Food Complex, Beati
Food Complex, Beati
Food Complex, Beati
FOR
FOOD COMPLEX FACTORY
January , 2016
3. Nationality Ethiopian
6. Premises Required for The envisioned project expansion requires a total of 3,000M2
expansion
7. Total initial investment Cost Br. 20,036,400 of which amount 30% equivalent to
6,010,920 financed by the owners equity and the rest 70%
equivalent 14,025,480 financed through bank loan
8. Employment Opportunity The total manpower required for the envisioned plant
expansion will be 141 employees at full capacity.
Among basic need of human being, Food comes to the prime that is very essential for human life
particularly to have a balanced diet for the development physical and mental status of the human
being. In relation to food complex have great nutrition values that fulfill nutrition need of human
being. Currently, processed food prices are increasing in the global market and domestic markets and
needs for current investment in this sector.
The Ethiopian government has highly encouraging private investment (local and foreign) to meet the
development agenda and to bring prosperity for its citizens. At present, the growth and
transformation are implementing that will pave the road for advancement of the economy.
Therefore, the lucrative market potential and those viable investment policies attracted the promoter
of the envisioned food processing complex factory to expand its factory for the production of various
types of processed food complex mainly Biscuits, Flour, Pasta and Macaroni in Dukem town,
Oromia Region State. Therefore, the owner is committed to establish the factory and believe to get
the required cooperation from regional and local governments.
Although Ethiopia has been passing through dynamic, fast and double digit economic growth in all
sectors of Economy for the last nine years, food processing industry has to be viewed in the context
of the low level of development that seeks more investment on it.
At present, the government of Ethiopia has implementing the second phase of the five years Growth
and Transformation Plan (2015/16-2019/20) that aimed to achieve wider development spectrum in all
sectors. GTP also plan expands industrialization with the involvement of private sectors to make the
nation under the category of middle income earner.
In addition to the above facts, the following points further explain the rationale for the expansion
project by the owner.
Availability of raw materials and inputs for the production of processed food complex.
The main objective of the expanded factory is to produce high quality , cost effective and diversified
processed food complex mainly Biscuits, Bread Flour, Pasta & Macaroni using the state of the- art-
technology for domestic market and international market in the future.
The envisaged expanded project deemed to contribute to the economic development of the nation in
general and the region in specific with following ways:
By producing and supply quality and diversified food complex mainly Biscuits, Flour, Pasta &
Macaroni the expanded project will satisfy the consumers need. Besides, the project will add to the
nutritional value of the citizens.
B. Source of Revenue
As public policy of any nation, the government collects different forms of taxes from different
business organizations and individuals. Among the different forms of taxes, business income taxes,
VAT and payroll taxes are collected from undertaking business activities. Therefore, the expanded
factory will serve as sources of revenue for both the region and nation in general.
C. Employment Opportunity
One of the problems that our country faced is unemployment. Therefore, the current objective of the
government is working on tackling the problem of unemployment and fostering the development
Food complex like pasta and biscuit are imported from the international market. Hence, the
expansion project will help to reduce the nation’s foreign exchange cost to import this product.
Besides, in the future, when the factory start export to global market, the nation will generate foreign
currency form this specific project.
As a corporate responsibility the company will engage in different development activities on the
surrounding areas (Dukem town). This will better worth the community and contribute for the
development of the region.
This expanded factory has positive externality in the zone that will encourage the economic
movement of local economy. There will be economic relationship and transactions among different
actors.
i. Location
The envisioned expansion project will be located in Dukem town(which is 37 kms far from the
center), Oromia Special Zone Surrounding Finfine, Oromia Regional State. The main justifications
behind the selection of this location are:
Strategically located to the central and largest market of the nation (Addis Ababa)
Relatively advanced development in infrastructure (Power, Water, Telephone internet, road
etc.
The gate to port Djibouti and Mojo dry port that will make ease for inputs and machines
The envisioned expansion project will require a total of 3,000M2, the premises required and the land
use plan shown as follows in table below;
Table Premises required and Land use plan for expansion project
SN Description Land
Requirement(M2 )
1 Production Area
1.1 Production Hall 800
1.2 Packing area 150
1.3 Quality Control 50
Total production area 1000
2 Warehouse
2.1 Raw Material & Input 500
2.2 Finished Products 600
Total warehouse area 1100
3 Office Building (G+1) 250
4 Waste Accumulation area 100
5 Green area, loading unloading 550
and Parking
Total 3,000.00
As sectors of the economy, the agriculture and construction sector also grows with double digit with
the average annual growth 10.31% and 12% respectively in the past 8 years. As shown in the table
below the growth of the sectors directly related with the economy as parts of the economy.
GDP in 1999/00
Prices -2.1 11.7 12.6 11.5 11.5 11.6 10 10.4
Distributive
services 5.5 6.4 14.7 14.2 16 15.2
This fast growth of these sectors resulted from different bodies like government, non government and
private activities in Ethiopia is growing in the fastest rate. Moreover, the current five years Ethiopian
Growth and transformation plan will expand the economic growth paramount level by harnessing the
resource and expanding industrialization.
As economics sciences witnesses, when there exist fast economic growth the income of the citizens
will be also increase that strengthens the purchasing power. Income and consummation of goods and
services have direct relationship. Hence, as one component of basic consumption goods, the fast
As a result from big population and population growth, which the kids and youth account the major
shares, the demand for food items particularly Biscuits, Bread, Flour, Pasta & Macaroni and different
others enriched food items.
2008 9,270
2009 9,548
2010 9,835
2011 10,130
2012 10,433
2013 10,746
2014 11,069
2015 11,401
2016 11,743
2017 12,095
2018 12,458
2019 12,832
2020 13,217
iii. Projected Demand, Domestic Supply and Unsatisfied Demand for Biscuits (Tonnes)
Year Total Projected Domestic Unsatisfied
Demand Supply Demand
2008 15,153 9084 6,069
14 G-TWO Investment and Environmental Consulting PLC
2009 15,516 9084 6,432
2010 15,889 9084 6,805
2011 16,270 9084 7,186
2012 16,661 9084 7,577
2013 17,060 9084 7,976
2014 17,470 9084 8,386
2015 17,889 9084 8,805
2016 18,319 9084 9,235
2017 18,758 9084 9,674
2018 19,208 9084 10,124
2019 19,669 9084 10,585
2020 20,141 9084 11,057
Therefore, the majority of Noodles are imported from aboard. Hence, this project deemed to bridge
the demand gaps for noodles in our country by locally producing.
Therefore, there are different forms of competition that may face this project. These are price and non
price based competition. Moreover, the different competitors may compete with the project under
discussion either directly or indirectly. But the project under discussion has diversified marketing
strategies that could enable it cope up with the different competitors in the market. In addition, it will
frequently conduct competitors research which focuses on, the strength and the weaknesses, the
different competitor’s strategies, the techniques they use in rendering the service, their customer
handling methods, and others. Then it will devise different strategies like:
From the above market demand and supply analysis for the envisioned expanded food process
complex project products (Pasta , Macaroni, Biscuits and Flour) there exists huge market gap in
Ethiopia. Hence, the factory will be pioneer and very successful by entering in to this market.
Website Development
Public Relations
Branding
The marketing strategy mainly focus on the satisfying the needs, order and the requirement of the
customers.
Based on plant capacity (105kg/hr biscuit, 800 units of bread per day, 250 kg/hr flour, 100kgs/hr of
pasta and macaroni ) and program this plant assumed to produce of 512,000.00 kgs of Pasta and
Macaroni, 1,280,000.00 kgs of Flour and 537,600.00 kgs of Biscuits at full capacity utilization (third
year) operating 320 days per year and 16 hours (2 shifts) per day.
Considering the gradual growth of demand and the time required to develop the required skill the rate
of capacity utilization during the first, second and third year of production will be 55%, 85 % and
100% respectively. Full capacity utilization will be reached during the third year of operation.
Description Year
1 2 3 and above
Capacity utilization (%) 55 85 100
Pasta & macaroni in kg 281,600.00 435,200.00 512,000.00
Flour in kg 704,000.00 1,088,000.00 1,280,000.00
Biscuit in kg 295,680.00 456,960.00 537,600.00
2.3. Pricing
It would be important to examine the possible level of price based on the competitor’s action. In this
connection, the existing average retail prices of similar imported products were assessed for the
benefit of comparison. Based on the existing price in the market the firm stetted the price as follows;
These include:
Biscuits
Flour
The first step in these product producing manufacturing involves dissolving the salt or kan sui, starch,
flavorings, and other ingredients (except flour) in water. This mixture is added to the flour and the
crumbly dough is rested to mature and then kneaded to uniformly distribute the ingredients and
hydrate all the flour particles. The dough is then passed through two rotating rollers to produce two
sheets which are compounded into a single pasta, Macaroni belt or sheet. The sheet is repeatedly
folded and passed through the rollers to facilitate gluten development, which gives the noodle its
The disadvantage of frying, however, is that fried noodles contain about 15-20% oil (compared with a
maximum of 3% fat in hot air-dried noodles) and are more susceptible to oxidation and spoilage; the
use of antioxidants prolongs the shelf life of fried food items. The dried pasta, Macaroni and noodles
are then quickly cooled, checked for moisture, color, shape and other quality characteristics, and
packaged with seasonings using films that are impermeable to water and air.
1. Dropping method
The dropping method is the most traditional method. About 5% of starch is cooked in water using a
double boiler to prepare starch paste and used as dough binder. The cooked gelatinized starch (starch
paste) is then mixed with 95% of starch and water to give 50% moisture content in the dough and
then mixed and stirred at the rate of 100 r/min about 10 min using a blender to distribute water evenly
and to obtain a smooth ball (starch dough) that does not stick to the hands. The dough was extruded
through the holes (diameter about 0.5–1.5 cm) of the stainless steel cylinder by gravity, directly into
hot water (98–100C), and heated for 30–60 s before transferring into cold water (when noodles
floated upon the surface of water then transfer them into cold water). After rinsing in cold water, the
19 G-TWO Investment and Environmental Consulting PLC
strands were drained, subsequently, separated and hung to partially dry, kept at 4C for 2 h and 10 C
for overnight, dried at 40 C in convection dryer, and then packed in polyethylene bags and stored at
room temperature.
Cooking temperature is immobile because starch strands drop into boiling water (100C or close to
100C). Cooking time, therefore, is a variable parameter in the cooking step.
Water uptake during cooking was closely related to the texture and cooking qualities of starch
noodles insufficient water uptake (swelling) usually results in noodles with hard and coarse texture,
but excess water uptake often results in too soft and sticky
4. Drying
After starch strands were retrograded by cooling, it should be dried at 40 C in convection dryer, and
cooled to room temperature finally before packing. The surface firmness of pasta increased as drying
temperature increased.
Extrusion cooking has become a popular processing method for starch-based foods and for pre-
gelatinized starches. It has also been used for the production of pre-cooked cereal-based blends and
pasta products . The extruding method involves this process for producing starch noodles, which
comprises adding 45–55 parts by weight of hot water to 100 parts by weight of starch obtained from
at least one member-selected from the group consisting of various starches and a product thereof
followed by being mixed to prepare large particles of dough, extruding the dough under degassing at
vacuum to produce a dough sheet, gelatinizing the dough sheet with steam, retrograding the
gelatinized dough sheet by cooling without freezing; cutting the dough sheet into noodles. Starch
food items can be produced efficiently in simple procedures without preparing starch paste separately
and need not special rollers. Further, starch foods produced in this method are highly transparent and
less melted by boiling.
The company will use world standard production technology mainly from china.
The proposed expansion project comprises stock of different components to be executed at different
phases of the project life. These activities include: Design and Construction of various buildings,
importing of machineries and vehicle.
As indicated in part 1 the total land requirement for the expansion project is estimated to be
3,000M2.The buildings are planned to accommodate production houses, store and other utility
requirements as well as offices and a show room/constructions.
In general the buildings must be capable of being kept clean and provision should be made for
keeping the sewerages drained out properly and room temperature is attained to keep healthy
environment. In most environments, equipment should be totally enclosed in a light structure: where
the climate is suitable. A concrete floor, which can be swept, is usual.
The loading and offloading areas together with incoming and outgoing roads are proposed to be
paved to ensure a clean environment around the project site. The site will be encircled by a chain
linked fence fastened to concrete posts. The project construction is designed by professional
engineers and construction will be done under close supervision and collaboration of the engineers.
22 G-TWO Investment and Environmental Consulting PLC
3.9. Utilities
A number of utilities would be put in place in order to ensure smooth functioning of this expansion
factory. These utilities include:
Water Supply,
Telephone line
Drainage Facility
4.4. Manpower
At the top of the organizational structure, there will be a general manager with the responsibility of
supervising the overall activity of the plant. Depending up on the nature of the center and the amount
of work to be performs; there will be auxiliary units under the general manager. Employees under
each unit will be supervised by the unit head that is accountable for the general manager.
The company will use efficient trained staffs in the area of marketing to be competitive supplier of
processed food complex to the market. The opportunities of being serviced by well skilled
professionals well enable the company to evaluate the internal weakness and strength of the company
as well as to assess the global opportunity and risks in the world market so that the company can cope
up with the dynamics of the market situation.
The total manpower required for the envisioned plant expansion will be 141 employees at full
capacity.
The total number of manpower, Manpower list, qualification and salary are listed in the table below.
The organizational structure of the project is designed by including all the necessary personnel under
the right division. At the top of the organizational structure, there will be a general manager with the
Owners
General
Secretary
Manager
Hence the following section deals with the duties and responsibilities of the departments.
1. Manager
Duties and responsibilities
She/he will plan, organize, direct and control the overall activities of the factory
She/he will devise policies and strategies that will enable the factory to be profitable.
She/he will incorporate modern technological innovation that will facilitate the service
delivery of the project center and increase customer’s satisfaction.
It is the core department of the project center for the production of processed foods. It will have the
following responsibilities.
Design and prepare the prototype of pasta , macaroni, Biscuits and Flour based on the plant
standard and customer preferences
Use modern manufacture, processing technologies that will enhance the quality of pasta ,
macaroni, Biscuits and Flour products.
Produce quality pasta , macaroni, Biscuits and Flour products that will enable the factory
competent both in the domestic and international market.
Control on the quality of raw materials, inputs, quality of the product and also the overall
production process.
Produce products in least cost so that the profitability of the center is guaranteed.
Moreover control over the quality of the final products(pasta , macaroni, Biscuits and Flour).
3. Administration and Finance Department
Duties and responsibilities:-
Will plan, organize direct and control the financial transaction of the plant by using the entire
necessary document.
Will develop sound financial control system by developing modern financial control systems.
Will prepare the annual financial statements and prepare condensed reports for the general
manager, owner and other concerned government body.
Will control the human and non human resources of the plant, which include: effective
handling of the different inventories of the machineries, equipments, raw materials, finished
products, and devise strategies of controlling against fraud and damage.
Manage and execute the company national and international procurement procedure
Administer and control the company logistic resource
Provide and manage general supportive service to the plant.
Will handle the overall marketing activities of the organization which include planning,
organizing, directing, and controlling.
Provide cost estimates for pricing
Gather information on new product design, profile
Approval of new products profile & brand plan analyzes market research.
Plan and execute sales.
Will develop effective customer handling strategies
Will develop the marketing strategies for future project center’s development.
Conduct both foreign and domestic market research for expanding the sales of the company
C. Vehicles
SN Description Q Unit Price in Total Price in Remark
t Br. br.
y
1 FSR Isuzu Truck 2 1,000,000 2,000,000 Duty Free
2 Worker service mid bus 1 900,000 900,000 Duty Free
3 Pick up 1 700,000 700,000 Duty Free
Total 3,600,000.00
F. Pre-Service Expense
SN Description Cost in br.
1 Project proposal 15,000
2 Environmental Impact Assessment 25,000
3 Licensing and other fee 1,500
4 Worker capacity training 100,000
Total 141,500
As indicated in part 4.2 (Manpower) of this study, the total cost of salary and wage is estimated
to be Br. 2,430,720.00
1
At the third year of Operation
B. Depreciation
Building 5%
Vehicles 20%
C. Working Capital
5.3.9. Profitability
According to the projected income statement, the project will start generating profit in the 1st
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 lifetime of the project.
The income statement and the other indicators of profitability show that the project is viable.
• Separate harmful chemical waste from organic waste, and use more care in handling
chemical waste. Dispose of chemical waste in methods in a manner that prevents
chemicals from leaching into ground or surface waters (such as clay- or concrete-lined
pits).
• Find ways of reducing harmful byproducts. For example, clean the floors in between
production cycles to get rid of excess dust, or install drip trays to catch acidic particles
(iii) Spoilage
Certain structural features of buildings used in food processing may lead to spoilage or
contamination of the products. Such site or building features include inadequate drainage or a
lack of screens to keep out insects/rodents. Increased spoilage causes more waste and less
profitability, while contamination may result in health problems for consumers.
• Storage areas should be well-ventilated and large enough so that excessive heat and
moisture
If machinery is difficult to access, then monitor wastes or emissions to detect leaks. For
example, check for puddles underneath machinery or chemical/fuel smells.
• Use wood shavings, drop cloths and/or oil/water separators to catch spills and leaks.
• If you are disposing of organic and chemical wastes separately, ensure that chemical or fuel
waste does not contaminate the organic waste.
• If it is not cost-effective to replace or to repair machinery, make sure harmful effects are
minimized. Increase ventilation around any machinery that has high gas or chemical
emissions.
• Regulate water flow. Using high-pressure water hoses can ease cleaning and cut water use;
usually this only involves adding a new nozzle to the end of a hose.
• Reuse water. Some food processors use steam to purify or clean packaging materials; a
closed-loop system can cycle hot water back into the system. This process saves money
on both water and energy costs.