113.

PROFILE ON TABLE SALT

 113-2
TABLE OF CONTENTS

PAGE

I. SUMMARY 113-3

II. PRODUCT DESCRIPTION & APPLICATION 113-3

III. MARKET STUDY AND PLANT CAPACITY 113-3

A. MARKET STUDY 113-3
B. PLANT CAPACITY & PRODUCTION PROGRAMME 113-6

IV. RAW MATERIALS AND INPUTS 113-6

A. RAW & AUXILIARY MATERIALS 113-6
B. UTILITIES 113-7

V. TECHNOLOGY & ENGINEERING 113-7

A. TECHNOLOGY 113-7
B. ENGINEERING 113-8

VI. MANPOWER & TRAINING REQUIREMENT 113-9

A. MANPOWER REQUIREMENT 113-9
B. TRAINING REQUIREMENT 113-10

VII. FINANCIAL ANALYSIS 113-11

A. TOTAL INITIAL INVESTMENT COST 113-11
B. PRODUCTION COST 113-12
C. FINANCIAL EVALUATION 113-13
D. ECONOMIC BENEFITS 113-14
 113-3
I. SUMMARY

This profile envisages the establishment of a plant for the production of table slat with a
capacity of 30,000 tonnes per annum.

The present demand for the proposed product is estimated at 281,514 tonnes per annum. The
demand is expected to reach at 413,412 tonnes by the year 2020.

The plant will create employment opportunities for 34 persons.

The total investment requirement is estimated at about Birr 14.56 million, out of which Birr 2.5
million is required for plant and machinery.

The project is financially viable with an internal rate of return (IRR) of 30 % and a net present
value (NPV) of Birr 16.49 million discounted at 8.5%.

II. PRODUCT DESCRIPTION AND APPLICATION

Table salt is a white crystalline powder salt fortified by Iodine.

Salt has become the most accepted food for iodine fortification because it is one of the few
commodities that are almost universally consumed by all sections of a community and at
approximately the same level throughout the year, irrespective of economic level.

III. MARKET STUDY AND PLANT CAPACITY

A. MARKET STUDY

1. Past Supply and Present Demand

Salt (sodium chloride) is essential to the health of human beings. The country's requirement of
salt has been met both from local production and import. Import of table salt is shown in Table
3.1.
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Table 3.1
IMPORT OF TABLE SALT (TONNES)

Import
Year (Tonnes)
2000 67,289
2001 149,642
2002 174,107
2003 296,044
2004 57,629
2005 73,174
2006 10,043

Source:- Ethiopian Customs Authority.

Table 3.1 reveals that import of table salt fluctuates from year to year. Local supply of salt
comes mainly from a place called Afdera which is found in the Afar Regional state. Other
traditional producers or local suppliers include cooperatives found in Somali and Oromiya
Regional States. However, the locally produced salt does not have the required iodine content.
As a result a disease of the thyroid gland commonly called goiter is wide spread in most parts
of the country. The major means of mitigating this problem is to establish a number of plants
that can iodized the locally produced salt from the above sources.

As mentioned above the demand for table salt is related with human consumption Hence, the
estimation of present demand for iodized salt is related with population size. Based on the
Ethiopian Nutrients Institute (ENI) , the consumption of salt per capita is 10 grams per day or
3.65 kg per year.

Accordingly the current demand for the product is thus, computed taking the latest (2007)
population size. The present demand estimated based on per capita consumption is shown in
Table 3.2.
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Table 3.2
TOTAL TABLE SALT CONSUMPTION ( 2007 )

Population Table salt

size Consumption
Per person Total (Tones)
( Kg)

SNNPRS 15,321,000 3.65 55,921

County Level 77,127,000 3.65 281,514

As can be seen from Table 3.2 the total country level consumption for table salt is estimated at
281,514 tones of which the share of SNNPRS is 55,921 tones.

2. Projected Demand

Table Salt consumption is directly related with population growth. Based on this fact
population growth rate which is about 3 % is used to project the future demand for iodized salt
by taking the current effective demand as a base. The projected demand up to the year 2020 is
shown in Table 3.2.

Table 3.2
PROJECTED DEMAND FOR TABLE SALT (TONNES)

Year Projected Demand

2008 289,959
2009 298,658
2010 307,617
2011 316,846
2012 326,351
2013 336,142
2014 346,226
2015 356,613
2016 367,311
2017 378,331
2018 389,681
2019 401,371
2020 413,412
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3. Pricing and Distribution

The ex-factory price of iodized salt have been set at Birr 1,700 per ton by considering the
current price of un iodized salt as well as similar product in the market.

The plant can use the existing whole sellers of salt for distributing its product throughout the
country.

B. PLANT CAPACITY AND PRODUCTION PROGRAMME

1. Plant Capacity

According to the market study, the demand of table salt in the year 2008 will be 289,959 tones,
whereas this demand will grow to 413,412 by the year 2020. Taking only about 10% of the
demand of the year 2008, the envisaged plant will have an annual production capacity of
30,000 tones of table will be installed. Production capacity is based on a schedule of 300
working days per annum and 8 shifts of eight hours per day.

2. Production Programme

The plant under consideration is assumed to operate in a single shift of 8 hrs a day for 300 days
a year. It is also planned that the plant will operate at 85% and 100% capacity in the first and
second year, respectively considering the problem of market penetration and skill development
of production.

IV. MATERIALS AND INPUTS

A. RAW MATERIALS

The major raw material for the production of table salt is common salt and iodine common salt
can be obtained from Afar and iodine will be imported. The plant also needs packing materials
 113-7
as auxiliary input. The list annual requirement and cost of raw materials is depicted in Table
4.1 below. The total annual cost of raw materials is estimated at Birr 45,657,000.

Table 4.1
ANNUAL RAW MATERIAL REQUIREMENT

Sr. Description Qty Cost ('000 Birr)

No. LC FC Total
1. Raw salt (tonnes) 30,597 30,597 - 30,597
2. Iodine (tonnes) 3 - 60 60
3. Packing material (plastic 60 15,000 - 15,000
bag + card box) million
Total 45,597 60 45,657

B. UTILITIES

Electricity is the major utility required as it is used as power source for heavy duty crushing
machines installed in the plant. The estimated annual consumption is 150,000 kWh. Water is
also required for general purpose in the plant. Its annual consumption is estimated to be 600
m3. The annual total cost of electricity and water is estimated at about Birr 71,040 and Birr
1,860 respectively. The total cost of utilities is estimated at Birr 72,900.

V. TECHNOLOGY AND ENGINEERING

A. TECHNOLOGY

1. Production Process

Common salt or sodium chloride (Nacl) is specially produced for human consumption. The
iodine content present in each kilogram of salt is around 70-100 mg, which is adequate to
prevent the formulation of goiter in the neck.
 113-8
The production of table salt is very simple because it involves few simple unit operations i.e.
crushing and mixing.

Usually in iodized salt production, raw salt either in rock or in evaporated brine salt form are
put in a crusher to reduce the size of the crystals to the required standard or then stored in an
intermediate silo or container. From there it is gradually fed to the mixer, where iodine a
specified amount of iodine is dozed. After the iodine is thoroughly mixed with powder salt for
some time in the mixer packing machine where is packed in half kilogram package of plastic
bag and card box.

B. ENGINEERING

1. Machinery and Equipment

The list of machinery for the production of 30,000 tones of table salt is shown in the Table 5.1.
The total cost of machinery and equipment is estimated at Birr 2.5 million.

Table 5.1
REQUIRED MACHINERY AND EQUIPMENT

Sr. No. Description Qty

1. Silos (stainless steel) 2
2. Crushers (Roller/ball) 2
3. Mixers 2
4. Packing m/c 1

2. Source of Technology

The following machinery suppliers can be contacted for the supply of iodized salt processing
machineries and equipment.
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1. ENDECO S.P.A .
Prato Oella Valle 81 - Padova
Tel. +39049655433
Fax +39049655697
2. Sunita impex Pvt. Ltd
36A Bentinck Street, 1st floor,
Kolkala 700 069, India
Tel. 2248 1986 /87, 22430102
Fax. 91-33 2248 3664
E-mail: kolkata: Admin@sunitaimpex.com

2. Land, Building and Civil Works

The plant requires a total of 1500 m2 area of land out of which 1,000 m2 is built-up area which
includes Processing area, raw material stock area, offices etc. Assuming construction rate of
Birr 1500 per m2, the total cost of construction is estimated to be Birr 1.5 million. The total
cost, for a period of 80 years with cost of Birr 1 per m2, is estimated at Birr 1,500. The total
investment cost for land, building and civil works is estimated at Birr 1,501,500.

3. Proposed Location

According to the resource potential study of the region, the raw material is identified in Hamer
woreda. Based on the availability of raw material infrastructure, utility and market out let
Dimeka town of Hamer woreda is selected and recommended to be the location of the
envisaged plant

VI. MANPOWER AND TRAINING REQUIREMENT

A. MANPOWER REQUIREMENT

The total manpower requirement of the envisaged plant is about 34 persons. Details of
manpower required and annual labour cost are indicated in the Table 6.1.
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Table 6.1
ANNUAL MANPOWER REQUIREMENT AND LABOUR COST ('000 BIRR)

Sr. Description Req. Salary

No. No. Monthly Annually

1. Manager 1 1800 21,600

2. Secretary 1 600 7,200
3. Administrative Staff 4 2400 28,800
4. Commercial Staff 5 3000 36,000
5. Production Technologist 1 1300 15,600
6. Technicians 2 800 9,600
7. Skilled Workers 5 2000 24,000
8. Unskilled Workers 15 250 45,000
Sub Total 34 187,200
Benefits 25% 46,800
Total 234,000

B. TRAINING REQUIREMENT

As stated above, the technological process is so simple that it doesn't require special skill.
Thus, no training is required.
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VII. FINANCIAL ANALYSIS

The financial analysis of the table salt project is based on the data presented in the previous
chapters and the following assumptions:-

Construction period 1 year

Source of finance 30 % equity
70 % loan
Tax holidays 3 years
Bank interest 8%
Discount cash flow 8.5%
Accounts receivable 30 days
Raw material local 30 days
Work in progress 5 days
Finished products 30 days
Cash in hand 5 days
Accounts payable 30 days

A. TOTAL INITIAL INVESTMENT COST

The total investment cost of the project including working capital is estimated at Birr 14.56
million, of which 53 per cent will be required in foreign currency.

The major breakdown of the total initial investment cost is shown in Table 7.1.
 113-12

Table 7.1
INITIAL INVESTMENT COST

Sr. Total Cost

No. Cost Items (‘000 Birr)
1 Land lease value 120.0
2 Building and Civil Work 1,500.0
3 Plant Machinery and 2,500.0
Equipment
4 Office Furniture and 100.0
Equipment
5 Vehicle 250.0
6 Pre-production 440.9
Expenditure*
7 Working Capital 9,650.9
Total Investment cost 14,561.8
Foreign Share 53

* N.B Pre-production expenditure includes interest during construction ( Birr 209.91 thousand ) and Birr 150
thousand costs of registration, licensing and formation of the company including legal fees, commissioning
expenses, etc.

B. PRODUCTION COST

The annual production cost at full operation capacity is estimated at Birr 47.15 million (see
Table 7.2). The material and utility cost accounts for 96.98 per cent, while repair and
maintenance take 0.24 per cent of the production cost.
 113-13
Table 7.2
ANNUAL PRODUCTION COST AT FULL CAPACITY ('000 BIRR)

Items Cost %
Raw Material and Inputs 45,657.00 96.82
Utilities 72.9 0.15
Maintenance and repair 113.65 0.24
Labour direct 112.32 0.24
Factory overheads 37.44 0.08
Administration Costs 74.88 0.16
Total Operating Costs 46,068.19 97.70
Depreciation 421 0.89
Cost of Finance 665.76 1.41
Total Production Cost 47,154.95 100

C. FINANCIAL EVALUATION

1. Profitability

According to the projected income statement, the project will start generating profit in the first
year of operation. Important ratios such as profit to total sales, net profit to equity (Return on
equity) and net profit plus interest on total investment (return on total investment) show an
increasing trend during the life-time of the project.

The income statement and the other indicators of profitability show that the project is viable.
 113-14
2. Break-even Analysis

The break-even point of the project including cost of finance when it starts to operate at full
capacity (year 3) is estimated by using income statement projection.

BE = Fixed Cost = 21 %
Sales – Variable Cost

3. Pay Back Period

The investment cost and income statement projection are used to project the pay-back period.
The project’s initial investment will be fully recovered within 4 years.

4. Internal Rate of Return and Net Present Value

Based on the cash flow statement, the calculated IRR of the project is 30 % and the net
present value at 8.5% discount rate is Birr 16.49 million.

D. ECONOMIC BENEFITS

The project can create employment for 34 persons. In addition to supply of the domestic
needs, the project will generate Birr 8.51 million in terms of tax revenue. The establishment of
such factory will have a foreign exchange saving effect to the country by substituting the
current imports.