165. PROFILE ON PRODUCTION OF
REGISTERS, ACCOUNT BOOK, ORDER &
RECEIPT BOOK
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TABLE OF CONTENTS
PAGE
I. SUMMARY 165-3
II. PRODUCT DESCRIPTION & APPLICATION 165-3
III. MARKET STUDY AND PLANT CAPACITY 165-4
A. MARKET STUDY 165-4
B. PLANT CAPACITY & PRODUCTION PROGRAMME 165-6
IV. MATERIALS AND INPUTS 165-7
A. RAW & AUXILIARY MATERIALS 165-7
B. UTILITIES 165-8
V. TECHNOLOGY & ENGINEERING 165-9
A. TECHNOLOGY 165-9
B. ENGINEERING 165-10
VI. MANPOWER & TRAINING REQUIREMENT 165-12
A. MANPOWER REQUIREMENT 165-12
B. TRAINING REQUIREMENT 165-12
VII. FINANCIAL ANALYSIS 165-14
A. TOTAL INITIAL INVESTMENT COST 165-14
B. PRODUCTION COST 165-15
C. FINANCIAL EVALUATION 165-16
D. ECONOMIC BENEFITS 165-17
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I. SUMMARY
This profile envisages the establishment of a plant for the production of profile on
production of registers, account book, order & receipt book with a capacity of
500 tonnes per annum.
The present demand for the proposed product is estimated at 607.1 tonnes per annum.
The demand is expected to reach at 2060.8 tonners by the year 2017.
The plant will create employment opportunities for 20 persons.
The total investment requirement is estimated at Birr 2.91million, out of which Birr
545,000 is required for plant and machinery.
The project is financially viable with an internal rate of return (IRR) of 23 % and a net
present value (NPV) of Birr 3.12 million, discounted at 8.5%.
II. PRODUCT DESCRIPTION & APPLICATION
A register is a book in which is written a record containing regular entries of items or
details. It can be an official or formal enumeration, description or record of particulars.
It is prepared in the form of books or system whereby municipal records of births,
marriages and deaths are prepared. It can also be used as a means of recording landed
property, a record containing the names of dwellers in kebele, sub city, towns and
regional states.
An Account Book: is a book in which orders from debit and credit entries are
chronologically posted.
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Order Book: is a book in which orders from customers are entered. It is a book specially
printed for making multiple copies of orders including one for the customer.
Receipt Book: is a book containing forms to be used in giving receipts for payment of
money.
All these items are prepared from paper of varying grades and quality. Some are of thin
sheets of paper while the others are relatively thick.
Registers can be used in schools, business and government offices, by merchants, in
industries, in banks and insurance companies, in post offices, etc. It is used to keep the
record of daily activities of offices, maintaining the accounts and other necessary
information. These items are one of the basic sources for formal education and
conveying and recording the ideas by writing.
Account book, order and receipt book are all paper –based stationery items used in the
field of accounting. They find application in all commercial businesses, government
offices, and in various socio-economic activities, either small business or large
businesses. The development of micro and small enterprises in the region demands the
use of these items.
III. MARKET STUDY AND PLANT CAPACITY
A. MARKET STUDY
1. Past Supply and Present Demand
Registers and account books are used for recording. A register is a formal or official
recording book of items, names or actions. It is a book in which names and transactions
are listed.
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Registers and account books are produced locally, the main supply being import. The
supply of imported registers and account books is presented in Table 3.1. The average
annual supply of registers, account books and order and receipt books is 376.1 tons at an
annual average growth rate of 13%.
Domestic production of registers and account books is estimated as 30% of the total
supply. The current effective demand is therefore estimated at 607.1 tons.
Table 3.1
IMPORTED REGISTERS, ACCOUNT BOOK, ORDER AND RECEIPT BOOKS
(TONNES)
Year Import
1997 332.6
1998 199.5
1999 194.1
2000 207.4
2001 373.5
2002 492.8
2003 431.6
2004 382.0
2005 487.2
2006 666.2
Source: Customs Authority.
2. Projected Demand
The demand for register and account books is related with business and social activities
which require the listings and registration of names, items, actions and entries.
Projected demand based on 13% annual growth rate of imported registers in 1997-2006 is
presented in Table 3.2. The demand for register books will attain 2,060 tonnes by the
year 2017.
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Table 3.2
PROJECTED DEMAND FOR REGISTER AND ACCOUNT BOOKS (TONNES)
Year Projected Demand
2008 686.0
2009 775.2
2010 876.0
2011 990.0
2012 1,118.5
2013 1,264.0
2014 1,428.3
2015 1,613.9
2016 1,823.7
2017 2,060.8
3. Pricing and Distribution
The price of commonly used register book having 200 sheets is Birr 17. The
recommended price for the new project is Birr 13.
Distribution of the product will be handled through stationeries.
B. PLANT CAPACITY AND PRODUCTION PROGRAMME
1. Plant Capacity
The market study for registers, account and receipt books indicate that the demand in
2008 will be 686 tonnes. This demand will grow to about 1,614 tonnes and 2,061 tonnes
by the year 2015 and 2017, respectively. It is anticipated that business will substantially
grow in the region due to conducive environment created for private sector in particular
and all socio-economic activities in general. It is therefore proposed that a plant be
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established in the region with an annual production capacity of 500 tonnes. This is
equivalent to 100,000 registers, 200,000 Nos. for account book, order book and receipt
book, each. The plant will operate single shift 8 hours a day and 300 days a year.
2. Production Programme
Production will start at lower capacity to given time for development of production skill
and for establishment of potential market outlets. Hence, the plant will operate at 65%
capacity during the first year, and then production will grow to 75%, 85% and 100%
during the 2nd , 3rd and 4th year and then after, respectively. Production build up
programme is shown in Table 3.3 below.
Table 3.3
PRODUCTION PROGRAMME
Year 1 2 3 4
Capacity utilization (%) 65 75 85 100
Production (pcs)
a) Register 65,000 75,000 85,000 100,000
b) Account book 130,000 150,000 170,000 200,000
c) Order book 130,000 150,000 170,000 200,000
d) Receipt book 130,000 150,000 170,000 200,000
Total 455,000 525,000 595,000 700,000
IV. MATERIALS AND INPUTS
A. RAW AND AUXILIARY MATERIALS
The major raw materials required for the production of the assorted paper products are
white paper, greyish paper and thin paper sheets for receipt book.
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Auxiliary materials include grey board, cardboard, stitching wires, gum, printing ink, etc.
Annual requirement of raw and auxiliary materials with related cost at full capacity is
given in Table 4.1.
Table 4.1
RAW AND AUXILIARY MATERIALS REQUIREMENT AND COST
Sr. Description Qty Cost (‘000 Birr)
No. (Tonnes)
A. Raw Materials
1 Paper white (for register) 145.5 1,673.54
2 Paper white, light green 355.5 3,160.46
Sub-total 501.0 4,838
B. Auxiliary Materials
1 Grey board (cardboard) 5 tonnes 46.4
2 Stitching wires; gum; printing Reqd 12
ink, others
Sub-total - 58.40
Total - 4,896.40
B. UTILITIES
Electricity and water are utilities required for the production of registers, account book,
order and receipt books. Electricity is used to operate production equipment, and for
lighting and power sockets. Water is used for human consumption, sanitation and other
purposes. It is estimated that a total of 5400 kWh of electricity is required per annum. At
the rate of Birr 0.474 per kWh, annual electricity cost will be Birr 2,560. Annual
consumption of water is estimated to be 200 m3, and at the rate of Birr 10.0 per m3, the
annual water cost will be Birr 2000. Thus, the total annual expenditure on utilities will be
Birr 4560.
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V. TECHNOLOGY AND ENGINEERING
A. TECHNOLOGY
1. Production Process
The assorted paper products are available in variety of dimensions and number of pages.
Registers commonly are approximately 18 inches by 9 inches size. Account books can
be of similar size or sizes as determined by manufactures or customers. Order and receipt
books are normally of smaller size than registers. Number of pages in them are mainly
dependent on demand. Registers however can be made of 76,120, and 144 pages. Order
and receipt books can be made of 50,100 and 200 pages.
The process of manufacture of registers, account book, order and receipt books consist of
the following steps.
a) Raw material preparation
b) Cutting of paper
c) Ruling (Line printing)
d) Printing of covers (if necessary)
e) Stapling (punching)
f) Binding
g) Finishing.
Paper is first ruled on the ruling machine according to the requirements. The ruled paper
is then cut to sizes of registers, account books, order and receipt books. Required
number of pages are then increased to the required size, stitched with cover page or
gummed as required. These are packed in numbers for sale. Quality of the product is
maintained as per customers specifications.
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2. Source of Technology
The machinery for the production of assorted paper products can be manufactured and
supplied by companies in Europe and Asia. Address of a renowned company that can
supply machinery and equipment is given below.
Maneklal and Sons (Exports),
237/239 Perin Nariman Street Fort
Mumbai – 400 001, INDIA
Tel. (+91 22) 22618951 / 22618962
Fax: (+91 22) 22618903 / 22679573
E-mail: Sales@maneklal exports. Com
B. ENGINEERING
1. Machinery and Equipment
Machinery and equipment required by the envisaged plant, and related costs in local and
foreign components is given in Table 5.1.
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Table 5.1
MACHINERY AND EQUIPMENT REQUIREMENT AND COST
Sr. Description Qty Cost (‘000 Birr)
No. (ton) LC FC TC
1 Double sided disc ruling
machine; size 36,” suitable to
rule on both sides of the paper in
one direction in one or two
colours at a time with two stop 1 - 250 250
arrangements
2 Paper cutting machine – 42” size 1 - 30 30
with 1 HP motor
3 Platen type printing machine 1 - 65 65
10”x5”
4 Wire stitching machine, power 1 - 25 25
operated – ½ HP motor
5 Gumming machine, hand 1 - 25 25
operated
6 Hand press 2 - 30 30
7 Testing equipment (physical
balance, measuring scales, Reqd - 10 10
gauges, etc)
8 Auxiliary items (wooden racks, - 10 10
cases, etc)
FOB price - 445 445
Freight, insurance, bank, 100 - 100
customs, materials handling
CIF Land Cost 100 445 545
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2. Land, Building and Civil Works
Total land requirement of the project is estimated at 1000 m2, out of which 400 m2 is
built-up area. Cost of building construction at the rate of Birr 2000 per m2 is estimated at
Birr 800,000. At a land lease rate of Birr 1.0 per m2 for a period of 80 years, the total
land lease value will be Birr 80,000. Thus, the total investment cost for land, building
and civil work will be Birr 880,000.
3. Proposed Location
Location of a plant is determined on the basis of proximity to raw materials, availability
of infrastructure and distance from potential market outlets. Moreover, fair distribution
of projects among SNNPRS woredas is also considered to determine plant location.
Accordingly, three woredas namely Awassa zuria, Wonago and Arbaminch zuria are
identified as potential locations. Of these Wonago woreda is selected as appropriate
woreda. It is therefore suggested that the envisaged plant be located in Dilla town.
VI. MANPOWER AND TRAINING REQUIREMENTS
A. MANPOWER REQUIREMENT
The envisaged plant requires both production workers and administrative staff. Details of
manpower and related monthly and annual salaries are shown in Table 6.1 below.
B. TRAINING REQUIREMENT
The operation of production equipment for the manufacture of paper products is simple
and can be handled easily by TVET graduates. Special training programme is not
therefore required.
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Table 6.1
MANPOWER REQUIREMENT AND LABOUR COST (BIRR)
Sr. Position Req. Monthly Annual Wages
No. No. Salary
A. Administration
1 Plant manager 1 2,000 24,000
2 Secretary 1 600 7,200
3 Salesman 1 700 8,400
4 Store man 1 700 8,400
5 Cashier 1 600 7,200
6 Personnel officer 1 800 9,600
7 Clerk 1 450 5,400
8 General services 4 250 12,000
Sub-total 11 - 82,200
B. Production
1 Production head 1 1,200 14,400
2 Skilled workers 5 600 360,000
3 Unskilled workers 2 250 6,000
4 Technician 1 600 7,200
Sub-total 9 - 63,600
Workers’ Benefit (25% BS) - - 36,450
Total 20 - 182,250
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VII. FINANCIAL ANALYSIS
The financial analysis of the profile on production of registers, account book, order &
receipt book 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
Raw material, import 90 days
Work in progress 1 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
2.91 million, of which 27 per cent will be required in foreign currency.
The major breakdown of the total initial investment cost is shown in Table 7.1.
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Table 7.1
INITIAL INVESTMENT COST
Sr. Total Cost
No. Cost Items (‘000 Birr)
1 Land lease value 80.0
2 Building and Civil Work 800.0
3 Plant Machinery and Equipment 545.0
4 Office Furniture and Equipment 100.0
5 Vehicle 200.0
6 Pre-production Expenditure* 290.4
7 Working Capital 902.1
Total Investment cost 2,917.4
Foreign Share 27
* N.B Pre-production expenditure includes interest during construction ( Birr 140.37 thousand ) training
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 5.48
million (see Table 7.2). The material and utility cost accounts for 89.41 per cent, while
repair and maintenance take 1.37 per cent of the production cost.
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Table 7.2
ANNUAL PRODUCTION COST AT FULL CAPACITY ('000 BIRR)
Items Cost %
Raw Material and Inputs 4,896.40 89.33
Utilities 4.56 0.08
Maintenance and repair 75 1.37
Labour direct 109.35 2.00
Factory overheads 36.45 0.67
Administration Costs 72.9 1.33
Total Operating Costs 5,194.66 94.77
Depreciation 174.5 3.18
Cost of Finance 111.98 2.04
Total Production Cost 5,481.14 100
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.
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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 = 33 %
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 5 years.
4. Internal Rate of Return and Net Present Value
Based on the cash flow statement, the calculated IRR of the project is 23 % and the net
present value at 8.5% discount rate is Birr 1.71 million.
D. ECONOMIC BENEFITS
The project can create employment for 20 persons. In addition to supply of the
domestic needs, the project will generate Birr 1.31 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.