Fodder Production and Trading Company

Pre-Feasibility Study
FODDER PRODUCTION &

TRADING COMPANY
((SM
T))
UMENT
CU
DOC
MEDA D
Small and Medium Enterprise Development Authority

Government of Pakistan
www.smeda.org.pk
HEAD OFFICE
6th Floor LDA Plaza Egerton Road, Lahore
Tel 111 111 456, Fax 6304926-7 Website www.smeda.org.pk
Helpdesk@smeda.org.pk
REGIONAL OFFICE
PUNJAB
REGIONAL OFFICE
SINDH
REGIONAL OFFICE
NWFP
REGIONAL OFFICE
BALOCHISTAN
8 th Floor, LDA Plaza,

Lahore,
Tel: (042) 111-111-456
Fax: (042)6304926-7
helpdesk@smeda.org.pk
5TH Floor, Bahria

Complex II, M.T. Khan Road,
Karachi.
Tel: (021) 111-111-456
Fax: (021) 5610572
Helpdesk-khi@smeda.org.pk
Ground Floor
State Life Building
The Mall, Peshawar.
Tel: (091) 9213046-47
Fax: (091) 286908
helpdesk-pew@smeda.org.pk
Bungalow No. 15-A

Chaman Housing Scheme
Airport Road, Quetta.
Tel: (081) 831623, 831702
Fax: (081) 831922
helpdesk-qta@smeda.org.pk
July 2008
Fodder Production and Trading Unit
DISCLAIMER
The purpose and scope of this information memorandum is to introduce the subject
matter and provide a general idea and information on the said area. All the material
included in this document is based on data/information gathered from various sources
and is based on certain assumptions. Although, due care and diligence has been taken to
compile this document, the contained information may vary due to any change in any
of the concerned factors, and the actual results may differ substantially from the
presented information. SMEDA does not assume any liability for any financial or other
loss resulting from this memorandum in consequence of undertaking this activity.
Therefore, the content of this memorandum should not be relied upon for making any
decision, investment or otherwise. The prospective user of this memorandum is
encouraged to carry out his/her own due diligence and gather any information he/she
considers necessary for making an informed decision.
The content of the information memorandum does not bind SMEDA in any legal or
other form.
DOCUMENT CONTROL
Document No.
PREF-27
Revision
Prepared by
SMEDA-Sindh
Approved by
Provincial Chief - Sindh
Issue Date
July 2008
Issued by
Library Officer
PREF-27/July 2008/Rev1
P ROJECT PROFILE
1.
This document is developed to provide the insight of the said business with potential
investment opportunity in fodder production and trading unit to cater to the need of the
emerging market. Fodder includes grazing, hay, silage and roots that are used as animal
feed. Availability of fresh fodder varies throughout the year, but livestock must eat
every day; fodder conservation is, therefore, desirable in most farming systems.
Increasing demand of live stock escalates the demand graph of fodder and to keep an
un-interrupted supply round the year, hay making is the most familiar type used by
most of the farms across the globe.
Haymaking is an ancient and simple agricultural operation. It is to preserve fodder in
such a way so that its nutrients are preserved with minimum loss in a storable form to
make it available to livestock as feed at the time of scarcity. Hay making is very
important for Pakistani farmers due to:
Seasonal fluctuation in fresh fodder availability
Difference in nutrient value of different fodders available in different seasons
Difference in price and quality of fodders at different times of the year
The aim of haymaking is to store feed for later use on the farm, but now-a-days, hay is
also a sellable commodity, as it is easy to transport and store. In some countries, urban
dairies and draught or riding animals provide a large market, and some small-scale
producers make hay for such markets. Others have to sell for ready cash and feed straw
to their own stock. Large farms may grow hay as a cash crop, while not keeping
livestock themselves.
The most acceptable form is Alfalfah (Lossan) which is also known as Queen of the
Fodder. This is the best animal feed available which is also economical for both buyer
and seller.
1.1 .
PROJECT BRIEF
Almost 70% populace of Pakistan is engaged directly or indirectly with the agricultural
sector. Live stock is a vital part of this sector for it to continue different activities, such
as, to produce milk and their bi-products. The basic need to make animal healthy and
productive round the year is their diet (fodder) which must be good and persistent
through out the year. But the availability of fresh fodder having same proportionate
ingredients through out the year is restricted by the natural circumstances. To preserve
fodder in the shape of hay by rinsing it with water and moisture by approximately 85%
helps to feed animals with the same quality forage round the year. Alfalfah which is
widely used as an animal feed to provide healthy and nutritious diet and plays a vital
role to maintain and increase the productivity. The harvesting period is not bound to a
specific season and one may reap this Alfalfah all year round. There are several
benefits for haymaking as listed below:
Decrease cost of production

Ensure permanent supply of nutrients to livestock throughout the season/year
Help maintain the milk yield

Keep away the animals from diseases associated with green fodder such as
bloat.
Animals consume green fodder in high quantity as it is backed by water so people dont
find it economical. While Alfalfah is consumed less as the making process rinse the
moisture, but give the same nutrition to the animal. Secondly, the requirement is
persistent across Pakistan and round the year vis--vis the international market is also
open and looking for a new venture to trade.
1.2 .
INVESTM ENT OPPORTUNITY IN THIS SECTOR
Government Support
Fodder production is the major limiting factor for livestock production. In terms of
Total Digestible Nutrients (TDN), there is a shortage of around 30.85 million tones and
in terms of Digestible Protein (DP), around 2.99 million tones. However, there is dearth
of formulated animal feeds to fulfill the requirements of livestock.
The following measures will be taken during the Medium Term Development
Framework period:
i) Availability of seed of high yielding multi-cut fodder varieties will be ensured;
ii) In order to improve the nutritive value, treatment of crop residues and addition of
molasses to feed, as well as silage and haymaking techniques will be demonstrated to
livestock owners;
iii) Animal feed industry in the private sector will be promoted and will be encouraged
to establish feed lots for fattening of animals to increase use of manufactured feed at
farm level; and,
iv) Promotion of fodder production will be made an integral part of veterinary
extension service.
The Alfalfah is the most demandable fodder type in the world especially in Pakistan
because green fodder is not available through out the year with the same nutritious
value and to maintain the production of live stock diet, the diet must be balanced.
Opportunities are spread over locally as well as internationally. In Pakistan, there is no
such production house particularly focusing on the Alfalfah supply, where as the
demand is on the rise in the rural areas because live stock is associated with the crop
production, milk production and meat selling. In rural areas, mostly fodder is being
required to run the routine operations by providing healthy feed to animals. There is a
high demand in the international market in different regions of the world. In addition,
the export of other related products like animal hair, animal leather, guts, bladders and
stomach of the animals, meat and meat preparation also depend upon the fodder
availability.
There is a great need to enhance yield per animal and depends on improvement in the
potential of local breeds and production of high quality fodder and feed. Scarcity of
feed and its high cost is a major limiting factor in urban dairy. At present, there is
insufficient quantity as well as quality of fodder, owing to which animals are underfed,
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www.pakistan.gov.pk - MTDF
weak, thin, and consequently produce less milk and meat which creates shortage of
meat, milk and dairy products. Therefore, the need for adequate fodder is apparent and
also which is available round the year to the milking animals.
Foreign investors have also shown an interest in the production of Alfalfah for animal
feed as a 2United Arab Emirates (UAE) delegation informed the Caretaker Federal
Minister for Food, Agriculture and Livestock (Minfal), Prince Muhammad Isa Jan
Baloch that their company had acquired 3,300 acres of land near Mirani Dam,
Balochistan for growing Alfalfahh for animal fodder.
Investment conditions are also very favorable in this sector as ample land on lower cost
with near perfect circumstances is available vis--vis the cost of input is also
comparatively on lower side with international market which includes mainly seeds and
labor. Government is introducing flexible terms such as reducing duties on agricultural
related machines and products which provide an easy access to state-of-the art
machines and techniques.
1.3 .
MARKET ENTRY TIMING
Fodder is used to feed live stock and this is obvious that what ever the seasonal and
economical conditions prevail, animals must be fed. This is the item which is
demanded throughout of the year in all the locations. Therefore, a fodder production
and trading unit could be established at any time of the year.
1.4 .
PROPOSED BUSINESS LEGAL STATUS
The legal status of business tends to play an important role in any setup; the proposed
fodder production and trading unit is assumed to operate on Sole Proprietorship basis.
1.5 .
PROPOSED CAPACITY
Production capacity of the proposed fodder production and trading unit would be
around 25 to 30 tons/acres per annum. At the initial stage, the unit would utilize 70% of
capacity to produce Alfalfah (but one may use 50% of land for Alfalfah while 20% may
use to harvest some other type of fodder) and which will be increased by 10% every
year.
1.6 .
PROJECT COST
In fodder production and trading unit, state-of-the-art machinery and technical

equipment is required for production. Other equipment like tractor, cutter, baler and
trolleys are required to run day-to-day operations. Despite the fact that processing
machinery used is relatively extensive, but during the discussion with existing
stakeholder, the primary input seed is available in the market for the harvesting of 2-5
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http://www.pakissan.com/english/news/newsDetail.php?newsid=16201
years production on a reasonable price. There are two additional cost which is also
associated with the production of fodder i.e. storage and logistic. The entire total
project cost of the fodder production and trading unit is approximately Rs. 11.4 million.
RECOMMENDED PROJECT PARAMETERS
1.7 .
Capacity
30/ton/acre/ year,
70% utilized initially
Human
Resource
Technology/
Machinery
Production
Land
19
Local/Imported
Machinery
Nawab Shah
Head office
(Use for export and
trading)
Karachi
Financial Summary
Project Cost
IRR
NPV (Rs)
Payback Period
Rs. 11.4 million
40%
14,428,543
3 Years 3 Months
1.8 .
Cost of Capital
(WACC)
17.5%
PROPOSED LOCATION
There are sufficient lands available in various regions of Pakistan, but Nawabshah has
adequate natural resources required to produce fodder. Sale points like mandi and farms
are also near-by. Additionally; Karachi is not far away from nawabshah and raw
materials are available at or near Nawabshah and Karachi. Therefore, production land
could be purchased in Nawabshah and the head office is recommended to be located in
Karachi.
1.9 .
KEY SUCCESS FACTOR
Alfalfah is not a very common fodder type available on large scale for livestock,
therefore, people are not inclined toward its benefits. The fear of waste and any harm to
their animals may also force people to use the existing fodder products. But, once they
realize the benefits and advantage of Alfalfah, they will continue its usage. The few
factors which may make them loyal are:
The consumption pattern; as alfalfah does not contain moisture so animal would
have an intake of approximately 4 to 6 kg, whereby other fodder type have
moisture which makes animals to eat 10 times extra forage as compare to
Alfalfah.
Availability is the second most important factor which affects the buying
pattern of customers as Alfalfah is persistently available through out the year
with sustainable quality.
SEC TOR & INDU STRY ANA LYSIS
2.
2.1 .
SECTOR CHARACTERISTICS AND OVERVIEW
The worldwide animal feed industry consumed 635 million tons of feed in the year
2006, with an annual growth rate of about 2%. The use of agricultural land to grow feed
rather than human food can be controversial; some types of feed, such as corn (maize),
can also serve as human food, while others such as grass cannot. Some agricultural byproducts which are fed to animals may be considered unsavory by human consumers.
2.2 .
SECTOR CHARACTERISTICS
Haymaking turns green, perishable, forage into a product that can be safely stored and
easily transported without danger of spoilage, while keeping losses of dry matter and
nutrients to a minimum. This involves reducing its moisture content from 70 - 90% to
20 - 25% or less. Techniques for natural pasture, sown pasture and crops specifically
cultivated for conservation at three levels of technology are considered: manual
haymaking; simple mechanization with draught animal power or small tractors; and
fully mechanized systems. It is, of course, possible to have some or all of the operations
of haymaking done mechanically under contract, provided that the fields are big
enough to warrant it. For the aforementioned, it is imperative that the climate at harvest
time is feasible and reliable. In areas of uncertain climate, however, it is less suitable,
since equipment must be close at hand for each operation as the condition of the hay
decrease.
Common plants specifically grown for fodder
2.3 .
Alfalfa (lucerne)
Barley
Maize (corn)
Rutabaga (swede)
Turnip
Clover
Orchard grass
Timothy-grass
Millet
Sorghum
Oats
Soybeans
Wheat
TYPES OF HAY
Hay may be made in several forms, according to the conditions, its intended use and the
level of technology. Types of hay are described as follows:
- Long hay, the traditional, age-old form of herbage, mown, turned and carted.
- Chopped hay is an option where conditions for drying are good and systems highly
mechanized; it is less bulky and better for mechanical handling, but must be
conditioned, windrowed and collected with a forage harvester.
- Baled hay. Originally baling was by hand (trusses or bottles) and then by stationary
machines. It has been automated since the 1950s with the introduction of the pick-up
baler. Big bales which can be individually handled by a tractor-mounted front-end
loader are now widely used in large-scale farming. Round bales are the simplest to
make and most popular. Their shape sheds rain and resists water better than traditional
bales.
- Hand-trussed hay is widespread in manual haymaking, often as a means of reducing
shattering.
- Wafered and pelleted hay is dense and free-flowing, so it is easy to transport, handle
and store. Field units are available, but expensive; they are used for high-quality
legume hay in climates which allow rapid drying. Losses are lower than with baling.
- Dried grass is herbage artificially dried at high temperatures and is produced from
time to time; the process allows conservation of a younger and higher quality material,
but it is not currently economically attractive.
- Barn-dried hay. Equipment for fan-assisted drying (with or without additional heat) is
now available, but is not widely used.
2.4 .
PROBLEMS IN HAYMAKING
Problems in haymaking vary according to the crop, climate and prevailing weather at
harvest:
- Under sub-humid and humid temperate conditions, the main problems are related to
gradual drying, with a view to avoid loss by spoilage and to dry the crop as quickly as
conditions will allow.
- Under hot, dry conditions, in contrast, the problems are more likely to be either
shattering of the finer parts of the plant, through too rapid drying, or bleaching, with
consequent loss of carotene and vitamins.
The main consideration is on the type of climate, where drying is a problem since much
difficulty is faced during the process of haymaking. Fine-leaf grasses and legumes are
traditional hay crops in most areas. In the subtropics, hay is made from coarse cereals,
such as, maize and sorghum, now mostly in small-scale farming, notably in India and
Pakistan.
Where hay is made from pasture, rather than arable crops, the fields may be both
grazed and mown at different seasons of the year. If the main output of a field is hay, it
will still be grazed when the weather is unsuitable, thereon left for the forage to reach
the correct stage at the optimum season for haymaking; the aftermath may, thereafter,
be left for animals to grazed. With grazing fields, the immediate requirements of the
stock has priority. But, at the peak of the season, grass growth and forage availability
outstrips the needs of the herd and the whole or part of field (shut off by electric fences)
is used for hay.
2.5 .
2.6 .
2.7 .
CROPS BEST SUITED FOR HAY

Clovers
Grasses
Oats
Barley
Timothy
STEPS IN HAY MAKING

Cutting/Mowing
Raking
Baling
PRODUCT DEMAND
Alfalfah is an animal feed widely grown throughout the world as forage for cattle, and
is mostly harvested as hay, but can be made into silage, grazed or fed as green chop.
Its primary use is for dairy production, followed by beef, horses, sheep, and goat.
Fodder production is a business which may start on a small or medium scale. Several
businesses are running in different part of Pakistan, since nature has bestowed
enormous natural resources, generous availability of water and other input(s) has made
these lands suitable for fodder production. Discussions with the fodder producers and
traders including exporters suggest that demand for fodder is basically filled by the land
lords who harvest fodder as a seasonal crop and which might not prolong to 2 or 3 cuts
per year means upto 3 to 4 months. Rest of the year they focus on other cash crops and
as a result 50% of the required demand is fulfilled by the aforementioned type of
production.
The sector is largely operating informally and no specific data is available on the total
producers; and those who are the main suppliers. Looking at the prevailing practices of
suppliers, they buy fodder of different types from various producers and sell it to the
farm houses or to the sale points where animals are gathered. The buying practices are
of two types; the seller may buy out the whole crop or trade on the basis of the load per
truck.
MARKET INFORMATION
3.
As live stock is playing a vital role in the economy of any country especially an
agricultural country and the products which may use to feed the animals is generally
high in demand. In the Pakistani market, alfalfa is the most acceptable type and when
Alfalfa is used as hay, it is usually cut and baled. Loose haystacks are still used in some
areas, but bales are much easier to transport and are easier to store.
Forage production is now more popular than ever before. There are three main reasons
for this;
Peri-urban and urban fodder production is more profitable than cash crops.
Cultivation of forage is easier and cheaper than cash crops as it does not require
much weeding, hoeing, and insecticidal sprays (e.g., cotton requires five to six
sprays), and,
It does not require a lot of other inputs like high doses of chemical fertilizer, etc.
With dairy units growing rapidly in smaller towns, the demand for forage at local level
is increasing. The forage trade is achieving importance compared to other cash crops.
3.1 .
MARKET POTENTIAL
Future of Fodder
The fodder industry is becoming progressively more mechanized. Todays producer is
becoming more efficient by having tractors, cutters and trucks for logistics.
Stakeholders related to this sector agree that providers and sources are not enough to
meet annual requirement of fodder.
The live stock is increasing in numbers which might increase the size of the market in
future, but, to be a successful fodder producer and trader, one requires plenty of
experience, energy and a good location.
3.2 .
TARGET CUSTOMERS
During the discussion with stake holders it was observed that the existing practice of
the market is that customers come to the door step and buy in bulk. But there are
several sale points available where a huge amount of fodder is being supplied. These
un-served segments comprise of regular and occasional mandis, farm houses and
down-town areas or suburbs where people use cattle, buffalo and cows.
3.3 .
PRODUCT MIX
There are numerous ways to preserve fodder, but, for the specified project emphasis is
on Alfalfah, in which two kinds are available in the market.
Dry
Green
The ratio between the production of dry and green Alfalfah is 70:30 initially, but, we
may harvest dry more rather green in the future.
3.4 .
CHANNEL OF DISTRIBUTION
Producer
Trader /
Exporter
Wholesalers /
Retailers
Customer
(Local/International
)
P RODUCTION PROCESS
4.
The hay making can be done through two stems as listed below. It is recommended that
thick stems are used.
Thin Stems
Thick Stems
4.1 .
TIMING THE HARVEST OPERATIONS
Mowing-conditioning is the first step in hay making and should occur based on the
maturity of the crop and the weather. The crop maturity decision is based on finding an
optimum between yield and growth stage. Alfalfa hay should be mowed before the crop
is in bloom, whereas, grass hay crops should be mowed when or shortly after the plants
shoot-up seed heads. Crops such as orchard grass must be cut before the seeds develop
as the quality of orchard grass drops very quickly after the seed head emerges
4.2 .
BASIC STEP S IN HAY MAKING FROM THICK STEM FODDERS
Stop irrigation one week before harvesting

Harvest the required area the same day
Chop the crop and spread in barnyard
Leave it for raking for at least for four days
At 20% moisture level, stack it in a verandah which has constant air flow from
all sides
Continue to heap on one side as new lot comes
The hay making of Alfalfah is being done through proper processes which comprise of
five basic steps widely used which are follows:
Preparation of Land
Sowing of Seed
Cutting/Mowing
Raking
Baling
The process flow is very easy to understand and to increase effectiveness machines and
labor skills must be jointly. Supervision must be in experienced hands to get the best
out from the efforts.
4.3 .
PROCESS FLOW
Prepa ra tio n of la nd
In making land, one has to understand that water is deemed necessary for the
cultivation of Alfalfah and it should be more appropriate to choose fertile land. Fertility
will increase the production capacity and useful life of the same crop.
Sowing of Seed
Selection of seed mainly depends on the land, water and the weather. There is variety
of seed types and seed is readily available in the market or you may ask research
institute(s) like Sargodha Research Institute or Faisalabad Research Institute for
providing the same. The seed vary in prices due to its useful life. By and large there are
three varieties which are available with three different useful cultivation life, i.e. 2, 3
and 5 years. Use and usage of seed vary from land location conditions and sowing may
start immediately after the land is properly prepared according to the standards guided
by the agricultural institutions.
Cutting /Mowing
The cutting criterion of Alfalfah is basically related with time and two main seasons
summer and winter. This is observed that in summer the total time span increases from
45 to 50 days, but, subsequently winter season decrease it to about 40 days. A total of
10 cut per year would be acceptable. Tractor(s) with small or medium size frame(s)
may be used to mow the land.
Raking
In this stage, Alfalfah crop may undergo a process for removing moisture which is
mandatory for storage and baling. This whole process could be done through a
mechanical machine called raker through which moisturizer would evaporate and the
Alfalfah in the form of hay is available for live stock with the same nutritious value.
Ba ling
There are two types of making bales through which Alfalfah may take depending on
certain shape and size according to the requirement(s). Baling would be done by
machine having steel fingers which bind it. The two types are stated as below:
Round/Square
Big/Small
Baling should occur only after the hay has reached the proper moisture for storage.
There are products available in the market to ensure the aforementioned that is applied
to the bale before it reaches the appropriate moisture level. These products help to
prevent molding and heating when hay is baled too wet. Often this occurs when rain is
expected before the hay is dry enough to bale. These products can be used on legume
hay at up to 25% moisture. Proper small bales, the baling moistures for dry hay should
range from 18 to 20% moisture. For large bales, the moisture should be 16% or lower.
The shape and size is depends upon the buyer choice, availability of vehicle(s) and the
destination place.
Harvest Losses
No matter how carefully you harvest your hay; there will always be a portion of the hay
that is lost during the harvesting process. Hay harvest losses from raking will increase
as the hay dries. Losses are highest when the field is low yielding. Losses can be as
high as 20% in some fields. Wheel and rotary rakes will cause more loss than parallel
bar type rakes. The best practice is to rake the hay once only and that should occur on
the day of baling. Other incidences of hay loss are owing to respiration and rain. These
losses are highly variable and can range from as low as 2% to as high as 100%. These
losses are typically a loss of the most digestible plant components. To minimize
respiration and rain losses, two strategies can be used: to avoid rain and to optimize the
annual harvest.
Hay Making Safety Considerations
Hay making can be a dangerous activity and so proper precautions should always be
followed. Here are a few considerations to keep in mind:
Shield disc mowers properly (knife tip speeds are 160 to 190 mph)
Always use a tractor with cab or at least a rollover protection system
Never stand behind conditioning rolls or flails
Remember that baler flywheels and hydraulic accumulators store energy
Keep fingers out of moving knotters (even if they are temporarily manually
powered)
Do not ride the wagon when a bale thrower is used
Handle bales safely
Keep equipment harvest ready
Keep guards and shields in proper order
Securely block hydraulically-raised equipment before working around or under

the machine
Disengage power and shut off engine before unplugging clogged equipment
Keep a fire extinguisher on all powered equipment
Do not allow kids or other riders on the equipment
4.4 .
PRODUCTION MIX OFFERED
Formulation of the production mix is the key to success. Careful consideration must be
given to the right mix according to the market demand and the weather acceptability
otherwise one can result in a long term loss. A mix and merge of dry and green would
be recommended and particularly dry is considered to be the main product.
4.5 .
RAW MATERIAL REQUIREMENT
For the production process seed, insecticides and pesticides are the required materials
which are used periodically in order to sustain the quality of the fodder. It is
recommended that seed should be taken after having considered the land fertility and
soil type vis--vis water requirement and the seasonal production.
4.6 .
MACHINERY REQUIREMENT
Machinery required for the production of fodder is available in local market but
imported machinery having state-of-the-art functionality, reportedly gives good quality
output. Following machinery will be required for setting up a fodder production and
trading unit:
S.
No.
Required No.
of Units
Tools Detail
Unit Price
Total Cost
(in Rupees)
Tractor FIAT-350 HP
750,000
1,500,000
Cutter
150,000
150,000
Raker
150,000
150,000
Baler
1,000,000
1,000,000
Hydraulic Trolleys
200,000
400,000
Tube wale Drilling
250,000
500,000
Other Accessories
200,000
200,000
3,900,000
Fire Fighting Equipment

1
Fire Fighting Equipment

Total
Total Tools & Equipment Cost
25,000
100,000
100,000
4,000,000
There are many international and local suppliers of fodder production machinery
working in Pakistan and other countries who may be contacted for obtaining
machinery; however, during the course of study for this pre-feasibility we have
obtained some contact details of local and foreign manufacturer(s) which are as
follows:
NEW CHAUDHRY AGRICULTURAL MECHANICAL ENGINEERS
Chowk A.T.M. Vehari Road Multan, Lahore.
Phone: +92-61-6527607, +92-61-6529022, +92-61-6526132. Fax# +92-61-4233706
AGROTRACTORS(PVT)LTD (The dealer of John deer)

38-AMAINGULBERG
LAHORE
Pakistan
92 42 5871746
http://www.deere.com/servlet/AgHomePageServlet
Harvesting Hay
Harvesting hay is the process of mowing a forage grass or legume, allowing it to air dry
thoroughly, then baling it into a round or square "package". There are many variations
and designs of machines that perform each step in this process and some that perform
optional steps that may speed up or improve the process
Machine Capacity
There are four different factors which can limit the capacity of a machine to harvest
hay. Depending on field conditions, power, throughput capacity, speed or traction can
limit the field capacity of a machine. Actually, in systems where machines must
interact (such as, harvest, transport, and unloading), machines capacity can be limited
by other machines. These factors which limit capacity are important concepts because
harvesting quality hay can depend largely on timing(s).
4.7 .
PLANT AND MACHINERY MAINTENANCE
Machinery is expected to be serviced on an annual basis. During the projection period,

maintenance expenses are estimated to be around 3% of the total cost of the machine.
5.
LAND AND B UILDING REQUIREMENT
5.1
Site Development
The fodder production and trading project is estimated to require a total area of 50 acres
for production and for export dealing and to run normal operational activities. These
areas will be used for setting up the production facility, storage and office. An office
may be located in the commercial area preferably I.I.Chundrigar Road.
5.2
Building Construction Cost
As per discussion with market experts, 50 acres area is sufficient for the production
facility. The production land would be located at any place in Nawabshah, where basic
infrastructure is established, with special emphasis on sufficient availability of water.
As per the discussion, an office is required on rent for trading which would be located
in Karachi for this purpose. Therefore, it will be feasible to acquire some office on rent
with alterations made accordingly. The land cost for fodder production and storage is
estimated to be approximately Rs. 480,000/- vis--vis the rented trading office
incurring a sum amount of Rs.35,000/- month.
6.
HUMAN R ESOURCE REQUIREMENT
Fodder production and trading requires highly specialized and skilled labor. A total of
19 persons will be required to handle the production process, storage and trading
operations. The business unit will work on two shifts (12 hours per shift). Skilled labor
with relevant experience will be required for production and trading. Total approximate
manpower requirement(s) for the business operations along with the respective salaries
are given in the table below:
Title/Designation
No of
Persons
Business Unit Manager/Owner

Production Staff
Manager
1
Supervisor /Foreman
2
Machine Operator
3
Land Labor
6
Total Production Staff
12
General Administration/ Selling Staff
Marketing Executive
2
Accountant
1
Office Assistant
1
Guard
1
Cook
1
Driver
1
Total G A /S Staff
7
19
TOTAL
6.1
Per
Month
Staff Salary
Per
Quarter
Per
Annum
40,000
20,000
10,000
8,000
40,000
40,000
30,000
48,000
120,000
120,000
90,000
144,000
480,000
480,000
360,000
576,000
20,000
15,000
8,000
6,500
8,000
7,000
40,000
15,000
8,000
6,500
8,000
7,000
120,000
45,000
24,000
19,500
24,000
21,000
480,000
180,000
96,000
78,000
96,000
84,000
113,000
213,000
639,000
2,556,000
Individual
Salary
Experience
Machinery and tractor operations involved at a fodder production land are of a

technical sort; therefore, it is proposed that tractor and machine operator, supervisor,
manager and other related staff must possess minimum of two to three years experience
of the same type of operations. For the position of the supervisor and manager, some
academic qualification pertaining to the sector is preferable from any recognized
agricultural university.
7.
FINANCIAL ANALYSIS & KEY ASSU MP TIONS
The project cost estimates for the proposed Fodder Production and Trading Unit have
been formulated on the basis of discussions with industry stakeholders and experts. The
projections cover the cost of land, machinery and equipment including office
equipment, fixtures, etc. Assumptions regarding machinery have been provided,
however, specific assumptions relating to individual cost components are given as
under.
7.1
LAND & BUILDING
Land area of 50 acres for setting up the proposed Fodder Production would be
purchased and the cost is estimated to be around Rs. 3,500,0000/-/ But, the trading unit
would be on a rental basis which will cost around Rs. 35,000/- per month for a 120 Sq.
ft office area.
It has been assumed that it would be a land with basic infrastructure available.
However, for the necessary land preparation, construction and renovation and
customization of the office facility around Rs. 480,000/- will be required, which has
been assumed to be depreciating at 10% per annum using diminishing balance method.
7.2
OVERALL FACTORY & OFFICE RENOVATION
To make the mandatory changes depending on the to the land and for the renovation of
office premises in Year 5 and Year 10, a cost would incur for which an amount
equivalent to 5% of the total land/office construction cost is estimated.
7.3
LAND / OFFICE FURNITURE & FIXTURES:
A lump sum provision of Rs. 200,000/- for procurement of office/land furniture is

assumed. This would include necessary items to be used by labor, such as, table, desk,
chairs and stationery for office. The breakup of land and office furniture & fixtures is
as follows:
Item
Beds and relevant necessities
Grocery Items
Table & Chair for Owner
Tables & Chairs for Admin/Marketing Staff
Waiting Chairs
Curtains & Interior Decoration for office
Chairs for Workers/Labor
Electrical Fittings & Lights
Others
Total
Number
1
1
4
6
-
Total Cost
15,000
5,000
25,000
15,000
6,000
50,000
5,000
60,000
19,000
200,000
DEPRECIATION TREATMENT
7.4
The treatment of depreciation would be on a diminishing balance method at the rate of

10% per annum on the following. The method is also expected to provide accurate tax
treatment.
1.
2.
3.
4.
7.5
Machinery
Land and Building Construction
Vehicle
Furniture and Fixtures, etc.
UTILITIES
Fodder production and trading unit will be operated using diesel/petrol for machines,
while water will be consumed for irrigation and harvesting of fodder. The cost of the
utilities including diesel/fuel, water, electricity and telephone is estimated to be around
Rs. 780,000/- per annum. Approximate cost of utilities has been given below:
Utility
1. Electricity
2. Diesel for Tractor, Tubewell & Other Accessories
3. Water
4. Telephone
Total
7.6
Total
Monthly Cost
(Rs.)
10,000
35,000
2,500
17,500
65,000
Total Annual
Cost (Rs.)
120,000
420,000
30,000
210,000
780,000
Annual
%age
Increase
5%
5%
5%
5%
WORKING CAPITAL REQUIREMENTS
It is estimated that an additional amount of Nine Lac Seventy Thousand rupees

(approximately) will be required as cash in hand to meet the working capital
requirements. These provisions have been estimated based on the following
assumptions for the proposed business.
Description
Amount in Rs.
First Three Months Salaries (Production staff)
640,000
First Three Months Other Utilities Charges
195,000
First Three Months Misc. Expenses
30,000
First Three Months Rent Expense
105,000
Total
970,000
7.7
VEHICLE FOR SUPPORT AND MAINTENANCE SERVICES
A loading vehicle would be required for providing services for transportation of raw
material(s) from market to land or any other destination. For this purpose a
transportation vehicle has been proposed which will cost around Rs. 500,000.
SELLING & DISTRIBUTION EXPENSES
7.8
For the purpose of this pre-feasibility, it has been assumed that the Fodder Production
and Trading Unit engaged with local/international sales and for the purpose to enhance
sales, certain strategies must be carried out concurrently which are stated as under;
Hire Distributor(s) in different part of Pakistan to increase the reach.

Locate sales points like farm houses and mandis and induce them through trial
to buy the product and be regular customers.
Find out companies across the regions and make strategic alliances to enter into
partnership contracts on a profitable percentage.
These arrangements would raise a considerable cost to the business for which an
amount equivalent to 2% of the annual sales has been assumed which also covers the
margin on bulk and off season buying.
7.10
MISCELLANEOUS EXPENSES
Miscellaneous expenses of running the business are assumed to be Rs. 10,000 per
month. These expenses include various items like office stationery, daily consumables,
meal expenses of workers and labours located on land, traveling allowances, etc. the
aforementioned expenses are assumed to increase at a nominal rate of 10% per annum.
7.12
FINISHED GOODS INVENTORY
The proposed setup is assumed to maintain finished goods inventory to meet persistent
demand from the local market or to complete any foreign order and to distribute as a
sample on different sale points. For this purpose, finished products equivalent to 15
days would be maintained. This would comprise of most demanded product category
.i.e. Alfalfah.
7.13
REVENUE PROJECTIONS
As per the discussions with market expert, around 25 to 30 tons per acre fodder can be
produced in a year and all are sold out because of its demand domestically and
internationally. In summer months like May and June, while in winter months like
October, November and December, are months in which there is a shortage of green
fodder in the market. For the projection purpose, annual revenue growth rate of 5% has
been assumed which would cover anticipated growth in the industry as well price.
Based on our discussions with the industry experts and entrepreneurs, it is anticipated
that the sales price will vary according to location.
7.14
ACCOUNTS RECEIVABLES
Considering the industry norm, particular to the Fodder Production and Trading unit, it
has been assumed that 90% of the sales will be on cash. Whereas, remaining 10% sales
will be on credit to local distributors only to facilitate them. A collection period of 30

days is assumed for the credit sales.
All of the above assumptions are based on the findings during the discussions with the
industry experts and stakeholders. A provision for bad debts has been assumed
equivalent to 2% of the annual credit sales.
7.15
FINANCIAL CHARGES
It is assumed that long-term financing for 5 years will be obtained in order to finance
the project investment cost. This leasing facility would be acquired at a rate of 15%
(including 1% insurance premium) per annum with 60 monthly installments over a
period of five years. The installments are assumed to be paid at the end of every month.
7.16
TAXATION
The business is assumed to be run as a sole proprietorship; therefore, tax rates

applicable on the income of a non-salaried individual taxpayer are used for income tax
calculation of the business.
7.17
COST OF CAPITAL
The cost of capital is explained in the following table:

Particulars
Required return on equity
Cost of finance
Weighted Average Cost of Capital
Rate
20%
15%
17.5%
The weighted average cost of capital is based on the debt/equity ratio of 50:50.
7.18
OWNERS WITHDRAWAL
It is assumed that the owner will draw funds from the business once the desired
profitability is reached from the start of operations. The amount would depend on
business sustainability and availability of funds for future growth.
7.19
ANNEXURES
7. 19.1
Summa ry of Key Assumptions
7. 19.2
Co st and Revenue Sheet
7. 19.3
Pro jected Inco me Sta tement
7. 19.4
Pro jected Ba lance Sheet
7. 19.5
Pro jected Ca sh Flo w Sta tement

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Pre-Feasibility Study

FODDER PRODUCTION &

Small and Medium Enterprise Development Authority

8 th Floor, LDA Plaza,

5TH Floor, Bahria

Bungalow No. 15-A

Fodder Production and Trading Unit

Provincial Chief - Sindh

Fodder Production and Trading Unit

Decrease cost of production

Fodder Production and Trading Unit

Help maintain the milk yield

INVESTM ENT OPPORTUNITY IN THIS SECTOR

Fodder Production and Trading Unit

MARKET ENTRY TIMING

PROPOSED BUSINESS LEGAL STATUS

In fodder production and trading unit, state-of-the-art machinery and technical

Fodder Production and Trading Unit

Rs. 11.4 million

KEY SUCCESS FACTOR

Fodder Production and Trading Unit

SEC TOR & INDU STRY ANA LYSIS

SECTOR CHARACTERISTICS AND OVERVIEW

Fodder Production and Trading Unit

Fodder Production and Trading Unit

CROPS BEST SUITED FOR HAY

STEPS IN HAY MAKING

Fodder Production and Trading Unit

Fodder Production and Trading Unit

Fodder Production and Trading Unit

TIMING THE HARVEST OPERATIONS

BASIC STEP S IN HAY MAKING FROM THICK STEM FODDERS

Stop irrigation one week before harvesting

Fodder Production and Trading Unit

Fodder Production and Trading Unit

Always use a tractor with cab or at least a rollover protection system

Never stand behind conditioning rolls or flails

Remember that baler flywheels and hydraulic accumulators store energy

Do not ride the wagon when a bale thrower is used

Handle bales safely

Keep equipment harvest ready

Keep guards and shields in proper order

Securely block hydraulically-raised equipment before working around or under

Keep a fire extinguisher on all powered equipment

Do not allow kids or other riders on the equipment

PRODUCTION MIX OFFERED

Fodder Production and Trading Unit

RAW MATERIAL REQUIREMENT

Tube wale Drilling

Fire Fighting Equipment

Fire Fighting Equipment

Total Tools & Equipment Cost

Fodder Production and Trading Unit

AGROTRACTORS(PVT)LTD (The dealer of John deer)

PLANT AND MACHINERY MAINTENANCE

Machinery is expected to be serviced on an annual basis. During the projection period,

LAND AND B UILDING REQUIREMENT

Fodder Production and Trading Unit

Building Construction Cost