Chilly Processing Plant Cost Analysis
Chilly Processing Plant Cost Analysis
ESTABLISHMENT OF CHILLY
PROCESSING UNIT
(WITHOUT CAPITAL SUBSIDY)
Submitted to Submitted by
Knowledge Partner
NABARD Consultancy Services
Department of Agriculture, Corporate Office: 24 Rajendra Place,
Cooperation & Farmers Welfare 7th Floor, NABARD Building, New Delhi
Registered Office: Plot No. C-24, G Block,
3rd Floor, NABARD Building, Bandra Kurla Complex,
Bandra East, Mumbai
Model DPR for Establishment of Chilly Processing Plant (without Capital Subsidy)
DISCLAIMER
The views expressed and the conclusions arrived at in this document, including
financial, are based on the data and information provided by various Government
Departments and agencies, overall policy and approach of the State Government,
discussions with the stakeholders at various levels as also the observations recorded
by NABCONS during the study. Being only advisory in nature, such views and
conclusions do not represent or reflect, in any way, the policy or views of NABARD.
CREDIT CITATION
Preparation of this document has been possible with broad-based support and
co-operation from various stakeholders. NABARD Consultancy Services
hereby, sincerely and gratefully acknowledges the support and valuable co-
operation extended by them.
Our sincere thanks are also due to all others who directly or indirectly helped
NABCONS in preparation of this document.
Model DPR for Establishment of Chilly Processing Plant (without Capital Subsidy)
1 This template is prepared keeping in mind the essential information required by the lending institutions to process the
loan application. Different formats of table/description can be used for preparation of the DPR but all the required
information in template should be included in the DPR.
Model DPR for Establishment of Chilly Processing Plant (without Capital Subsidy)
2
Model DPR for Establishment of Chilly Processing Plant (without Capital Subsidy)
Cash
1
Credit
To be filled by the applicant
Term
2
Loan
Other
3
s
6. Project Details
a. Objective of the proposed project: CHILLY PROCESSING UNIT
b. Category of proposed infrastructure as per the Scheme:
c. Type of Operating Model (Rental, PPP, captive, Lease, Franchise etc.) and
details
To be filled by the applicant, some sample details are added
7. Land Details:
SN Particulars Details
5000 sq ft (land considered as
1 Land Area
Owned/ Leased)
2 Status of Legal title & Possession
3 if leased, Period of lease
Model DPR for Establishment of Chilly Processing Plant (without Capital Subsidy)
SN Particulars Details
4 Coordinates of location
5 Details of CLU
Connectivity to roads
6 I. State Highway (in Km.) XX Km from YY road
II. National Highway (in Km.)
7 Availability of Water Borewell and water pipe line
8 Availability of Power State electricity board connection
8. Proposed facilities:
I. Details of proposed facility
Total Capacity
Type of facilities proposed No. of No. of Days
SN [MT, Ltrs,
to be created Units of operation
MT/Hr.
1 Warehouse
2 Silos
3 Pack-house
4 CA Store
5 Cold store
6 Frozen store
7 Pre-cooling Chambers
Processing unit, Weighing,
300 KG Per
8 Packing facility [Modify as 2 Unit 225 days
Hour
per actual]
9 Ripening Chambers
10 IQF
11 Blast Freezing
Refrigerated Vehicles/
12
Reefer vans
13 Mobile Pre-coolers
Insulated/ non-insulated
14
distribution vehicle
15 Irradiation Facility
16 Organic input production
Bio Stimulant production
17
units
18 Others (Specify)
Model DPR for Establishment of Chilly Processing Plant (without Capital Subsidy)
Amount (Rs. In
S. No. Particulars
Lakhs)
1 Civil Works 16.00
2 Plant & Machineries 16.05
3 Working Capital Margin Money 5.35
4 Preliminary & Preoperative Expenses 0.60
Project Cost 38.00
b. Plant and Machineries
A list of plant and machinery required for a chilly processing unit
are as under:
Qty. in Price in
[Link] Name of Machinery
Nos Rs.
1 Automatic chilly grinding machine 1 670,000
2 Digital weighing scale 1 25,000
3 Packaging machine 1
Model DPR for Establishment of Chilly Processing Plant (without Capital Subsidy)
Qty. in Price in
[Link] Name of Machinery
Nos Rs.
250,000
4 1
Sieving machine 125,000
5 1
Dryer 65,000
1
6
Quality testing equipment 100,000
1
7
Washing tank 20,000
8 Grading machine 1 150,000
9 Miscellaneous 1 200,000
Total Machineries (Rs. In Lakhs) 16,05,000
Total Cost of Plant and Machineries (Rs.
In Lakhs) 16.05 Lakhs
c. Means of finance
*CMA data to be provided along with projected balance sheet, profit & loss
statements, covering entire period of repayment.
e. Financial Parameters
Details Ref Page No. in
SN Particulars
(Ratio/%) DPR*
Internal Rate of Return (IRR) [(a) With
1 76.84% -
and (b) without grant/ subsidy]
Avg. Debt Service Coverage Ratio
2 3.4 -
(DSCR)
3 Break Even Point (BEP) 47.23% -
4 Debt-Equity Ratio ( TTL/TNW) 1.74 -
5 Fixed Assets Coverage Ratio 1.41 -
Collateral Security proposed to be offered and its approximate value for the
applicable cases. (To be furnished only in case of loans above Rs.2 crore)
10. Availability of Raw Materials in the Catchment Area - provide details such
as Adequate Volume, Wider Mix of Raw Materials, Days of Operation in a
Year along with supporting data. Based on this information
feasibility/viability of the project should be justified.
Raw material is to be acquired from nearby farmer suppliers. The unit has
agreed to procure the chillies from the farmers at the prices agreed in the
agreement.
The unit shall operate for 225 days in a year.
Model DPR for Establishment of Chilly Processing Plant (without Capital Subsidy)
India being the world's largest producer, consumer and exporter of chillies has the
largest area of 7.33 lakh ha (18.11 lakh acres) accounting for 42.81% of world area.
Chilli powder is the dried, pulverized fruit of one or more varieties of chilli pepper,
sometimes with the addition of other spices (where it is also sometimes known as
chilli powder blend or chilli seasoning mix).It is used as a spice (or spice blend) to
add pungency (piquancy) and flavor to culinary dishes.
Capsaicin in red chillies is known to reduce inflammation and act as natural pain
relief remedy. It binds with nerve endings that sense pain to reduce the feeling of
pain. Capsaicin also helps reduce pain and inflammation in the muscles and joints of
the lower back. Red chillies are good for digestive health as they help increase the
secretion of digestive juices which prevent problems such as constipation and gas.
Red chillies are also used as a preservative due to their antibacterial and antifungal
properties, which also helps in reducing harmful bacteria. This can help in keeping
the intestines healthy.
15. Details of pollution issues (if any) and adoption of modern technology for
reducing the carbon footprints and increasing operational efficiency:-
Place: ______
Model DPR for Establishment of Chilly Processing Plant (without Capital Subsidy)
Annexures
Contents Table
Contents Link
Annexure 1 - Estimated cost of the project Ann 1'!A1
Annexure 2 - Means of Finance Ann 2'!A1
Annexure 3 - Complete Estimate of Civil and Plant and Machinery Ann 3'!A1
Annexure 4 - Estimated Cost of Production Ann 4'!A1
Annexure 5- Projected balance sheet Ann 5'!A1
Annexure 8 - Details of Manpower Ann 8'!A1
Annexure 9 - Computation of Depreciation Ann 9'!A1
Annexure 10 - Calculation of Income tax Ann 10'!A1
Annexure 11- Break even analysis (At maximum capacity utilization) Ann 11'!A1
Annexure 13 - Repayment schedule Ann 13'!A1
Annexure 14 - Cash flow statement Ann 14'!A1
Sales Budget Budgets!A1
Assumptions Assumptions!A1
DPR without subsidy
2 Site Development -
(a) Total -
3 Civil Work
(a) Civil Work 16.00
Total 16.00
7 Preliminary Expenses -
(a) Security Deposit -
Total -
8 Pre-Operative Expense
(for 6 months upto the date od commencement of
commercial production)
(a) Establisment and Travelling and Other Expenses
(b) Legal and Misc Expense 0.60
Total 0.60
** The Plant and Machinery cost estimate is as per the available technology
Annexure 4 - Estimated Cost of Production
Input chilly 36,936,000 44,015,400 47,401,200 50,787,000 54,172,800 57,558,600 60,944,400 64,330,200 67,716,000
Electricity expense 1,270,000 1,326,000 1,384,800 1,446,540 1,511,367 1,579,435 1,650,907 1,725,952 1,804,750
Insurance cost @ 2% of purchase cost 64,100 67,305 70,670 74,204 77,914 81,810 85,900 90,195 94,705
Running and Manintenance expense @15% of raw material 5,540,400 6,602,310 7,110,180 7,618,050 8,125,920 8,633,790 9,141,660 9,649,530 10,157,400
Cost of Production 43,810,500 52,011,015 55,966,850 59,925,794 63,888,001 67,853,635 71,822,867 75,795,878 79,772,855
Add: Opening Stock - 469,800 978,750 1,526,850 2,114,100 2,740,500 2,074,950 1,370,250 626,400
Less: Closing Stock 469,800 978,750 1,526,850 2,114,100 2,740,500 2,074,950 1,370,250 626,400 -
Sub Total 43,340,700 51,502,065 55,418,750 59,338,544 63,261,601 68,519,185 72,527,567 76,539,728 80,399,255
Administrative salaries and wages 2,277,600 2,437,032 2,607,624 2,790,158 2,985,469 3,194,452 3,418,063 3,657,328 3,913,341
Packaging cahrges @ Rs. 2 per kg 481,140 521,235 561,330 601,425 641,520 695,385 736,290 777,195 816,480
Selling charges @ Rs. 1 per kg 320,760 347,490 374,220 400,950 427,680 463,590 490,860 518,130 544,320
Fixed charge for office 210,000 210,000 210,000 210,000 210,000 210,000 210,000 210,000 210,000
Total 3,289,500 3,515,757 3,753,174 4,002,533 4,264,669 4,563,427 4,855,213 5,162,653 5,484,141
Cost of Sales 46,630,200 55,017,822 59,171,924 63,341,077 67,526,270 73,082,612 77,382,781 81,702,381 85,883,396
Expected sales revenue 48,114,000 57,335,850 61,746,300 66,156,750 70,567,200 76,492,350 80,991,900 85,491,450 89,812,800
Gross Profit 1,483,800 2,318,028 2,574,376 2,815,673 3,040,930 3,409,738 3,609,119 3,789,069 3,929,404
Financial expense
Interest on Term Loan 171,436 149,798 123,167 96,537 69,906 43,275 16,644 - -
Interest on WC Loan 53,500 53,500 53,500 53,500 53,500 53,500 53,500 53,500 53,500
Total Financial expense 224,936 203,298 176,667 150,037 123,406 96,775 70,144 53,500 53,500
Operating profits (PBT) 1,258,864 2,114,730 2,397,708 2,665,637 2,917,524 3,312,963 3,538,975 3,735,569 3,875,904
Preliminary Expense 60,000 - - - - - - - -
depreciation 400,750 348,638 303,542 264,491 230,649 201,300 175,829 153,706 134,477
Net Profit before Tax 798,114 1,766,092 2,094,166 2,401,146 2,686,875 3,111,663 3,363,146 3,581,863 3,741,427
Income Tax 257,434 529,828 628,250 720,344 806,063 933,499 1,008,944 1,074,559 1,122,428
Profits after Tax 540,680 1,236,265 1,465,916 1,680,802 1,880,813 2,178,164 2,354,202 2,507,304 2,618,999
Distribution of profits (80%) 432,544 989,012 1,172,733 1,344,642 1,504,650 1,742,531 1,883,362 2,005,843 2,095,199
Profit transfer to balance sheet 108,136 247,253 293,183 336,160 376,163 435,633 470,840 501,461 523,800
1. Electricity are semi-fixed cost. Rs. 150,000 pa is fixed, balance is variable at Rs. 14 per unit usage
2. Electricity usage in units is given below
Usage in units 80000 84000 88200 92610 97240.5 102102.525 107207.6513 112568.0338 118196.4355
Variable cost 1120000 1176000 1234800 1296540 1361367 1429435.35 1500907.118 1575952.473 1654750.097
3. It is assumed that insuarance cost is 2% of purchase price and this will increase 5% annually
4. Closing stock is valued at Rs 145 (avg cost)
5. Input cost of chilly would increase 10% per annum while 5% of input is wasted.
Annexure 5- Projected balance sheet
B Liabilities
1 Capital 380,000.00 488,136 735,389 1,028,572 1,364,733 1,740,895 2,176,528 2,647,368 3,148,829
Add- Profit 108,136.02 247,253 293,183 336,160 376,163 435,633 470,840 501,461 523,800
Less- Drawings - - - - - - - - -
Closing capital 488,136.02 735,389 1,028,572 1,364,733 1,740,895 2,176,528 2,647,368 3,148,829 3,672,629
2 Term Loan 2,663,076.92 2,219,231 1,775,385 1,331,538 887,692 443,846 - - -
3 Working capital 535,000.00 535,000 535,000 535,000 535,000 535,000 535,000 535,000 535,000
4 Creditors 12,742,920.00 15,185,313 16,353,414 17,521,515 18,689,616 19,857,717 21,025,818 22,193,919 23,362,020
Total liabilities 16,429,132.94 18,674,933 19,692,371 20,752,786 21,853,204 23,013,091 24,208,186 25,877,748 27,569,649
Current Ratio
Current Assets 13,624,883 16,219,320 17,540,300 18,865,206 20,196,273 21,557,461 22,928,385 24,751,653 26,578,031
Current Liabilities 13,277,920 15,720,313 16,888,414 18,056,515 19,224,616 20,392,717 21,560,818 22,728,919 23,897,020
Ratio 1.02613082 1.03174283 1.038599612 1.044786668 1.050542311 1.057115666 1.063428353 1.088993869 1.112190186
Average 1.057058924
Details of Manpower
S. No. Designation In no. Salary per person per month Annual cost
i. Accountant cum cashier 1 22,000 264,000
ii. Mechanic 4 10,000 480,000
iii. Helpers 1 15,000 180,000
iv. Labour 4 12,000 576,000
v. Security 2 10,500 252,000
Total 1,752,000
Computation of Depreciation
Sr. No. Particulars Civil work Plant and Machinery Misc Fixed Asset Amount in lakhs
i. Cost 1,600,000 1,605,000 - 32.05
ii. Pre operatives - - - 0.00
iii. Contingencies - - - 0.00
Total 32.05
Rates of Depreciation 10% 15% 10% Total depreciation for the year
Year 1 160,000.00 240,750.00 - 400,750.00
Year 2 144,000.00 204,637.50 - 348,637.50
Year 3 129,600.00 173,941.88 - 303,541.88
Year 4 116,640.00 147,850.59 - 264,490.59
Year 5 104,976.00 125,673.00 - 230,649.00
Year 6 94,478.40 106,822.05 - 201,300.45
Year 7 85,030.56 90,798.75 - 175,829.31
Year 8 76,527.50 77,178.93 - 153,706.44
Year 9 68,874.75 65,602.09 - 134,476.85
Annexure 10 - Calculation of Income tax
Sales 68,734,286
Variable cost
- Running and maintenance cost 10,310,143
- Interest on Working capital 53,500
- electricity expense 1,654,750 12,018,393
Contribution 56,715,893
Less: Fixed costs
Wages and salaries 2,277,600
Depreciation 400,750
Fixed charges for office 210,000
Electricity fixed charge 150,000
Insurance cost 64,100
Interest on TL 171,436
Fixed cost 3,273,886
Break-even point is the condition when an entity generate sufficient revenue that it can meet its fixed
expense after deducting any variable expense, i.e., the point where contribution is equal to the fixed
expense.
For the first year of operation the break-even capacity comes at 47.23% capacity, it is because of the fact
that in the Initial year the fixed expense of consultancy for project is taken in to consideration for
calculation of BEP. considering our operational capacity in year 1 to be 60% which is more than the BEP,
hence we can conclude that the project is sound enough to cover its fixed expense.
Annexure 13 - Repayment schedule
Repayment schedule
Amount of Loan (in lakhs) 28.8500
Rate of interest 6.00%
Moratorium period 6 months
Net cash inflow 535,000 3,532,283 3,773,400 3,664,190 3,519,756 3,342,333 4,184,041 5,359,755 7,026,963 8,615,471
Net Present value 535,000 3,332,342 3,358,313 3,076,525 2,787,977 2,497,585 2,949,584 3,564,543 4,408,804 5,099,484 31,075,157
Sales Budget
Year ending March 31st
Particulars
I II III IV V VI VII VIII IX
Estimated ocupational capacity 60% 65% 70% 75% 80% 85% 90% 95% 100%
Production capacity (kgs) 324,000 351,000 378,000 405,000 432,000 459,000 486,000 513,000 540,000
Input required to produce above output (kgs) 462,857 501,429 540,000 578,571 617,143 655,714 694,286 732,857 771,429
Sales (kgs) 320,760 347,490 374,220 400,950 427,680 463,590 490,860 518,130 544,320
Revenue in Rs. 48,114,000 57,335,850 61,746,300 66,156,750 70,567,200 76,492,350 80,991,900 85,491,450 89,812,800
Per annum capacity in kgs 540,000 Assumed that 1000 kg per hour is the production capacity
Operational days 225 dys
Production Budget
Year ending March 31st
Particulars
I II III IV V VI VII VIII IX
Opening Stock - 3,240 6,750 10,530 14,580 18,900 14,310 9,450 4,320
Production 324,000 351,000 378,000 405,000 432,000 459,000 486,000 513,000 540,000
Sales 320,760 347,490 374,220 400,950 427,680 463,590 490,860 518,130 544,320
Closing Stock 3,240 6,750 10,530 14,580 18,900 14,310 9,450 4,320 -
Assumed input output ratio is 0.6:1,i.e., to say that 1 kg of rhisomes produce 600 grams of turmeric powder
assumed that the output is sold in wholesale market
S. no. Assumptions
1 Electricity are semi-fixed cost. Rs. 150,000 pa is fixed, balance is variable at Rs. 14 per unit usage
2 Electricity usage in units is given below
Usage in units 75000 78750 82687.5 86821.875 91162.96875 95721.11719 100507.173 100507.173 100507.173
Variable cost 1050000 1102500 1157625 1215506.25 1276281.563 1340095.641 1407100.423 1407100.423 1407100.423
3 Asssumed that 90 days of purchases are average creditors maintained
4 Assumed that 60 days of sales are average debtors maintained by the business
5 It is assumed that insuarance cost is 2% of purchase price and this will increase 5% annually
6 Input cost of rhizomes would increase 10% per annum and there would be 5% wastage in processing on inputs
(Wholly – owned subsidiary of NABARD)
6 Studies / Baseline Baseline surveys are taken up for measuring impact of community
Surveys investment made by public and private sector Companies.
Studies are conduct on women, children, disadvantaged groups /
regions, etc.
7 Livelihood Mapping Livelihood mapping and analysis is done for identification of
potential activities to be taken up by SHGs
8 International Visitors’ Entails organizing study tours / exposure for the visiting foreign
Programme / delegates to their areas of interest such as watershed, micro-
International Exposure finance, fin-inclusion, cooperatives, projects appraisal, agro-
Visits processing, post-harvest technologies, farmers’ clubs, etc.
9 Consultancy on Banking Designing and execution of priority sector strategies, advisory
and Finance services on Treasury and Investment Management for Banks,
preparation of IT Policy, etc.
10 Transaction advisory Transaction Advisory for setting up of Agri-mall, Silos & Cold
Storages
11 Skills for Livelihood Skilling of rural BPL youth and placement in the formal sector,
monitoring skill initiatives of MORD, Govt. of India, facilitating
access to credit for trainees, etc.