. The

machine’s manufacturing capacity would be 1,00,000 pcs per day capacity with 8 hours per

day and 300 days per year operation capacity. Bangladeshi brick demand is mounting steep

day by day parallel to rapid growth of real estate sector of Bangladesh. The project design

combines a highly efficient tunnel kiln technology, with a unique technique of forming green

bricks: granulated coal is injected for internal combustion. This approach results in lower

energy usage, higher quality bricks and reduced pollution. Bricks of any size, shape and

pigmentation can be produced at the plant with minor modifications. All bricks will be of

uniform quality and will meet international standards for strength, quality and appearance.

The sponsors intend to implement the scheme with financial assistance from Bank/Financial

institution for acquisition of state of the art capital machinery, operating with efficient and

expert management team along with their skilled workforce and a vision to excellence. It is

anticipated that the project will go into commercial operation within 12 months from the date

of opening of letter of credit.

The proposed project, when implemented would fulfill to the following objects:-

a. Ensure development of new entrepreneur.

b. Earn a good return on investment by way of value addition.

c. Create a good number of employment opportunities.

d. Generate adequate profit for the sponsors.

e. Revenue to the national exchequer after expiry of Tax Holiday period of the project.

f. Ensure supply of quality products.

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8. Total Cost of the Project.

SL Item

Tk Cost in 000

01 Land & Land Development 130,00002 Factory steel structure & Civil Works 47,69403 Machinery & Equipments(Including L/C commission,Inter.freight etc.) 209,57604 Generator 1500KVA05 Cable, Cable Distribution System06 Excavator 0.5 cm 2pcs07 Pay Loader 1.5cm 2pcs08 Dumping Truck 5 Pcs09 Sub Station 1500KVA10 Local Material11 Furniture, Fixture& vehicles

Total 387,270

9. I) .Means of Finance.

(TK.in 000)

 Against Total Estimated Cost of the Project

Against Total Cost of Machinery & Equipment

Tk Amount in 000

% Tk Amount in 000 %

Long-term Loan

309,816 80% 167,661 80%

Bridge Financing

0 0% 0 0%

Owner's Equity

77,454 20% 41,915 20%

Total 387,270 100% 209,576 100%

II)

1st. year 2nd. Year 3rd. year 4th. Year

Total Working Capital

Requirement44,610.49 46,309.36 47,612.29 48,049.56

Margin against W/C Finance8,922.10 9,261.87 9,522.46 9,609.91

W/C for Bank Finance35,688.40 37,047.49 38,089.83 38,439.65

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10. Operating Results: (in 000)

1st. year 2nd. Year 3rd. year 4th. Year

Capacity Utilization 95% 97% 98% 98%

Sales 185,538 197,421 199,920 199,920

Gross Profit 84,367 82,258 81,705 80,543

Operating Profit 76,663 73,979 72,899 71,170

Net Profit 37,858 40,332 44,428 47,968

Operating Profit to sales 41.32% 37.47% 36.46% 35.60%

Net profit to sales (%) 20.40% 20.42% 22.22% 23.99%

Investment service coverage

(Time)1.08 1.11 1.18 1.25

10. a)

Qty in pc

annual, capacity

100,000 daily

Unit/Price

(In taka)

Total Amount

(Tk.in 000)

Sales:(Net Sales after inventory

adjustment Vat payment)28,500,000 6.5 185,250

Item-wise Unit Cost:Total Costin “000”

Pcs Production

Unit Cost

Raw Materials 60918.75 28500000 2.14

Salaries & Wages for Factory Stuff 8150.54 28500000 0.29

Depreciation 12863.50 28500000 0.45

Utilities 25436.25 28500000 0.89

Stores & Spares 1047.88 28500000 0.04

Repair & Maintenance 1286.35 28500000 0.05

Tax & Insurance 2038.10 28500000 0.07

Financial Expense 38804.96 28500000 1.36

Total Cost 5.28

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11. Break-even- sales : TK 113157.11 Tk 118387.63 Tk 112168.50

12. Break-even- capacity of operation: 58 % 58% 55%

13. Internal Rate of Return (IRR) : 17.03%

14. Economic Aspects:

Employment Generation : 95 Person

Cost per job created : Taka 4076.53 Thousands

Contribution to GDP : Tk 101,273.87 Tk 102,051.36 Tk102,373.62

Benefit cost ratio : 1.65

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MANAGEMENT ASPECTS

Type of the Organization:

The organization is a Private Ltd

THE PROMOTERS:

The project of………………… has been enlightened and experienced group …..(…..)

persons residing at …... They intend to set up a Automatic Brick industry with the financial

assistance from any financial institution. A pre-investment Feasibility report to this effect has

been prepared about the project design, covering in details of its probable cost, profitability

and other relevant aspects especially the, Managing Director and Directors of the company

have sufficient business/ industrial experience. It is expected that as the Managing Director

have already gathered sufficient knowledge in this line of production system as well as the

technology involved in it and marketing approach of the products it will be an extra plus

point for managing the project.

The management of the company is vested with Board of Directors of the company.

The promoters of the project are as follows:

MANAGEMENT ASPECTS

BOARD OF DIRECTORS

The proposed project will be promoted by the following seven directors. The status and the

share of each director are stated below:

Name of the Directors Share Status@100 Tk each share

Share Value in BDT

TOTALTable 4

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CORPORATE SET UP

PERSONAL DETAILS AND NET WORTH STATEMENT

Personal Details

Pic

Name :

Father’s Name :

Mother’s Name :

Marital Status :

Spouse Name :

Children :

Address :

Business Address :

Present Address :

Permanent Address :

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Education :

Profession :

Nationality :

Date of Birth :

Age :

TIN No :

ID :

Net WorthAmount in BDTAsset :LandCash / EquivalentGoldHouse hold furnitureTotalLiabilityBank LiabilityPersonal Loan and liabilityTotalNet worth (Total Asset- Total Liability)

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Personal Details Pic

Name :

Father’s Name :

Mother’s Name :

Marital Status :

Spouse Name :

Children :

Address :

Business Address :

Present Address :Permanent Address :

Education :

Profession :

Nationality :

Date of Birth :

Age :

TIN No :

ID :

Net Worth

Amount in BDTAsset :LandCash / EquivalentGoldHouse hold furnitureTotalLiabilityBank LiabilityPersonal Loan and liabilityTotalNet worth (Total Asset- Total Liability)

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Personal DetailsPic

Name :

Father’s Name :

Mother’s Name :

Marital Status :

Spouse Name :

Children :

Address :

Business Address :

Present Address :

Permanent Address :Education :

Profession :

Nationality :

Date of Birth :

Age :

TIN No :

ID :

Net Worth

Amount in BDTAsset :LandCash / EquivalentGoldHouse hold furnitureTotalLiabilityBank LiabilityPersonal Loan and liabilityTotalNet worth (Total Asset- Total Liability)

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Personal Detailspic

Name :

Father’s Name :

Mother’s Name :

Marital Status :

Spouse Name :

Children :

Address :

Business Address : Present Address :

Permanent Address :Education :

Profession :

Nationality :

Date of Birth :

Age :

TIN No :

Passport NO :

Net Worth

Amount in BDTAsset :LandCash / EquivalentGoldHouse hold furnitureTotalLiabilityBank LiabilityPersonal Loan and liabilityTotalNet worth (Total Asset- Total Liability)

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Personal Details

pic

Name :

Father’s Name :

Mother’s Name :

Marital Status :

Spouse Name :

Children :

Address :

Business Address :

Present Address :

Permanent Address :

Education :

Profession :

Nationality :

Date of Birth :

Age :

TIN No :

Passport :

Net Worth

Amount in BDTAsset :LandCash / EquivalentGoldHouse hold furnitureTotalLiabilityBank LiabilityPersonal Loan and liabilityTotalNet worth (Total Asset- Total Liability)

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Personal Details

pic

Name :

Father’s Name :

Mother’s Name :

Marital Status :

Spouse Name :

Children :

Address :

Business Address :

Present Address :

Permanent Address :

Education :

Profession :

Date of Birth :

Age :

TIN No :

Passport No :

Net Worth

Amount in BDTAsset :LandCash / EquivalentGoldHouse hold furnitureTotalLiabilityBank LiabilityPersonal Loan and liabilityTotalNet worth (Total Asset- Total Liability)

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Personal Details

pic

Name :

Father’s Name :

Mother’s Name :

Marital Status :

Spouse Name :

Children :

Address :

Business Address : Present Address :

Permanent Address :

Education :

Profession :

Nationality :

Date of Birth :

Age :

TIN No :

Passport No :

Net Worth

Amount in BDTAsset :LandCash / EquivalentGoldHouse hold furnitureTotalLiabilityBank LiabilityPersonal Loan and liabilityTotalNet worth (Total Asset- Total Liability)

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All these directors who are also holding the directorship of …….……….will add this new line

of project ……………….as a sister concern of their group along with their other

manufacturing unit. They have long and wide and deep experience in the prominent export

oriented business of the country and by virtue of their strong entrepreneurial expertise they

would carry on the project to the apex of success. A Total Quality Management approach

would assure the fact as they are already an ISO standardized group. Hopefully they would

further add greater value to country’s economy and environment by carrying the project

rightfully and successfully. The group has a yearly turnover of BDT ………. and asset value

of ……….. which is a stunning picture of the group’s immense capacity to successfully glorify

in this field.

ORGANIZATION SET UP

The overall management of the company would be vested to the board of Directors. The

Chairman/Managing Director will be responsible to keep the board and management

organized, informed and on task. As a chairman he would be the spokesperson of the

company and lead the management and administration of the company under the board

policy/guidelines of the board of directors. Besides, the management of the company will be

assisted by a team of qualified and experienced professional personnel under the leadership

of the Managing Director and the General Manager. He will exercise those powers which will

be delegated to him by the board of directors from time to time.

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ORGANIZATION CHART DESCRIVING ARRANGEMENT FOR MANAGEMENT

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General Manager

Production Manager

Extruder

Mixer M/Operator

Electrician

Dryer operator

Fire Man

Skilled worker

Un- Skilled worker

General Manager

Accounts Manger

Commercial Manger

Marketing Executive

Junior Executive

Guard/Peon

Production Manager

Engineer

Supervisor

Machine Operator

Skilled worker

Un- Skilled worker

Peon/Guard

Board of Directors

Managing Director

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TECHNICAL ASPECTS

PRODUCTION PLANNING AND OPERATION TECHNIQUE

The project envisages setting up of an automated solid,… hole and…. hole brick and

hollow block brick making unit. The demand for building material is increasing day by

day, brick is one of the pertinent objects that are of high demand and echo friendly

brick making technology is also a burning issue. The sponsors intend to implement

the scheme with financial assistance form Bank/ Financial institution with acquisition

within 12 months from the date of opening of letter of credit for imported machinery

with state of the art technology of higher quality machinery. Total fixed cost of the

project has been estimated at BDT …………..

Our chosen technology is Tunnel Klin technology developed in Germany. In addition

to kiln efficiency, the process technology employs a direct fuel injection technique to

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create better thermal bonding and reducing fuel usage and thereby lowers CO2 and

other emissions.

The Tunnel kiln can be made from firebricks or from green bricks. In the latter event, the

green bricks get “cooked” during kiln operation. The inner kiln lining is made from standard

bricks and then plastered over by refractory cement. The firing chamber can be filled

manually or automatically with green bricks.12 colum base tunnel kiln usually ……………

pcs production per day.

The fuel, granulated coal, is fed into the firing zone in the kiln through stoke holes on the

roof. Air required for the combustion process is forced from behind; and, as it reaches the

line to be fired, it is already preheated from the previous firing zone thus reducing firing time

and energy usage. The temperature in the firing zone is about 200-300° C. The process is

extremely simple and is carried out manually.

In addition to kiln efficiency, green bricks will be injected with pulverized coal, a technique

commonly used in China to make bricks. This technique enables improved thermal bonding

and reduces fuel usage, and hence CO2 and other emissions. Clay is premixed with

granulated coal and then extruded to produce the green bricks. This is a unique process that

is fundamental to the energy efficiency achieved in brick making in China. Almost 80% of the

total energy required is injected into the bricks and only about 20% is fed externally into the

firing chamber. Most of the fuel mixed into the bricks is almost completely burnt during firing.

PRODUCTION CAPACITY

The annual production capacity of bricks of the project based on two shifts operation of 8

hours each per day and 300 working days in a year and the daily production capacity is

1,00,000 pcs of solid brick.

LAND AND LOCATION

The project has been proposed to be located in Kapashiya adjacent to Dhaka city connected

with good communication from water and road transport mode. The proposed site will be

very near to electric power line. The area of land required …….. Bigha The land & land

development has been estimated Tk 1300 lac.The land has been selected considering its

suitability for setting up such a project. The site has all the logistical support like Power,

Water, Drainage and Communication for setting the project having economical labor and raw

materials available around the adjacent areas.

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CIVIL WORKS

The entire civil works of the project comprises 9369 smt. in total (Machinery room, Drying

room, Tunnel kiln, Civil Construction of shed, Office room, Labor shed, Boundary etc.)

constructions; it has been designed and will be supervised by a group of highly qualified

Architect and Engineers.

IMPORTED MACHINERY

For implementation of the scheme, the project will require state of the art capital machinery

from renowned Chinese suppliers. It will be a complete set of composition of basic operating

machinery (Back process Unit + Baking Unit + Drying Unit) along with supporting unit

including of electric cabinet and other supporting machinery and equipment. In selection of

machinery, the quality and the cutting edge technology has been given priority. The

machinery of the project has been proposed to be imported. The cost of imported machinery

has been estimated at BDT 2,09,576 thousands.

MANUFACTURING PROCESS

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Technical Plan flow chart

1、Process Flow

Clay Fuel: Coal ↓ ↓

Bulldozer or loading machine Coal crusher ↓ ↓

Box feeder Belt conveyor ↓ ↓

Belt conveyor ←← ←←← ← ← ← ←← ←←← Coal box feeder ↓

Rolling crusher ↓ Belt conveyor

↓ Double shaft mixer ←←← ←←← ←←← ←← Water adding

↓ Belt conveyor

↓ Ageing room for material

↓ Box feeder

↓ Belt conveyor

↓ (Fine pulverizing double-roll grinder)

↓ (Belt conveyor)

↓┌→→→→→→→→→ (Intense mixer and extruder) ←←←←←←←←Water addingBelt ↓Conveyor Belt conveyorfor ↓fault Vacuum extruder ←←←←←←←←←←←←←←Vacuum pumpbrick

↓| Column cutter| ↓└←←←←←←←←←←← Brick cutter

↓Green brick distributing and transportation machine

↓Stack green brick to drying car by labor

↓Hydraulic ferry pusher

↓Drying car into drying chamber

↓Drying car’s trailer

↓(Tunnel kiln) baking

↓Take out the finished brick from kiln by labor

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↓Finished brick yard

Brief description of production

Production Timing (Production hour in job process basis):

Time Raw materialtreatment

Molding Drying Baking

Workinghours/Year

2400 2400 3600 3600

Working days/Year 300 300 300 300

Workinghours/Day

8 8 12 12

Table 4

Clay and coal material prepare and treatment

By the Bulldozer or Loader to send the raw clay to the box feeder, the box feeder adopted

the valve controller; it can control the feeding quantity according to the requirements. Then,

the raw clay through the belt conveyor goes to the rolling crusher for primary pulverizing.

Coal will be crushed by the coal crusher and being piled up. Then by labor vehicle or loading

machine send the coal to coal feeder, which adopt valve controller, can control the coal

feeding quantity according to requirement. Through the belt conveyor, coal powder will go to

rolling crusher, together with the clay crushing, coal powder and clay will be mixing primary.

After primary pulverizing, the clay will be sent to the double-shaft mixer. By water adding let

the clay and the water are completely mixed round and uniformity. The water input quantity

in this process will be around 90% of the total water required. Clay after the first time mixing

will be sent to the ageing storeroom for 24-72 hours homogenization, which will make the

water filter into the clay grains and make them more uniformed. This will improve the finished

brick quality a lot.

The clay will receive second time smash by the fine pulverizing double roll grinder in order to

get the proper grain size. Then clay comes into the intense mixing and extruding machine,

by water adding again and mix, extrude, cut up, so that to get a better molding quality.

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Molding

Moisture content when molding is controlled to 18%-20%.The molding adopts JKR40/40F-25

double stage vacuum extruder. The ready raw material come from the intense mixer and

extruding machine through the belt conveyor being sent to the vacuum extruder, the vacuum

pump extract the air from the mud material. The vacuum extruder squeeze out the mud

material from the extruder mouth then pass the auto column slitter and brick cutter , being

cut into the required bricks. In order to let the surface of the brick more beautiful and

combine with the mortar more fastness when establish the building, we can add embossing

device on the forepart of the column cutter, thus the effectiveness will be better.

Drying

In order to save energy, reduce the CO2 emission and take full use of the heat, green bricks

are dried by the tunnel drying chamber with small size cross section. Heat resource comes

from the remaining heat of the Tunnel kiln. Green bricks come from the cutter then being put

on the drying cart by man after bricks distributing and transferring machine, and then it will

be sent to the drying chamber by the ferry pusher. The structure of the drying chamber is

brick-concrete structure. There are heat supply system, adjusting system and humid exhaust

system. In order to guarantee the brick’s quality, save coal fuel, we equip the control system

temperature-supervise meter. When the heat is not sufficient or coal heat quality below

standard, workers can discover in time and adopt measure accordingly, so that this can keep

the brick quality steady and prevent the pollution by the leak heat. Take daily production

1,00,000 pcs for example, use tunnel type drying chamber

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Picture: Clay brick plant show

need about 1800m2, but traditional natural drying by sunshine need about 15000m2. So that

it save big area of land for green brick drying, improve the worker’s working environment.

And the brick production do not affect by the weather, brick’s quality and production quantity

are both improved also. Compare to same capacity old type brick factory, it can save about

80% land area for the country.

Baking

Dried bricks via the hydraulic ferry pusher are sent to the trail car. Then, the workers push

the drying car onto the trail car, and then send to the Tunnel kiln for unloading, stacking and

baking. Workers will pick out the dry waste when adobe stacking. The Tunnel kiln is with

three centered arch structure. Kiln backing is mainly based on coal powder from outside,

assist by the internal combustion. In order to easy control the baking temperature, guarantee

finished brick quality, save coal energy, and avoid any additional damage of the kiln and

equipment, we equip the temperature test, alarm and protection facility in the Tunnel kiln

baking system. This will reduce the baking temperature too high or too low condition

happens, prolong the kiln’s working life time, reduce unnecessary economy and energy

expense, meanwhile will improve the factory’s work efficiency. Talk about the advantages of

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Tunnel kiln, first is High energy efficient. Take one million standard brick for example, Tunnel

kiln need about 100 ton coals for baking, with energy saving of 50-60% compare to the old

technologies. Tunnel kiln require less land area, daily production capacity 300,000pcs’

Tunnel kiln need about 2800-3000m2 lands. Its operation easy, weather proof, the kiln can

work whole year-round. Old traditional kiln can only work 5-6month. There are about 14

million hectare of land in Bangladesh, yearly abandon rate for the land is about 8000

hectare. There are over 4000 energy inefficient kilns in Bangladesh, each kiln consuming an

average of 240 tons of coal to produce one million bricks. Almost all the coal being used is

low-grade coal, each kiln there fore produce 760tones of CO2 per year. Total annual CO2

emissions from the 4000 kilns are, therefore, over 3.0 million tones. Above information

shows the old technology kiln with high pollution and high cost of energy. New technology

kiln will be beneficial for Bangladesh country.

ECHO FRIENDLINESS & POLLUTION CONTROL

We have adopted the state of the art automatic brick making technology the Tunnel Kiln

which is a green technology with energy efficient and environment friendly features

introduced by UNDP research in Bangladesh to reduce the pollution. The United Nations

Development Program (UNDP) and the Global Environment Facility (GEF) have recently

introduced energy efficient, smokeless brick-making technology to curb greenhouse gas

emissions in Bangladesh. This new device, known as the Tunnel Kiln, was originally

developed in Germany to replace the older, highly pollutant brick-making technology. It was

later modified in China and remodeled to accommodate the specific needs of Bangladesh’s

brick-making industry. As a result, brick-making technology in Bangladesh is now maximally

efficient, eco-friendly and cost-effective.

PRODUCTION PLANNING AND OPERATION

Raw materials

Raw material is clay. No impurity contained and its physical property and chemical

composition should meet the baked brick’s requirement.

.

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Products Specification

Name Dimension in inches Type

Clay brick 10×5×3 Solid & Hollow

Table 5

Power Distribution

The project will require a connected load of 1000 KW for production process and domestic

use. The Maximum demand would be 1000 KW. Required power will be met from REB.

Moreover, the project will procure Diesel generators for supply of power in case of power

failure. The cost of generator has been considered with the cost of local machinery.

Power Kwh

Connected Load(KWH) 1000

Maximum Demand(KWH) 1000

Peak Hour 6

Off-Peak Hour 18

Table 6

The power distribution system would require low voltage distribution panel 2sets, QTJ start-

up cabinet 4sets, Operation box on site 3sets, Cable, electrical wire, tools etc.

Water

The project will require water pipe and accessories, valves, water tank steel plate, water

pump etc. The cost of all these has been incorporated in the local machinery cost.

The Project

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The Proposed project has been designed to manufacture Auto Bricks, Blocks of different

kinds/sizes which have wide market demand in the country as well as all over the world.

Production Capacity

The annual rated capacity and product mix of the proposed project at 100% capacity

utilization based on one shifts Operation per day and 300 working days per year has been

given in the following table:

SL.NO. Product Mix Quantity (In pcs.) Unit Price

(In Taka)

Total Value

(TK .in ‘000’)

01 Bricks 30,000,000 8.00 240,000

Total: 30,000,000 240,000

Raw materials Requirement

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Raw Materials:

SL.NO.

ItemQuantity (In Cft.)

Unit Price(Tk.)

Total Amount(Tk.in ‘000,)

Clay 3750 Mt 11,500 43,125

Coal 2,100,000 10 21,000

Total: 64,125

Logistic

The project will carry procured raw materials through water and land with relevant mode of

transport. And also they would deliver the finished brick by truck. The project would be

situated beside river which would be good medium to transport for required clay and coal for

production.

Workforce

The project would require an estimated 95 personnel for its operation. The personnel would

comprise of 70 technical workers directly related to automated brickfield operation and 25

personnel for general and administration purpose totaling 95 personnel for the project.

A. TECHNICAL

The requirement of technical personnel based on one shift operation per day has

been estimated 70 personnel; the allocation of the personnel has been estimated

on the basis of labor requirement of each process as below

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Factory Staff:

. (Amount Tk. In 000’)

Position No(s) Salary/ Month Total Salary

Factory Office Staff

10 8,

444 1,013.28

Machine Room Staff

20 8,

267 1,984.08

Dryer Staff

10 7,

500 900.00

Klin Staff

30 8,

041 2,894.76

Total 70 6792.12

B .Administrative Staff:

SL.NO Category No. Salary/month Annually Salary

(Tk.in’000,)

01.CEO 1 40000 480

02General Manager 1 30000 360

03 Manager (Admin & Personnel) 1 15000 180

04Manager ( Marketing) 1 15000 180

05 Manager ( Finance & Accounts) 1 15000 180

06Manager ( Commercial) 1 15000 180

07Manager ( Production) 1 15000 180

08Officer Sales & Marking 1 10000 120

09Purchase Officer 1 10000 120

10Stock Officer 1 10000 120

11Commercial Officer 1 10000 120

Accounts & Finance Officer 1 10000 120

Asst. Sales Officer 1 10000 120

Asst. Marketing Officer 2 10000 240

Asst. Store officer 9 10000 1080

Security inspector 1 10000 120

Total 25 3900

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Building and other civil works.

To implement the proposed project Pretty Auto Bricks Ltd the sponsors of the project will

construct Steel Structured building having measuring areas of …….smt.project will include

Office building, factory building the total cost of building has been estimated at Tk………lac.

The details of which is given below:

SL No

Items Specifications Rate/Smt. Cost Tk. In ‘000’

01 02 03 04 0501 Kiln 144.35mx 21m

=3031sqm.

02 Drying Chamber 75mx42m=3150sqm.

04 Silo Store & machine Room 54.5mx58.58m=3188.25sqm

05 Total:

Machinery and Equipments

The cost of the proposed imported & local machinery and equipments of the project has

been estimated Tk 209,576 thousands excluding duty, tax, internal freight etc. The details of

machinery and equipments have been shown in the quotations enclosed here with.

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Land and Location

The project will be located on a plot of land measuring …… Bigha

at Kapashia,Gazipur, The cost of land is Tk. 130,000 thousands including registration, land

development cost etc.

The area of land is considered adequate for accommodating the present physical facilities of

the project as well as its future expansion.

The location of the project situated for the implementation of its functional operations since

the necessary infrastructural facilities liked road, communications, power (Electricity supply)

Gas, water supply together with the requisite manpower. Raw materials procurement &

products/ services marketing facilities are available there.

The location being within Gazipur industrial belt is very easily accessible by road transport

without any inconvenience.

The project location will enable the infrastructural provisions & electricity service connections

to be effected ready at reasonable costs, thereby effecting economization in the project

investment cost.

Since, the project location is situated within Gazipur industrial belt, it is expected there shall

be an adequate supply of locally available necessary factory workers & skilled technicians

for the project.

Erection and Installation

Erection and installation of machinery will be done by experts. An amount of Tk. ……..lac

has been estimated for this purpose.

Furniture and Fixture& Vehicles

Furniture, Fixture and vehicles of the project has been estimated at Tk…… lac.

Internal Freight.

An amount of Tk……. lac has been estimated for both imported and local machinery to

reach the project site.

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Utilities

I. Water: Water will be required the cost of which has been in corporate in the local

machinery cost as Tk….. lac. Fuel and gas Tk 375,000 thousands.

ii. Electricity

The total electricity to be required for the project has been estimated at 1000 kw at 100%

capacity and it will get from Power Development Board. The related cost has been estimated

at Tk 11 per unit.

Repair and Maintenance

The cost of repair and maintenance for machinery has been estimated @ 0.5%,1% & 1.5%

and onwards of it’s of machinery and equipments in 1st, 2nd, 3rd and subsequent years of

operation.

Stores & Spares

The stores & spares of machinery to be required has been estimated @ 0.5%,1% & 1.5%

and onwards of its cost of machinery and equipments in 1st, 2nd, 3rd and subsequent years

of operation

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FINANCIAL SUMMARY

Financial Evaluation

The Profitability analysis on the proposed Project has been computed for 10 years of

operation to assess the financial viability of the project. The financial projection that has

been made includes estimate of sales, cost of goods sold, administrative and general

expenses. The consolidated statement showing the result of the project in the earning fore

cast statement at Annexure-iii

Assumption underlying the financial projections

A. The capacity of the project is projected to be 95%, 97%, 98% of the rated capacity in the

1st three years and onwards.

B. The cost of other accessories have been kept constant throughout the period on the

assumption that increase in raw materials will be offset by increase in selling price of

products.

C. The rates of depreciation / amortization of various assets of the project are considered as

normal rate that prevails in the industrial sector.

D. Insurance premium is to be charged at 0.50% of the cost of the fixed assets and raw

materials stocks.

E. Other expenses viz.power, fuel & lubricants etc. Are charged as per prevailing market

price.

F. General and administrative expenses are estimated as per prevailing market price.

G. Tax-Holiday for the project has been estimated to be 5 years.

Debt Service Coverage Ratio (DSCR)

The details debt service coverage ratio may be seen at Annexure-x.

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Break-Even- Analysis

The break-even- analysis has been carried out on the basis of cost & sales of projected

operation. The project is expected to be break-even- at 58% of the rated capacity. The

details of break-even- analysis has been given at annexure- xvii.

Cash flow statement

The projected earning forecast statement indicates that the project will have sufficient fund

generation at the end of the year. The project will be able to all its operational expenses,

repay its debt obligation, provides substantial returns to the sponsors and build a reasonable

reserve. The detailed of cash flow may be seen at Annexure-xi.

Projected Balance sheet

The projected balance sheet also shows that the project will be able to maintain health

liquidity throughout the operational life. The derails of Balance sheet may be seen at

Annexure-xii.

Internal are Rate of Return

The internal rate of return has been computed following the DCF technique. The details are

given in Annexure-xv.

Investment Period

The investment period has been considered 7 years.

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SOCIO-ECONOMIC ASPECTS

Employment Generation:

The project after implementation will create employment opportunity for 70 persons and the

cost per job created will be Tk 4076.53 Thousands

ADDITIONAL EMPLOYMENT GENERATION AND LABOUR INTENSITY :

The proposed project expects to provide permanent employment throughout the year.

Workers, Technicians, administrative and commercial staffs and effect payment of Tk.

187,88.20 thousands annually in the 5th year of projected operation to them in the form of

wages and salaries. This will marginally alleviate the local unemployment situation and the

employees again a livelihood for themselves and their families, besides, this, the proposed

project will create huge indirect employment.

CONCLUSION

As evaluation of the Socio-economic, Private & national benefits, which expected to accrue

from the implementation of this project & continuous execution of its operational activities will

easily highlight the rational & economic justification of establishing this unit. The Project is

expected to generate very substantial financial returns for the promoters, all method of

project appraisal & analysis, financial, management & economic evaluation justify the

establishment & implementation of this unit. The unit will be able to pay to pay income tax,

after expiry of tax holiday period. Such levies & taxes will help to enhance the Governments

funds, available for public sector development expenditure.

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MARKETING ASPECT

Marketing Aspect:

.

Objective:

The objective of this market study is to examine and investigate into demand pattern,

sources and uses of Tiles, Bricks .The proposed project will be set-up for manufacturing of

different sizes and types bricks. Brick has employed by most cultures through the ages to

build everything from temples to castle, cottages to factories - even the “Great Wall” of

China. Favored for its versatility and the readily raw material from which bricks are

fashioned, clay, many ancient buildings such as those built by Romans still stand today!

MARKETING ASPECTS:

INTRODUCTION:

Modern development process has come to produce rapid urban growth. Hence one of the

objectives of planned development is to improve the physical conditioning of living such as

housing and water supply. But as people aspire for comfort rural community also needs to

have access to such basic facilities of life. In fact poor countries have come to be regarded

as rural slums and the rural to urban migration is an attempt to escape it. The program of

development of physical infrastructure, therefore, covers both urban and rural communities

in public and private sectors. The program consists of development of housing office and

commercial buildings, site development for private housing, office & commercial buildings,

city roads etc.

In the Five years plan rather a comprehensive approach was for the first time taken to bring

development to the door of people and steam urban migration. This consisted of the

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government policy of decentralization of administration and acceleration of development

activities at upzilla level. This policy will require creation of necessary physical infrastructures

there within the frame work of national physical plan and the demand for construction

materials like bricks etc. will also increase.

APPLICATION OF PRODUCTS / SERVICES:

The Products of the project will be automatic bricks, to be produced from local clay.

Automatic bricks have comparative advantage over hand made bricks in respect of unit

price, size/smoothness in surface, bright in color hardness in strength and cheaper as

compared to hand made bricks being produced by the brick fields situated in the rural areas.

the initial cost of this type of project though high but the over –head working cost is less. As

such this type of project can supply bricks at a relatively cheaper price. Furthermore it can

cater to the large volume of Government/private institutions/organizations place orders. It

may be mentioned here that some times various public works are interrupted due to

shortage of bricks. This type of project of implemented may be able to solve this problem.

Bricks are mainly used in constructing houses roads and bridges. Bangladesh is a

developing economy and from 1976 onward the economy is striving forward, in both public

and private sectors. With the development of trade and industry and overall expansion of the

economy, construction sector has also exhibited considerable growth. It has already been

mentioned here that bricks are mostly used in the construction of houses apartments, roads

and bridges. Besides the private housing sector, the major users of bricks are the various

governments. Semi-government and autonomous organization of which the following

deserve special mention

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a) Public works department

b) Roads and Highways

c) Water and power Development

d) Public health Engineering:

e) Rural Electrification

f) Pourashavas and others:

g) Zilla parishad

(i) Thanas

h) Titas Gas etc.

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TARGET MARKET –EXPORT:

Besides export potentiality, the aforesaid products will be marketed locally, as usual

practices that prevail in the country.

PROSPECTIVE BUYERS OF BRICKS IN REAL ESTATE SECTOR:

Besides, Prospective buyers of other sectors there are a good number of property

developers are registered with REAL ESTATE AND HOUSING ASSOCIATION OF

BANGADESH (REHAB). Out of which the largest/ medium standard, property developers

who are regularly develop commercial space and apartment project is shown in TABLE-1

TABLE-1

LARGEST/MEDIUM STANDARD PROPERTY DEVELOPERS IN DHAKA CITY

Sl. no

Name & Address Large/Medium standard

01 ABC REAL ESTATES LTD.ABC (6th F1)8, Kamal ataturk Avenue Banani C/A, Dhaka-1213.

Medium

02 ADVANCED DEVELOPMENT CONSULTANTS LTD.House-15, Road-11/1, Block-BBanani C/A, Dhaka-1213.

Large

03 ADVANCED DEVELOPMENT TECHNOLOGIES176, Gulshan Avenue North Gulshan, Dhaka-1212.

Large

04 AMIN MOHAMMAD FOUNDATION LTD. 764,Satmasjid Road, Amin ChamberDhanmondi Dhaka.

Large

105 ASSETS DEVELOPMENT & HOLDING LTD. House -29, Road-39, Gulshan, Dhaka-1212.

Large

06 ATLANTIC DEVELOPMENT LTD.168, Elephant Road (2nd F1) Dhanmondi Dhaka.

Medium

07 BORAK REAL ESTATE (PVT) LTD.

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UTC Building, Level-5 8 Panthapath, Dhaka-1205

Medium

08 BUILDING DEVELOPMENT & DESINGN LTD.36,Topkhana Road (2nd F1)Dhaka-1000.

Medium

09 BUILDING TECHNOLOGIES & IDEAS LTD. Road-113/A, Plot No.3 & 5Gulshan, Dhaka-1212

Large

10 CONCORD REAL ESTATE & BUILDING PRODUCT LTD.8, Mohakhali C/A, Dhaka

Large

11 DOM –INNO DEVELOPMENTS LTD.House-49, Road -17Banani, Dhaka.

12 EAST WEST PROPERTY DEVELOPMENT (PVT)LTD.195, Motijheel C/A, (13th F1),Dhaka

Large

13 ESTERN HOUSING LTD.Islam Chamber (6th F1)125/A Motijheel C/A, Dhaka.

Large

14 GREEN DELTA HOUSING & DEVELOPMENT (PVT) LTD.Meherba plaza (11th F1)33, Topkhana Road, Dhaka-1000.

Medium

15 MEGA BUILDERS LTD.42, Satmosjid Road (2nd F1)Dhanmondi, Dhaka.

Medium

16 NAGAR HOME 227, Lake Road, New DOHS, Mohakhali,Dhaka-1213

Medium

17 NAVANA REAL ESTATE LTD.House-35, Road-9A (New)Dhanmondi, Dhaka.

Medium

18 PROPERTY DEVELOPMENT LTD.12, R.K. Mision Road,GPO Box -83, Dhaka1212

Large

19 RUPAYAN HOUSING ESTATE LTD.72, Mohakhali C/A, Dhaka1212

Medium

20 SHELTECH (PVT.) LTD122/1, Kakrail Road (3rd F1)Dhaka-1000.

Large

21 SUVASTU DEVELOPMETN LTD. 69/1, Panthapath, Dhaka.

Large

22 THE STRUCTURAL ENGINEERS LTD.29/1 West panthapath Dhaka-1205

Large

23 URBAN DESIGN & DEVELOPMENT LTD. House-68 Road -6/ADhanmondi R/A, Dhaka.

Medium

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DEMAND/SUPPLY ANALYSIS (AUTOMATIC BRICKS):

DEMAND ANALYSIS AT MICRO LEVEL:

Bricks are heavy in weight and cannot be transported easily and cheaply to any long

distance. Therefore, bricks and like designed ceramic bricks are sometimes brought in form

distant places

The plant under consideration will be located at Keranigonj and is expected to supply bricks

to various parts of Dhaka, Manikganj and Gazipur District.The demand for bricks depends on

the number on additional brick built houses As per census 1991 total household in Dhaka

and Gazipur District stood at 125,487 of which about 50 & a/ has been assumed to be

pucca houses . on the basis of the growth date of 5% per annum, the projected number of

pucca houses has been estimated and is shown in Table –11

Table –11

ESTIMATED NUMBER OF PUCCA HOUSES

Year No. of Houses1999 1,017,9422000 1,053,0432001 1,088,1442002 1,123,2452003 1,158,3462004 1,193,4472005 1,228,548

It appears from table -111 that the additional number of pucca houses in Dhaka District will

rise from 35101 Nos. on an average per annum. Assuming that each pucca house requires

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about 40,000 bricks on an average, the total number of bricks to be required for the

additional pucca houses has been worked out 140 .40 crore.

In addition to the demand for bricks in the private sector, huge demand for bricks comes

from the real estate developers for construction of multistoried apartment/ commercial

complexes. The apartment project was started in late 70’s in Dhaka city. Ispahani Group is

the pioneer in this sector. But in early 80’s with the inception of Eastern housing Ltd. the

business stared flourishing. Now this is a booming sector of the economy. A good number of

real estate developers are now active in this business. During the last decade apartment

project has got tremendous progress. World bank estimated the demand for housing in

urban areas of Dhaka, Chittagong and Khulna for the period 1980 and 2000 as detailed in

Table -111

Table -111

DEMAND FOR HOUSING

Item 1980 2000 Demand for Housing

Population No.of Houses

Population No.of Houses

Dhaka Cittagong Khulna

351407

050201

934023

170704

120503

Total: 56 08 156 28 20

b/ Bangladesh urban Sector Memorandum, May, 1981 world Bank.

The study shows that annually the number of houses required to be built in Dhaka comes to

60,000 units which is likely to be 12 times higher than the number of actual unit constituted

per year. Assuming 40,000 Nos. of Bricks per house the total number of bricks to be

required for apartment project comes to 800, 00 crore pcs.

In addition to the residential household, various Government departments and agencies are

using bricks. Empirical observation reveals that their requirement for bricks would not

exceed 10% of the bricks required by household. Hence the total requirement for brick in

both public and private sector would be as shown in Table-1V.

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Table-1V.

TOTAL REQUIREMENT OF BRICKS

Category Demand in million Nos.Household 1,404Apartment 8,000Government 940

10,344

It appears from Table – 1V. that annual requirement of bricks would be about 130 44 million Nos.

EXISTING SUPPLY:

At present the supply of bricks mostly comes from a bricks fields which produce bricks of

inferior quality which are being sold at a higher price. Due to non- existence of adequate

number of automatic brick manufacturing plant in the area, the household users and the

government and private institutional users are to use mostly this grade of brick to meet their

demand. As such the brick fields will not be the competitor of automatic brick plant rather he

automatic brick plant will have comparative advantage over fields in respect of quality and

price.

MARKET SHARE:

To what extent the proposed project will be able to win over the users by way of creating a

market share for the product will depend on the efficiency of the sponsors to handle

appropriate marketing strategies in the form of determination of product pricing, procurement

of raw materials, maintenance of product quality adoption of promotional measures etc. so

long as the sponsors of the project will be able to adopt suitable and appropriate marketing

strategies it will create effective demand for the product.

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QUALITY:

Maintenance of quality of bricks is considered to be one of the determinants for the

successful marketing of the product. To have better market the quality of the product must

be ensured otherwise it may not be able to compete in the local market.

The users/ consumers for brick generally look forward to the following properties in bricks:

-Proper size and thickness

-Bright colour:

-Smoothness of surface:

-Strength:

To maintain the above qualities, the project is required to be equipped with automatic

machinery to be handled with efficient personnel. Since the project will be equipped with

automatic machinery, it is expected that it will be able to produce quality bricks as per the

requirement /standard of the users/consumers.

OUT PUT PRICING:

Next to product quality, determination of product pricing plays an important role in achieving

the market share for the project. The prices of the product must be competitive to create a

market share in the domestic market. To be competitive, the selling prices of bricks should

be determined in such a way that it remains at per within the prevailing price structure.

Otherwise it may be difficult for the project to sell their output in the domestic market if the

prices are not maintained at a competitive level. The sponsors of the project are also

required to adjust selling prices are not maintained at a competitive level. The sponsors of

the project are also required to adjust selling prices form time to time with the changing

prices of other existing units. Bricks to be produced from automatic machine being lower in

respect of prices the project may able to enjoy a price advantage and to occupy a major

share for his product

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AVAILABILITY AND PROCUREMENT OF RAW MATERIALS

The basic raw material for use in the plant the sponsors of the project have managed to

procure clay from local sources. Gas is an imported item and will be available form Titas Gas

Transmission and Distribution Company Ltd. The project will not suffer or the production will

not be interrupted /stopped due to shortage of raw materials. The sponsors of the project will

be able to maintain the continuous flow of adequate quantum of raw materials for the project,

so that the production is kept at regular and continuous level.

PROPOSED MARKETING / DISTRIBUTION ARRANGEMENTS:

The products of the project would be supplied to the market through the wholesalers /

Distributors at manufacturer’s cost according to their order / direct sales from factory and

from their own sales center, Dhaka. Retailers would get supply from the wholesale market /

manufacturers sales Center / Factory.

A Schematic diagram of the distribution channel has been shown as follows:

Table – V

Channels of Distribution

PRICE COMPETITIVENESS:

Much attention has been given of the pricing of the products. For such products, product

quality and the price has equal role in penetrating in to the market. Depending on the cost of

raw materials and other inputs required for production, selling price for the products

56

ProducersDistributors / Agents / Wholesalers

Retailers / Sales Centre Consumers

Page 58: Auto Brick Business Plan (Business Plan)

proposed by the unit has been suggested. Special attention has been given to keep the

price at a lower side in comparison to the existing market price.

The proposed price languish the existing Ex-Factory price may be stated in the following

Table – V1.

Table – V1.

PRICING OF THE PRODUCTS

Particulars Ex-Factory PriceProposed Ex-Factory

Price a) Solid Bricks (9.75”×4.75” ×2.75” various Types)

8.00/Pc

SALES PROMOTIONAL ASPECTS :

Sales Promotion in our country are being done through advertising on the nature of

products. For these products advertising has been proposed. Since the sponsors are having

personal contacts in the wholesale market they with depend on personal selling approach as

means of products promotion. To create mass awareness the proposed project is having a

loan to advertise their product rough Radio, Television, Paper, Stickers, Calendars etc. after

going in to commercial production.

CONCLUSION:

A detailed analysis and evaluation, of the existing and projected worldwide market demand,

producers and consumers, multiplicity of usage’s economic competitiveness and

assessments of other relevant factors, considerations and criteria will reveal that the

project’s success potentials is indeed present and that its future is optimistic.

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