PROJECT MASTERPLAN: HIMALAYAN GOLD INDUSTRIAL EXPORTS
Strategic Vision: Scaling the Authentic Nepal Chhurpi into a Global Pet-Tech Powerhouse.
Production Target: 20,000 kg (20 Tons) / Month.
Project Location: Duhabi-Itahari Industrial Corridor (Biratnagar), Nepal.
PART 1: EXECUTIVE SUMMARY
This project represents a high-yield industrial value-addition venture. By transitioning from
traditional cottage-industry trading to an Automated Finishing and Expansion Facility, the
project targets a monthly EBITDA of NPR 1.08 Crore. The project focuses on "Zero-Waste"
technology, converting every gram of raw material into high-margin "Puffed Treats" and "Dental
Bars."
PART 2: THE TECHNICAL WORKFLOW (A TO Z)
Step 1: Procurement & Sourcing (The Buy)
Locations: Direct collection points in Ilam, Dhankuta, and Taplejung.
Standard: Buying "Green Chhurpi" (20-25% moisture).
Holding Strategy: Digital moisture meters used at the farm-gate to ensure we don't pay
for water weight.
Step 2: Reception & Sterilization
Action: Arrival at Biratnagar facility.
Process: Initial cleaning and UV-C light sterilization tunnel to eliminate surface bacteria
(Salmonella/E. coli).
Step 3: Precision Dehydration
Technology: Industrial Heat Pump Dehydrators.
Goal: Slow-moisture extraction at 45°C–55°C to bring moisture below 12%. This prevents
cracks and mold.
Step 4: Cutting & Value-Addition
Hard Bars: High-speed food-grade band saws cut uniform S, M, L sizes.
The "Profit Pivot": All ends, scraps, and B-grade pieces are routed to the Continuous
Microwave Expansion Tunnel.
Puffies: These pieces expand 300% in size, creating a crunchy, high-value training treat.
Step 5: Finishing & Polishing
Process: Automated sanding machines remove smoke residue, giving the product a
"Golden" aesthetic preferred in the USA and Japan.
Step 6: Packaging & Export
Hard Bars: Double-chamber vacuum packaging.
Puffies: Nitrogen-flushed stand-up zipper pouches for retail.
Logistics: FCL (Full Container Load) via Biratnagar ICD (Sea Freight).
PART 3: DETAILED CAPITAL EXPENDITURE (CAPEX)
A. Land & Infrastructure (Lease Model)
We recommend the Lease Model to preserve Working Capital for the 11 Cr loan.
| Item | Description | Cost (Approx. NPR) |
| :--- | :--- | :--- |
| Land Lease (1 Bigha) | Duhabi-Itahari Corridor (10-year lease) | 15,00,000 (Advance) |
| Factory Building | 15,000 sq. ft. PEB Structure (Export Grade) | 2,50,00,000 |
| Interior Finishing | Epoxy Flooring, Tiled Walls, Rodent-proofing | 50,00,000 |
| Electrical Infrastructure | 200 KVA Transformer + Industrial Wiring | 25,00,000 |
| Power Backup | 125 KVA Silent Generator | 20,00,000 |
| SUB-TOTAL | | 3,60,00,000 |
B. Machinery & Equipment (Big & Small)
Machine Total Cost
Item Quantity
Category (NPR)
Industrial Heat Pump Dehydrators
Main Tech 3 Units 1,20,00,000
(Large)
Continuous Microwave Expansion
Profit Tech 1 Unit 45,00,000
Tunnel
Cutting Food-Grade High-Speed Band Saws 4 Units 12,00,000
Automated Polishing/Sanding
Finishing 2 Units 8,00,000
Machines
Safety UV-C Germicidal Sterilization Tunnel 1 Unit 10,00,000
Packaging Double-Chamber Vacuum Sealers 3 Units 15,00,000
VFFS Automatic Pouch Filling (for
Packaging 1 Unit 20,00,000
Puffs)
Moisture Meters, SS Tables, Weighing
Small Tools 20 Units 10,00,000
Scales
Laboratory Fat/Protein/Bacterial Testing Kit 1 Set 15,00,000
SUB-TOTAL 2,55,00,000
PART 4: ONE-TIME DOCUMENTATION & LICensing
License/Certification Authority Cost (NPR)
Industry Registration Dept. of Industry (Large Scale) 1,50,000
EXIM Code & Bank Guarantee Dept. of Customs 3,10,000
DFTQC Food License Govt of Nepal 25,000
US FDA Facility Reg. US Food & Drug Admin 1,50,000
ISO 22000 / HACCP International Audit Agency 8,00,000
BRCGS Certification International Audit Agency 12,00,000
Trademark Registration Nepal & USPTO (USA) 3,00,000
Consultant/Law Firm Fees Turnkey Compliance Management 10,00,000
SUB-TOTAL 39,35,000
PART 5: OPERATIONAL EXPENDITURE (MONTHLY - 20 TONS)
Item Calculation Amount (NPR)
Raw Material Buy 20,000 kg Mixed Grade 1,98,00,000
Labor 30 Staff (Production + Admin) 6,00,000
Electricity/Fuel Off-peak Night Running 3,50,000
Logistics (Sea) 18,000 kg Finished Product 27,00,000
Packaging Bags Custom Retail Pouching 12,60,000
TOTAL OPEX 2,47,10,000
PART 6: FINANCIAL PROJECTIONS & DEBT SERVICING
A. Revenue Strategy
Hard Bars (12,600 kg): NPR 2,20,50,000
Puffies (5,400 kg): NPR 1,40,40,000
Total Monthly Revenue: NPR 3,60,90,000
B. Profitability & Bank Repayment
Monthly EBITDA: NPR 1,13,80,000 (1.13 Crore)
Interest on 11 Cr Debt (12%): NPR 11,00,000
Net Profit After Interest: NPR 1,02,80,000
Annual Export Subsidy (5%): NPR 2.1 Crore (Extra Income)
PART 7: THE LOGISTICS MASTERSTRATEGY (SEA FREIGHT)
To maintain the 1 Crore monthly profit, we reject Air Freight.
1. Route: Biratnagar ICD → Kolkata → Savannah/New York Port (USA).
2. Container: 20ft FCL (Full Container Load) - Monthly one container.
3. Finance: Use Bill Discounting (Post-Shipment Loan). Once the container is on the ship,
the bank releases 80% of the invoice value to you within 48 hours. This solves the "Sea
Time" cash flow problem.
PART 8: RISK MANAGEMENT
Raw Material Risk: Collection centers across 3 districts ensure supply even if one district
has weather issues.
Market Risk: Forward-contracts with US-based Amazon aggregators to lock in prices for
12 months.
Quality Risk: In-house laboratory and UV-C treatment ensure zero salmonella rejections.
PART 9: PROJECT TIMELINE
Month 1-2: Land Lease, Building Construction, License Procurement.
Month 3-4: Machinery Import & Installation.
Month 5: Staff Training & Trial Batches.
Month 6: Full Commercial Production & First Export Container.
PART 10: CONCLUSION
This project turns a 97 Lakh Net Monthly Profit after paying all bank interests. It is a robust,
recession-proof business model that utilizes Nepal’s unique geographic identity to serve a high-
spending global market.
Investor Recommendation: This venture is ready for immediate deployment. The inclusion of
"Puffy" technology ensures the highest possible IRR (Internal Rate of Return) in the Nepali
agribusiness sector.