University 0f Gondar

College of Business and Economics

School of Management and Public
Administration
Masters of Business Administration Program
Project Management

Project profile on the establishment of cotton yarn making plant

By Fikreselassie.F

Submitted to Yihays F. (PhD)

 Table of Contents

1. Executive Summary............................................................................1
2. Product Description and Application..................................................1
3. Market Study, Plant Capacity and Production Program................1
Market Study 1
Present Demand and Supply...........................................................................................................1
Projected Demand 3
Pricing and Distribution.................................................................................................................4
Plant Capacity 4
Production Program........................................................................................................................5
4. Raw Materials and Utilities...........................................................5
Availability and Source of Raw Materials.....................................................................................5
Annual Requirement and Cost of Raw Materials and Utilities......................................................5
5. Location and Site................................................................................6
6. Technology and Engineering..............................................................6
Production Process.........................................................................................................................6
Machinery and Equipment.............................................................................................................6
Civil Engineering Cost...................................................................................................................7
7. Human Resource and Training Requirement.................................7
Human Resource............................................................................................................................7
Training Requirement.....................................................................................................................8
8. Financial Analysis..............................................................................8
Underlying Assumption.................................................................................................................8
Investment 9
Production Costs...........................................................................................................................10
Financial Evaluation.....................................................................................................................11
9. Economic and Social Benefits and Justification...............................12
 1. Executive Summary
The project envisages production of 400 tons of Cotton Yarn per annum. The total
investment requirement of the project including the working capital is estimated at about
Birr 8.1 million; of which 4 million is for building and construction, Birr 2.5 million is
for machinery and equipments, and Birr 934 thousand is the cost of the working capital.
Based on the cash flow statement, the calculated internal rate of return (IRR) of the
project is 39.4 % and the net present value (NPV) at 18 % discounting rate is about Birr
6,564 thousand. The plant is expected to create employment opportunities for about 51
persons.

2. Product Description and Application

Cotton yarn is a type of yarn made from cotton fibers. Of various yarns in the world at
present, the cotton yarn is predominant not only because it has many excellent properties
in use but because it can be produced and supplied at stable and reasonable prices.
Therefore, with a long history and accumulation of technical know-how as the largest
textile industry of the world, the cotton yarn spinning industry has greatly improved its
productivity based on modernized facilities.
Most woven fabrics and knitwear fabrics are made from cotton yarn which is made in
textile spinning factories. Yarn is produced to be an input for the weaving department in
textile mills and to be sold in the market to the handloom industry where it is made to
traditional clothes for women and men.

3. Market Study, Plant Capacity and Production Program

Market Study

Present Demand and Supply

Almost all Ethiopian wear traditional clothes- such as netela, gabi, kutta, buluko and
others- made from cotton yarn by traditional weavers using traditional or semi-modern

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weaving machines. Besides, Ethiopian wear traditional dresses (Ye Habesha Libse)
woven by traditional weavers made from cotton yarn. Such demand for cotton yarn in
Ethiopia is met mainly from local suppliers who spin cotton manually in a very small
scale at a household level. Moreover, currently, large numbers of newly emerging cottage
industries (which are working on diversifying, upgrading and modernizing Ethiopian
traditional costumes) are demanding large amount of cotton yarn as their major input.
These cottage industries are being supplied by the existing textile factories which sell
cotton yarn after satisfying their own requirement of yarn to produce cotton fabrics. The
gap between the demand for yarn and the domestic supply is filled by imports;
particularly in the recent year there is a huge surge in the cotton yarn imports. Unless
there additional cotton yarn plants will be established in the country the import growth
seems to continue.
Table 3.1
Domestic Production and Imports of Cotton Yarn
Year E.C Domestic Production Import
(In Kg) (In Kg)
2005 -
2,657,000
2006 3,707
3,408,000
2007 2,625
3,977,000
2008 50
5,726,000
2009 -
7,736,000
2010 62
5,467,000
2011 2,342
5,487,000
2012 14,534
4,299,000
2013 446
9,193,000
2014 31,586
10,736,000
Total
58,686,000
Average
5,668,600
In the past decade, except the slight declines witnessed in 2010 E.C and 2011 E.C the
local production of cotton yarn has exhibited a continues growth; which was computed to
be 17 % per annum on average. During the period, the average annual local production of

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 cotton yarn was nearly 5,669 tons. If we consider the past five years alone, this figure
increases to more than 7,036 tons. In parallel to this, the import in cotton yarn has shown
a big surge in the past three years. The price of the imported cotton yarn is very large as
compared to the price of the local yarn. This clearly justifies the immediate establishment
of additional cotton yarn producing plants in the country.

There are only two textile mills in the whole ANRS; and one of them is about 50 years
old with very little renovation during all these years. The two mills produce small
quantities (up to 500 tons per year) of cotton yarn for the local market, but their yarn
production is not sufficient to satisfy the yarn demand of the Region which is estimated
to be more 2,500 tons of cotton yarn per annum.

As a result, large quantities of yarn are supplied to the Region from other parts of the
country and via imports. With the existing two textile mills getting old and obsolete, the
production of yarn from these factories will decrease. To supply the yarn requirement of
the Region from Regional production, one medium scale spinning mill is needed.

Textile factories can be built either as integrated units (spinning and weaving) or as
separate units like spinning or weaving. Spinning mills can have different capacities and
still be viable. The yarn market in the ANRS can absorb the production of a small to
medium spinning mill which can be viable technically and financially.

Projected Demand

As noted earlier cotton yarn based clothes are very common in rural and urban Ethiopia.
It is believed that this favorable market situation will persist in the future. Since income
rise and population growth rate affect the demand for cotton yarn based domestic
products, 10 % annual growth rate is taken to project the future demand. Besides, by
ignoring the highly fluctuating cotton yarn import, the local production of cotton yarn in
the year 1999 E.C is taken as base year figure for the projection (See Table 3.3).

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 Table 3.3
Demand Projection for Cotton Yarn

Year E.C National ANRS

( In Tons) (In Tons)
1999 10736 2684
2000 11810 2952
2001 12991 3248
2002 14290 3572
2003 15719 3930
2004 17290 4323
2005 19019 4755
2006 20921 5230
2007 23014 5753
2008 25315 6329
2009 27846 6962
2010 30631 7658

As it is seen in the above projection, the demand for cotton yarn at the national level is
expected to reach at 19,019 tons in 2005 E.C and at 30,631 tons in 2010 while it is
expected to reach at 4,755 tons and 7,658 ton in 2005 E.C and in 2010 E.C, respectively
,at ANRS level. This huge future demand clearly justifies the establishment of additional
cotton yarn producing plant both at the regional and country level.

Pricing and Distribution

The price of imported cotton yarn ranges from Birr 20 to Birr 35 per Kg depends on the
quality and country of origin. The wholesale price of the locally produced cotton yarn
ranges from Birr 22 to Birr 25 per kg. The envisaged plant is assumed to sell its product
to the wholesalers at Birr 22 per Kg. The product will find its market outlet through the
existing textile and yarn distributors throughout the country.

Plant Capacity
Based on the available minimum economic capacity, it is envisaged to establish a plant
with capacity of 400 ton per annum. The plant will operate 16 hours per day, in two shifts
and 275 days per year. The working days are set by deducting Sundays and public
holidays and assuming that annual maintenance works and unexpected work interruptions
will take 25 days.

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Production Program

Considering a little period needed for production skill development and market
penetration, the capacity utilization rate in the first year is assumed to be 90 %; and it will
be 100 % starting from the second year of the operation.

4. Raw Materials and Utilities

Availability and Source of Raw Materials

The land resources of the ANRS can produce all the cotton that the region needs to
produce the textile fabrics and yarn requirement of the people. Of course, to produce this
cotton, large scale cotton plantation should be allowed to be started in suitable areas of
the region.

Annual Requirement and Cost of Raw Materials and Utilities

The major raw material is cotton fiber, and its annual requirement is indicated in Table
4.1.The total cost of raw material and other miscellaneous inputs is estimated to be Birr
3.5 million.

Table 4.1
ANNUAL RAW MATERIAL REQUIREMENT
(AT FULL CAPACITY)

Cost(In Birr)
No Raw Material Unit Qty.
F.C L.C Total
1 Cotton Fiber Tons 430 3,440,000 3,440,000
2 Miscellaneous
Materials 12,000 8,000 20,000
Total 12,000 3,448,000 3,460,000

Electricity and water requirement is about 816 MWH and 1000 m3, respectively. Based
on this, the total annual cost of utility at full capacity is equal to Birr 451,450.

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 Table 4.2
UTILITIES REQUIREMENT

No. Utility Requirement Unit Price Cost

(Annual) (Birr)
1. Electricity 816 MWH Birr0.55 /KWH 448,800
2. Water 1,000 m3 Birr2.65 /m3 2,650
Total 451,450

5. Location and Site

For its convenience to procure raw cotton, Gondar is an appropriate choice for the cotton
yarn producing plant in the ANRS.

6. Technology and Engineering

Production Process

The major steps in the manufacturing process of cotton yarn are stack mixing, blow room
carding, drawing open and spinning process, doubling cane winding and quality
inspection.
With regard to alternative technology, instead of buying lint cotton as a raw material, it is
possible to have a cotton ginnery plant that changes the raw cotton into lint cotton. This
involves higher investment cost but it also brings additional profit.

Machinery and Equipment

The lists of machinery and equipments required to establish a cotton yarn producing
plant is given below (Table 6.1).

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 TABLE 6.1
LIST OF MACHINERY AND EQUIPMENT

Name No.
1. Open End Rotor Machine 1Set
2. Humidification Plant 1Set
3. Carding Plant 1Set
4. Mixing Bale Operator 1Set
5. De-dusting Unit 1Set
6. SHS Draw Frame with 4 Deliveries 1Set
7. Cotton Weighing Machine 1Set
8. Combined Delivery Apparatus for One MBO 1Set
9. ERM Cleaners
10. 2-Way Distributor

The total cost of machinery and equipment is estimated at Birr 2.5 million of which Birr
million is in foreign currency and Birr 300,000 in local currency.
Machinery Suppliers Address:
Company Name: Ozcelik Textile Machinery and Die Casting Co.
Product: Spinning Machine
Location: Ornek Sanayi Sitesi 12 St. No. 3, Kusget, Gazianep, Turkey

6.3 Civil Engineering Cost

The building area required by the plant is estimated to be 2000m 2, and it costs Birr
4,000,000. This would include cost of land preparation and associated civil works. The
total land area of the plant, including the open space, is 5000 m 2 and its lease cost equals
Birr 300,000. The cost of the land lease is as per ANRS land lease rate for Gondar which
is equal to Birr 60 per square meter for industrial purpose. Of the total cost of the lease 5
% is paid in the beginning while the rest will be paid in 40years.

7. Human Resource and Training Requirement

Human Resource

Details of the manpower requirement of the plant is shown in Table 7.1

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 Table 7.1
MANPOWER REQUIREMENT
Description No Monthly Salary Annual
(Birr) Salary (Birr)
A. Administration
1. Manager 1 3000 36000
2. Supervisors( Sift Leaders) 2 1000 24000
3. Technicians 6 1000 72000
4. Personnel Officer 1 1000 12000
5. Accountant 1 1000 12000
6.Seretary 1 800 9600
7.Slaesman 1 800 9600
8. Cashier 1 600 7200
9. Storekeeper 1 600 7200
10.Driver 1 600 7200
10.Guards 4 300 14400
Sub-total 20 211,200
B. Production
1. Skilled workers (Operators) 21 600 151200
2. Unskilled Workers 10 300
(Assistants and Laborers) 36000
Benefits (20%) 79,680
51 478,080

The total annual wages and salary, including 20 % benefits, amount to Birr 478,080.

Training Requirement

One month on job training is required for the technical personnel. And this can be
managed by hiring one or two experts in the area from the technology suppliers.

8. Financial Analysis
Underlying Assumption

The financial analysis of Cotton Yarn producing plant is based on the data provided in
the preceding chapters and the following assumptions.

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 A. Construction and Finance

Construction Period 2 Years

Source Of Finance 40% Equity and 60% Loan
Tax Holidays 2 Years
Bank Interest Rate 12%
Discount For Cash Flow 18%
Value Of Land Based on Lease Rate of ANRS
Spare Parts, Repair & Maintenance 3% of the Fixed Investment

B. Depreciation

Building 5%
Machinery And Equipment 10%
Office Furniture 10%
Vehicles 20%
Pre-Production (Amortization) 20%

C. Working Capital (Minimum Days of Coverage)

Raw Material-Local 30 Days

Raw Material-Foreign 120 Days
Factory Supplies In Stock 30 Days
Spare Parts In Stock And Maintenance 30 Days
Work In Progress 10 Days
Finished Products 15 Days
Accounts Receivable 30 Days
Cash In Hand 30 Days
Accounts Payable 30 Days

Investment
The total investment cost of the project including working capital is estimated at Birr 8.1
million as shown in Table 8.1 below. The Owner shall contribute 40 % of the finance in
the form of equity while the remaining 60 % is to be financed by bank loan.

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 Table 8.1
Total Initial Investment

Items L.C F.C Total

Land
15,000 15,000
Building and Civil Works
4,000,000 4,000,000
Office Equipment
100,000 100,000
Vehicles
250,000 250,000
Plant Machinery & Equipment 300,000 2,200,000
2,500,000
Total Fixed Investment Cost 4,665,000 2,200,000
6,865,000
Pre Production Capital
Expenditure* 343,250 343,250
Total Initial Investment 5,008,250 2,200,000
7,208,250
Working Capital at Full Capacity 934,235
934,235
Total 5,942,485 2,200,000 8,142,485
*Pre-production capital expenditure includes - all expenses for pre-investment studies, consultancy fee
during construction and expenses for company‘s establishment, project administration expenses,
commission expenses, preproduction marketing and interest expenses during construction.

The foreign component of the project accounts for Birr 2.2 million or 27 % of the total
investment cost.

Production Costs

The total production cost at full capacity operation is estimated at Birr 5.8 million (See
Table 8.2). Raw materials and utilities account for 67.9 %.

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 Table 8.2
PRODUCTION COST AT FULL CAPACITY
Raw Material Requirement Cost
1.Local Raw Materials 3,448,000
2.Foreign Raw Materials 12,000

Total Production Cost at full Capacity

Items Cost
1. Raw materials 3,460,000
2. Utilities 451,450
3. Wages and Salaries 478,080
4. Spares and Maintenance 205,950
Factory Costs 4,595,480
5. Depreciation 578,650
6. Financial Costs
586,259
Total Production Cost 5,760,389

Financial Evaluation

I. Profitability
According to the projected income statement (See Annex 4) the project will generate
profit beginning from the first year of operation and increases on wards. The income
statement and other profitability indicators also show that the project is viable.
II. Breakeven Analysis
The breakeven point of the projects is given by the formula:

BEP = Fixed Cost

Sale –Variable Cost at full capacity.

The project will break even at 18.6 % of capacity utilization

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 III. Payback Period

Investment cost and income statement projection are used in estimating the project
payback period. The projects will payback fully the initial investment less working
capital in two years.

IV. Simple Rate of Return

The project’s simple rate of return (SRR) is given by the formula:

SRR= (Net Profit + Interest)/ (Total Investment Outlay) at full capacity utilization.

The SRR would be 32.9 % at full capacity utilization.

V. Internal Rate of Return and Net Present Value

Based on cash flow statement (See Annex 2) the calculated internal rate of return (IRR)
of the project is 39.4 % and the net present value (NPV) at 18 % discount is Birr 6,564
thousands.

VI. Sensitivity Analysis

The sensitivity test result which undertaken by increasing the cost of production by 10 %
still indicates that the project would be viable.

9. Economic and Social Benefits and Justification

Based on the foregoing presentation and analysis, we can learn that the proposed project
possesses wide range of benefits that complement the financial feasibility obtained
earlier. In general, the envisaged project promotes the socio-economic goals and
objectives stated in the strategic plan of the Amhara National Regional State. These
benefits are presented below:

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 A. Profit Generation

The project is found to be financially viable and earns on average a profit of Birr 2.5
million per year and Birr 25.2 million within the project life. Such result induces the
project promoters to reinvest the profit which, therefore, increases the investment
magnitude in the region.

B. Tax Revenue

In the project life under consideration, the region will collect about Birr 8.6 million from
corporate tax payment alone (i.e. excluding income tax, sales tax and VAT). Such result
create additional fund for the regional government that will be used in expanding social
and other basic services in the region.

C. Employment and Income Generation

The proposed project is expected to create employment opportunity to several citizens of

the country. That is, it will provide permanent employment to 51 professionals as well as
support stuffs. Consequently the project creates income of Birr 478 thousands per year.
This would be one of the commendable accomplishments of the project.

D. Pro Environment Project

The proposed production process is environment friendly.

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