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Pre-Feasibility Study

Printing Press

Small and Medium Enterprise Development Authority


Government of Pakistan
www.smeda.org.pk
HEAD OFFICE

6t Floor, LDA Plaza, Egerton Road, Lahore


Tel: (042) 111-111-456, Fax: (042) 6304926-7
helpdesk@smeda.org.pk
REGIONAL OFFICE PUNJAB

8th Floor, LDA Plaza,


Egerton Road, Lahore.
Tel: (042) 111-111-456
Fax: (042) 6370474
helpdesk@smeda.org.pk

REGIONAL OFFICE
SINDH

5TH Floor, Bahria


Complex II, M.T. Khan
Road, Karachi.
Tel: (021) 111-111-456
Fax: (021) 5610572
helpdesk-khi@smeda.org.pk

REGIONAL OFFICE
NWFP

REGIONAL OFFICE
BALOCHISTAN

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

December, 2007

Pre-Feasibility Study

Printing Press

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-69

Revision

Prepared by

SMEDA-Punjab

Approved by

GM Punjab

Issue Date

December, 2007

Issued by

Library Officer

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Pre-Feasibility Study

Printing Press

1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
3
3.1
4
4.1
4.2
4.3

INTRODUCTION .............................................................................................................. 3
Project Brief ....................................................................................................................... 3
Opportunity Rational .......................................................................................................... 3
Legal Status........................................................................................................................ 4
Regulations......................................................................................................................... 4
Project Capacity and Rationale ........................................................................................... 4
Project Cost ........................................................................................................................ 4
Product Mix........................................................................................................................ 5
Location ............................................................................................................................. 5
Key Success Factors/Practical Tips ..................................................................................... 5
CURRENT INDUSTRY STRUCTURE ............................................................................. 5
MARKETING.................................................................................................................... 7
Market Size and Future Prospective .................................................................................... 7
PRODUCTION PROCESS................................................................................................. 9
Product Mix........................................................................................................................ 9
Process Flow (Off-Set Printing) .........................................................................................10
Production Process ............................................................................................................11
4.3.1
The Design/Creative Stage ..................................................................... 11
4.3.2
The Prepress Stage ................................................................................. 11
4.3.3
The Printing Stage..................................................................................11
4.3.4
The Bindery Stage..................................................................................12
4.4 Raw Material .....................................................................................................................12
4.5 Technology/Process Options..............................................................................................13
5
HUMAN RESOURCE REQUIREMENT..........................................................................15
6
MACHINERY &EQUIPMENT REQUIREMENT ............................................................16
6.1 Machinery & Equipment Requirement...............................................................................16
6.2 Alternative Machinery Options ..........................................................................................17
6.3 Machinery Suppliers..........................................................................................................18
7
LAND & BUILDING........................................................................................................18
7.1 Total Land Requirement ....................................................................................................18
7.2 Recommended Mode of Acquisition..................................................................................18
7.3 Suitable Location...............................................................................................................19
8
THREATS.........................................................................................................................19
9
PROJECT ECONOMICS ..................................................................................................20
10 FINANCIAL ANALYSIS .................................................................................................21
10.1 Projected Income Statement...............................................................................................21
10.2 Projected Balance Sheet.....................................................................................................22
10.3 Projected Cash flow Statement ..........................................................................................23
11 KEY ASSUMPTIONS ......................................................................................................24

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Printing Press

INTRODUCTION

1.1 Project Brief


The basic aim of this pre-feasibility is to provide the basic information for setting up a
printing press business. Printing Press is a capital oriented venture. The major cost of the
project includes acquisition of printing and related machinery, which is almost 42% of
the total project cost.
The output of this business is printed material and can be classified in to four broad
categories:
Promotional material, which includes items like financial reports, brochures,
catalogues posters calendars, diaries and visiting cards etc.
Office stationery, which includes letterheads, printed files, vouchers, invoices,
inward/outward documents etc., and books of account.
Publishing material, which includes literature books and text books etc.
Packaging material includes packing material of all kinds like boxes, cartons etc.
1.2 Opportunity Rational
The importance of the printing and graphic arts sector is often under-estimated. Due to
stability in economy in last few years, there has been a positive trend in all major
business sectors of the country. Print media is one of the most effective and economical
mediums of communication and promotion and is used by all major businesses.
Since, the invention of printing press in 1436 by Gutenberg of Germany, it has
contributed a lot towards evolution of humanity. Its significance in day to day business
promotion and marketing cannot be ignored.
In todays competitive environment, businesses require appropriate marketing &
promotional tools to build product recognition in the market. From brochures to
packaging all are means of effective sales promotion tools and require services of
printing press.
Major share of customers for printing press are institutional buyers. Institutional buyers
in Pakistan for printing press can be divided into following broad categories:
1.2.1

Business Sector

Due to stability in economy in past few years, a handsome amount of investment has
taken place in the countrys business sectors. In year 2006-07 1, there was a growth of
8.4% in overall manufacturing industry, 8.8% in large-scale manufacturing and 8.0% in
service sector. The overall growth in GDP in year 2006-07 was 7%.
There are more than 775 public limited companies listed in Pakistan with an immense
requirement of printed material for their businesses. According to directorate of
industries, more than 61,000 industrial units are operating only in the Punjab province.

Source: Economic Survey of Pakistan (2006-07)


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1.2.2

Printing Press

Educational Sector

Another sector, which requires extensive services of printing press, is the educational
sector in the form of books and other printed material. Government of Pakistan has
realized the importance of increasing the literacy rate to jump start economic growth and
alleviate poverty in the country. In year 2007-08, the Government has allocated $ 24.5
billion up by 23.1% for education, which is 50% higher than the previous year.
There were 156,732 primary, 39,370 middle, 22,909 secondary and 2,996 higher
secondary educational institutes operating in Pakistan in year 2005-062.
1.3 Legal Status
The legal status for a printing press is recommended to be a sole proprietorship or
partnership as the business has low capital investment. The benefits of registering the
business as a partnership are:
1.
Less legal requirements for registration.
2.
Lower tax rates as compared to private or public limited company.
1.4 Regulations
A printing press will require:
1 Approval from Audit Bureau of circulation is required before starting of operations.
2 Registration with income tax department and sales tax department.
The rate of general sales tax applicable on printing supplies is 15 %, if supplies are to
registered counterparts and 18 % if supplies are to non registered businesses. The press
may opt for turnover tax enrolment instead of GST, if its annual turnover does not exceed
Rs. 2.5 million. The rate of turnover tax on supplies is 2% without deducting/adjusting
any input tax (sales tax paid on purchase of raw material).
Income tax rate for the business will depend on the legal status of the firm, the prevailing
rate of income tax for sole proprietor and partnership is in various slabs with maximum
of 25%.
1.5 Project Capacity and Rationale
The proposed unit has a capacity of printing 14,000 impressions per hour with two (2)printing machines. The proposed machines have ability to print sheets of 140x180mm to
483x640mm dimensions.
The attainment of the project capacity will depend upon the factors like involvement of
the management to facilitate production, marketing, quality and design of the product,
and the skills and motivation of the labour force involved in the production of products.
1.6 Project Cost
The total project cost for setting up a printing press is calculated to be Rs 3.176 million.
This also includes working capital requirement of Rs 0.980 million.

Ministry of Education, Pakistan.


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Printing Press

1.7 Product Mix


The proposed project with installed machinery has the capability to produce all the
products of offset printing industry except newspapers. For the purpose of this feasibility
following products will be printed.

Books
Financial reports & prospectus
Office stationery & visiting cards
Invitation cards
Catalogues & pamphlets
Brochures & handbills
Posters

1.8 Location
As the major customers of printing press are industrial buyers, so the unit can be
established in any city with a large business cluster. So, cities like Karachi, Lahore,
Faisalabad, Multan, Islamabad can be suitable locations for setting up printing press.
1.9 Key Success Factors/Practical Tips
1

To obtain higher profits, it is really important to acquire order of all different printing
jobs of a company.

Relations in business sector are really important in success of a printing press as it is a


order based business.

Technical skills are really important for effectively operating the business, as skilled
workers can reduce wastage, insure lower machine maintenance cost, in time delivery
and quality finish of the product.

Order size is of a great importance for profitability of the business, as major cost of
printing is the designing, image setting and plate making i.e. fixed costs. So, if the
order size is large the cost per unit will be lower.

CURRENT INDUSTRY STRUCTURE

Lahore and Karachi are the two major centers of printing and publishing business in the
country. There are approximately 167 printing presses in organized printing sector of
Karachi3. In Punjab, total no. of presses are approximately 987 (out of which 690 are
located in Lahore only) with installed capacity of 763,940,460 impressions per hour and
employment absorption of around 4,800 people4. According to some estimates total
investment in this printing and publishing in the Punjab only stands at Rs. 275 million.
Currently, printing industry in the country is segmented and unorganized. There is an
association in Lahore named All Pakistan Small Printing Press Association but it is not
fully operational and does not encompass the entire industry. However, printing business
in Karachi is comparatively more organized and better documented. One major trade
3
4

Source: Pakistan Association of Printing and Graphic Arts Industry (PAPGAI)


Source: Directorate of Industries, Punjab
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Printing Press

association in Karachi relevant to the business is PAPGAI, which is trying to organize the
sector in association with Govt. of Sindh. In a recent development, Sindh Information
Department has advised all the owners of printing presses throughout the province to get
their establishments registered under the existing rules.
District wise break up of number of units of printing press in Punjab are as following:
Table 2-1

District wise Details of Printing Presses in Punjab5

District
Bhakkar
D.G. Khan
Faisalabad
Gujranwala
Jhang
Jhelum
Lahore
Ludhran
Mianwali
Multan
Rawalpindi
Sargodha
Sialkot
Toba Tek Singh
Print
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.

No. of Units
3
5
100
15
13
12
690
2
10
14
35
48
25
15

industry is currently producing following products:


Books (text books and others)
Newspapers & magazines
Financial reports & prospectus
Office stationery & visiting cards
Books of account
Packaging material
Calendars & diaries
Invitation & ceremonial card
Catalogues & pamphlets
Brochures & handbills
Posters
Tags & stickers etc.

Source: Directorate of Industries, Punjab


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Investment ( 000 )
1,150
3,500
20,335
7,763
1,430
3,140
201,969
90
4,145
3,590
6,265
13,821
3,317
4,450

Pre-Feasibility Study

Printing Press

Some of the major industry players in Lahore in the organized sector are as under:
Table 2-2

Major Industry Players in Lahore

Name
Friends Sons (Pvt.) Ltd.

Address
74-Main Industrial Area Kot Lakhpat, Lahore

Lion Art Press (Pvt.) Ltd.


Nisar Art Press (Pvt.) Ltd.
Nuqoosh Press
Balance Ad

112, The Mall Road, Lahore 54000


9, Industrial Area, Gulberg-III, Lahore
Nuqoosh Building, 7-Kabir St.Urdu Bazar, Lahore
Kothalia Mansion, 2-Mcleod Road, Lahore

MARKETING

3.1 Market Size and Future Prospective


The market for printing products can be divided into following segments:
Table 3-1

Categories of Printing Products

Description
Products
Cultural & Educational Items Books, brochures, newspapers and magazines
Industrial & Promotional
Items
Stationery & Other Items

Sales Promotional Printings, annual reports, Securities,


blueprints, printed wrappings and labels
Pictures, colour and drawing books for children, art
prints, calendars, engraving, school and office supplies,

The market for printed material in Pakistan has been developing steadily over the last
decade. Books have the largest share in local printing industry. Almost 100% of the local
demand is met by local industry, with the exception of some highly professional books
(medical, business and engineering books). Major portion of this category consists of
textbooks used by students from a variety of academic background. The details of
educational institutes and enrollment in Pakistan are given in the table below:
Table 3-2

Educational Institutions in Pakistan Year 2005-066

Description
Pre-Primary
Primary
Middle
Secondary
Higher Secondary
Secondary Vocational/(Technical)
Colleges
Universities
Non-Formal Basic Education
6

Institutions
794
156,732
39,370
29,909
2,996
3,059
1,135
116
10,185

Source: Ministry of Education, Pakistan.


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Enrollment
7,135,447
16,834,417
5,262,323
2,133,008
853,535
238,687
325,993
424,012
361,747

Pre-Feasibility Study

Printing Press

Market demand of other cultural items can be judged from the following table:
Table 3-3
Item/Year
Dailies
Weeklies /
Bi-weeklies
Fortnightly
Monthlies
Quarterlies
Annually

Average circulation of Newspapers and Periodicals (Magazines)7


2003

2004

2005

2006

Growth
(%)
4%

6,245,775

7,817,958

7,889,639

8,208,874

588,058

699,688

588,387

672,024

14%

96,562
1,312,635
6,875
730

92,942
1,364,652
8,050
730

98,296
1,487,707
21,050
855

109,887
1,630,569
24,673
855

12%
10%
17%
0%

As far as demand for industrial and promotional items is concerned, it can safely be
assumed that every industrial unit whether it is large or small, requires services of
printing press. There are 702 public listed companies in Pakistan and printing of quarterly
and annual reports is mandatory for them. Current growth rate in manufacturing
industries is 7.7% in large scale manufacturing 8.7%and in services sector 5.3%.
Industrial units mostly require services of printing press for their packaging material i.e.
(labels, wrappings, boxes). The table below shows some of the industries acquiring the
services of printing press for packaging purposes.
Table 3-4
Item/Year
Dailies
Weeklies /
Bi-weeklies
Fortnightly
Monthlies
Quarterlies
Annually

Average circulation of Newspapers and Periodicals (Magazines)8


2003

2004

2005

2006

Growth
(%)
8,208,874
4%

6,245,775

7,817,958

7,889,639

588,058

699,688

588,387

672,024

14%

96,562
1,312,635
6,875
730

92,942
1,364,652
8,050
730

98,296
1,487,707
21,050
855

109,887
1,630,569
24,673
855

12%
10%
17%
0%

The annual turnover in the printing industries is strongly influenced by the state of the
economy in general. About 25% of the total demand comes from the individual
Consumer, while remaining 75% from the institutional buyers.

7
8

Source: Federal Bureau of Statistics 2002-03


Source: Federal Bureau of Statistics 2002-03
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Printing Press

PRODUCTION PROCESS

4.1 Product Mix


Proposed product mix with utilization of capacity on the basis of 8 hours shift is given in
the following table. The maximum attainable capacity of machines is assumed at 80%
because of the wastage of time during cleaning & trial runs of the machine.
Table 4-1

Product Mix and Capacity Utilization Details

Product
Solna 125 Machine
Financial Report
Brochure
Book
Pamphlet
Letterhead
Rota Machine
Vouchers
Visiting Cards
Packing Material
Invitation card

Production
Proportion

100% Capacity
Units

25%
15%
50%
5%
5%

46,601
233,009
71,301
470,588
1,882,352
Units
11,349,753
1,391,304
1,241,379
945,812

40%
5%
35%
20%

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Maximum Attainable
Capacity (80%)
Units
37,280
186,407
57,040
376,470
1,505,881
Units
9,079,802
1,113,043
993,103
756,649

Pre-Feasibility Study

Printing Press

4.2 Process Flow (Off-Set Printing)

Getting Order

Conceiving Idea

Sketching

Approval of Sample

Image Setting

Plate Making

Ink & Water

Press Run

Ink & Water

Binding

Packing

Delivery

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Paper

Pre-Feasibility Study

Printing Press

4.3 Production Process


4.3.1 The Design/Creative Stage
In the Design Stage the designer prepares the design of the product taking into account
the overall look and feel of the paper. Text to be printed is typed and graphics to be
shown are created. Designing of graphics is of two types, halftone and line art. Halftone
is the reproduction of continuous-tone artwork (such as a photograph) through the
application of a screen that converts the image into dots of various sizes. Line art is the
art that is made up of continuous lines such as pen & ink drawings or typefaces. There is
no tonal difference from one area to another. After designing the designer sets page
layout and the design is sent to the pre-press department.
4.3.2 The Prepress Stage
In the Pre-press Stage the artwork is taken from its delivered state (either reflective art or
digital file) all the way to the press plates. In pre-press stage:
1.
2.
3.

The artwork is transformed to negative film either by imaging a digital file through
an image setter, or by shooting reflective artwork with a copy camera.
The pages are stripped together into a flat9 that reflects how the pages will be
printed on the press sheet.
The flat is burned onto a metal plate.

After the flat is burned onto the plate, the plate washed in the developing chemical. This
developed plate is wrapped around the press cylinder.
For the purpose of this feasibility, this process will be outsourced because of the high
capital cost of machinery and equipment used in the process and the infrequent use of
machinery.
The outsourcing rates for pre-press activities are as follows:
Cost of image setting

Rs. 3.0 per square inch per color.

Development cost of plate making

Rs. 50 per plate.

4.3.3 The Printing Stage


The Printing Stage covers the transfer of an image to paper. Offset lithography is based
upon the principle:
The ink and water do not mix.
The paper is fed through the press from a pile of paper already cut to the size of the
machine. Offset printing presses print at a high speed. The speed can reach 6,000
impressions per hour in case of Rota and 8,000 impressions per hour in case of Solna.
When a printing plate is made, the printing image is rendered ink-receptive and waterrepellent, while the non-printing areas are rendered water-receptive and ink-repellent.
The ink is distributed to the plates through a series of rollers.
9

Negative placed on metal plate.


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Printing Press

On the press, the plates are dampened, first by water rollers, and then ink rollers. The
rollers distribute the ink from the ink fountain onto the plates. The image area of the
plates picks up ink from the ink rollers. The water rollers keep the ink off of the nonimage areas of the plate. Each plate then transfers its image to a rubber blanket that in
turn transfers the image to paper. The plate itself does not actually touch the paper. All of
this occurs at a high speed. During the process the machine man checks the blending of
inks to maintain the colour control. Print quality is checked frequently by the press
operator.
4.3.4 The Bindery Stage
The Bindery Stage is when any trimming, folding, perforating, collating, stitching, or
gluing is performed as required. Mostly, Printing Press performs the trimming and
folding in-house, and works closely with an outside bindery on the collating, stitching
and gluing.
A typical job such as an 8.5 x 11 newsletter may include:
1 A post press cut
2 A half fold
3 A double parallel fold
For the purpose of this feasibility, this process will be outsourced because the process is
labor intensive and to perform the process in-house the business requires steady orders of
binding.
4.4 Raw Material
Imported as well as local paper and board is being used by the industry. Imported paper is
normally used in annual reports, brochures, catalogues, prospectus and visiting cards etc.
Imported paper is readily available in local markets. Mostly, the business is done on just
in time (JIT) concept due to readily availability of the raw material, but it is
recommended that some amount of raw material inventory is maintained if the project is
located at a distance from suppliers. From the following table it is evident that increase in
production of paper is being consumed by the printing industry.
Table 4-1

Availability of Raw Material (Paper) Local10


Units

Paper & Board


Table 4-2

List of Raw and Processing Material

Description
Mat Art Paper 135 gm (per rim)
Mat Art Paper 115 gm (per rim)
Mat Art Card 260 gm (per pack)
Offset Paper 100 gm (per rim)
10

Tons(000)

2005-06
394.9

July to April
2006-07
388.8

Price (Rs.)
3,200
2,750
1,350
2,400

Source: Economic Survey of Pakistan


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Availability
Imported
Imported
Imported
Imported

Pre-Feasibility Study

Printing Press

Offset Paper 90 gm (per rim)


Offset Paper 80 gm (per rim)
Flying Paper 68 gm (per rim)
Plate 645 x 510 x 0.20 mm
Plate 645 x 510 x 0.24 mm
Plate 510 x 400 x 0.24 mm
Ink Yellow (per kg)
Ink Magenta (per kg)
Ink Cyan (per kg)
Ink Black (per kg)
4.4.1

2,200
1,950
1,125
125
154
100
410
425
425
400

Imported

Imported
Local
Imported
Imported
Imported
Imported/local
Imported/local
Imported/local
Imported/local

Suppliers of Paper, Plates & Ink

AKBARI PAPER STORE


15-Shahrah-e-Millat, (Ganpat Rd.) Lahore
Ph # 92-42-7232599

Fax # 92-42-7236484

JAVED COMMERCIAL CORPORATION


4-Ahtesham Chambers, Paper Market, Shahrah-e-Millat, Lahore
Ph # 92-42-7248509, 7357635
Fax # 92-42-7244671.
GRAPHO SCAN SUPPLIES (PVT.) LIMITED
Kashif Centre, 2nd Floor, 55-A, Chamberlaine Road, Lahore.
Ph # 92-42-7232582, 7351200.
Fax # 92-42-7351100.
MALIK PAPER MART
Ganpat Road, Lahore.
Ph # 92-42-7353482, 7311553, 7224255.

Fax # 92-42-7248115, 5837408.

ROYAL PAPER HOUSE


10 Royal Park, Lahore.
Ph # 92-42-6313265, 6363266.

Fax # 92-42-6363266.

ZAP TRADERS
Paper Market, 473 Shahrah-e-Liaquat, Karachi
Ph # 92-21-2621423, 2628387.
4.5 Technology/Process Options
Following different technology/process options are available for printing:
1.
2.
3.
4.
5.
6.
7.
8.

Offset Lithography
Web Printing
Letter Press
Flexo
Gravure
Screen Printing
Waterless Lithography
Digital Printing
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Pre-Feasibility Study

4.5.1

Printing Press

Off Set Lithography

The basic principle of offset printingthe dominant printing processis simple: ink and
water don't mix. Early lithographers etched images onto flat stone. These images would
accept ink, while the porous stone accepted water. When ink was applied, it stayed on the
greasy image area and avoided the rest of the stone.
Modern lithography uses the same concept but adds one important element. In modern
presses, the image is transferred from the printing plate to a rubber blanket and then to
the paper. This process is called offset printing.
Although there are many different kinds, sizes and qualities of offset presses, the basic
configuration remains the same. When the printing plate is exposed, an ink-receptive
coating is activated at the image area. On the press, water rollers dampen the plate, first,
then by ink rollers. Ink adheres to the image area and water to the non-image area. As the
cylinders rotate, the image is transferred to the blanket. Paper passes between the blanket
cylinder and the image is transferred to the paper.
The major types of offset presses are sheet fed and web. In a sheet fed press, cut paper is
delivered into the machine. In a web press, paper comes on a large roll and is cut after
printing.
4.5.2

Web Printing

Web printing is offset lithography printing on large continuous rolls of paper known as
webs. Expensive at shorter runs, it is most commonly used for the production of
newspapers, magazines and catalogues due to its speed and economy at runs over
250,000 per hour.
4.5.3

Letter Press

Formerly the standard printing process, letterpress is now largely used for specialty work
such as fine art prints, books and posters. In the process, the image area is actually raised
above the rest of the plate, so the image makes a physical impression on the paper.
Modern letterpress uses a photo-etching technique to remove the non-image area from the
plate.
4.5.4

Flexo

Modern flexography, often called flexo, is a versatile process that uses photo-etched
plates. The non-image areas on these plates are etched away, leaving only the printing
surface that carries the ink directly to the printing material (referred to as the substrate).
Flexo is best suited for printing on a rolled substrate other than paper such as box boards,
foils, plastics, newsprint and more. Common applications for flexo include labels, tabs,
corrugated boxes, cartons and newspapers.
4.5.5

Gravure

Basically, gravure turns everything in the image into halftone dots. The plate cylinder
consists of tiny cells, varying in depth and width, which hold the ink. As the press runs, a
blade scrapes excess ink off the surface of the plate, leaving ink only in cells. As the
paper contacts the plate, the ink is transferred, reproducing type, rules, graphics, and
14
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Pre-Feasibility Study

Printing Press

photographs as composites of very fine dots. Gravure is used only in very long runs,
usually for publications and packaging printing.
4.5.6

Screen-Printing

In screen-printing, ink is expressed through a stretched fabric mesh by a squeegee blade


to reproduce the original image onto the substrate below. A variety of materials such as
paper, plastic, metal, fabric and glass can be screen-printed.
4.5.7

Waterless Lithography

Print buyers are hearing more and more about waterless offset as the process becomes
more commonly used in the United States. Almost any offset printing press can be
converted to run waterless if it is retrofitted with a cooling system that, among other
things, helps maintain the ink's temperature. Newer presses are available with the
conventional dampening system and a cooling system so that they can run waterless.
Special plates must be used so that the non-image area still repels the ink.
4.5.8

Digital Printing

Unlike traditional (offset) printing presses, digital presses are made to produce short-run
(1 to 5000 copies) quick-turnaround, full color jobs.
In traditional printing, your job goes from your desktop to a digital proof, to an image
setter (for making film), to another proof, to a plate maker, to the printing press. But in
digital printing your job goes from your desktop to a proof to plates to the press - or even
directly from desktop to press.
Limitations of digital printing include limited paper size and quality of 4-color
reproduction. In addition, not every printer offers digital printing options.
5

HUMAN RESOURCE REQUIREMENT

The project is machine oriented but skilled labour is important for success of the
business. Skilled machine man is required to operate the machine efficiently and
effectively. Skill of machine man will result in lower wastage of paper and ink, lower
maintenance cost of machines and also longer life of machines. This will enhance quality
of product and timely delivery of order and hence, help in creating a good image among
customers.
In Lahore, there is an institution named Poly Technique Institute for Printing and Graphic
Arts affiliated with Punjab Board of Technical Education engaged solely in providing
education and training in the field of printing, which is producing qualified diploma
holders with sound theoretical as well as practical knowledge.

15
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Printing Press

Number of workers required for each department is given below:


Table 5-1

Human Resource Requirement Details

Description

Number

Production Section
Supervisor
Machine Man
Cutting Master
Helper
Total
Design Section
Graphic Designer
Composer
Total
Administration Section
Director
Accounts officers

Salary/month
(Rs.)

1
1
4

10,000
8,000
6,000
4,500

120,000
192,000
72,000
216,000
600,000

2
2

12,000
8,000

288,000
192,000
480,000

1
1
1
1

25,000
10,000
4,500
6,000

300,000
120,000
54,000
72,000
546,000
1,626,000

Peon
Security Guard
Total

Annual salary
(Rs)

MACHINERY &EQUIPMENT REQUIREMENT

6.1 Machinery & Equipment Requirement


The project is machine oriented and nature of jobs to be undertaken mostly depends upon
the availability of machinery. So, selection of machinery is the most important aspect of
this project.
Following is the detail of machinery required for this project.
Table 6-1

List of Machinery & Other Equipment

Description

Qty

Offset Printing Machine


(Rota Reconditioned)
Offset Printing Machine
(Solna 125, Sweden Reconditioned)
Cutting Machine (920mm)

Cost
per unit
400,000

1,000,00

100,000

Die Cutting Machine(660x930 mm)


Total

125,000
16

PREF-69/December, 2007/2

Total
Availability
Cost
400,000 Imported but
Locally available
1,000,000 Imported but
Locally available
100,000 Locally
manufactured
125,000 Same as above
1,625,000

Pre-Feasibility Study

Table 6-2

Printing Press

Other Equipment Details

Description
Pentium 4 Computers
Printer-colour (DeskJet HP)

Qty
4
1

Per Unit Cost


40,000
15,000

Total Amount (Rs)


160,000
15,000

Printer-mono Laser Jet (HP)


Scanner- flat bed (BEN Q)
UPS
Furniture
Fax Machine

1
1
4
1
1
2
12
7

7,000
7,500
6,000
100,000
10,000
25,000
550
1,500

7,000
7,500
24,000
100,000
10,000
50,000
6,600
10,500
390,600

Air Conditioner

Tube Lights
Fans
Total

Technical specifications of these machines are given in the following table:


Table 6-3
Machine
Rota

Solna 125

Technical Specifications of Machines


Max. sheet
size(mm)
345x454
483x640

Max.
Capacity(imp/hr)
6,000
8,000

Installation Area
(LxW) (mm)
1840x1030
1960x1304

Power
(KW)
1.15
3.70

Expected
Useful life
20
20

6.2 Alternative Machinery Options


Many substitutes in these sizes are available like Hamada and Printmaster GTO 52 for
(345x454mm) and Roland and Hamada Impulse for (483x640mm). Said machines are
suggested due to their durability and easy availability of spare parts in the market.
Moreover new machinery of said brands is also available in the market at comparatively
very low prices.
Details of new machinery for printing available with local dealers are given below:
Table 6-4

Alternative New Machines

Machinery

Qty

Offset Printing Machine (345x454mm)


(Hamada E-47, Japan )

Price
(C&F Karachi.)
3,000,000

Offset Printing Machine (508x660mm)

13,500,000

(Hamada Impulse-66, Japan)

17
PREF-69/December, 2007/2

Availability
Imported but Locally
available
Imported but Locally
available

Pre-Feasibility Study

Printing Press

6.3 Machinery Suppliers


In Pakistan some suppliers of machines are:
PAKISTAN MACHINERY AND EQUIPMENT CO. (PVT.) LTD.
303, Aamir Trade centre, 233-1/A, PECHS, Block II
Shahrah-e-Quaideen, Karachi
Phone# 92-21-4551798, 4522776
Fax# 92-21-4522786
E-mail: pme@super.net.pk
PAKISTAN PRINTING EQUIPMENT CO. (PVT.) LTD
C-11/3, Sidco Avenue Centre, 264 R.A.Lines, Stretchen Road, Karachi
Phone# 92-21-5656981, 5656982.
Fax #: 92-21-5653620
E-mail: ppe@ppecl.com
7

LAND & BUILDING

7.1 Total Land Requirement


For printing unit with installation of above said machines approximately 1,300 sq. ft. area
is required. The details of covered area requirement for the project is given in below
table:
Table 7-1

Covered Area Details

Description
Owners Office
Accounts & Admin. Office
Design Section
Printing Hall
Cutting Hall
Store
Total

Covered Area in (Sq. ft.)


120
120
120
600
150
150
1,260

7.2 Recommended Mode of Acquisition


It is recommended that this project should be started in a rented building, as this will
reduce the initial capital cost. The details of monthly rent assumed for the project is given
below and further it is assumed that six (6) months rent will be paid advanced:
Table 7-1

Rental Cost Details

Description
Approximate Rent

Monthly Rent (Rs)


Annual Rent (Rs)
30,000
360,000

18
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Printing Press

7.3 Suitable Location


Availability of skilled labor, raw material and proximity from the customers is important
for such a project. Karachi, Lahore and Faisalabad are comparatively better locations for
printing project because necessary technical and skilled manpower is easily available.
Secondly, good quality and sufficient quantity of raw material at competitive prices is
easily available in these areas and finally, these areas have large business clusters.
THREATS
8
Capital requirement for composite unit of printing press having all the facilities in house
is very high with comparatively low expectation of return. Thats why this industry is
fragmented and most of the units are small having little in house facilities, resulting in
over dependence on outsourcing. This may decrease the likelihood of timely completion
and delivery of order/job.
Paperless environment is becoming a serious threat to printing industry. Use of
networked computers for communication, promotion and data transmission is increasing
rapidly. Government is also promoting this culture. For example Securities and Exchange
Commission of Pakistan has made it mandatory for listed companies to maintain their
web sites. A proposal is also under consideration of the Commission to allow the listed
companies to place their quarterly accounts on their website instead of transmitting the
same to its shareholders by post11.

11

Circular no. 13 with reference no.EMD/D-II/7/2002 dated 26th May, 2003


19

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Printing Press

PROJECT ECONOMICS

Table 9-1

Project Cost/Capital Requirements

Project Costs
Machinery & Equipment
Office Equipment
Total Fixed Cost

1,625,000
390,600
2,015,600

Pre-Operating Costs12
Cash in Bank
Working Capital
Total Investment

180,000
800,336
180,000
3,175,936

Table 9-2

Financing Plan

Description
Equity
Debt
Total
Table 9-3

Ratio
50 %
50 %

Amount in (Rs)
1,587,968
1,587,968
3,175,936

Project Returns

Description
Internal Rate of Return
Net Present Value (NPV) (Rs)
Payback Period (Years)

Details
47%
11,131,000
3.91

12

These expenses are incurred before the unit is operational, e.g. salaries of key personal stationery,
company formation expenses, legal and registration charge, etc.
20

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Pre-Feasibility Study

10

Printing Press

FINANCIAL ANALYSIS

10.1 Projected Income Statement

SMEDA

Projected Income Statement


Year 1

Year 2

Year 3

Year 4

Year 5

Year 6

Year 7

Year 8

Year 9

Year 10

Revenue

16,018,702

21,024,565

26,490,948

32,451,413

38,941,698

40,888,783

42,933,222

45,079,883

47,333,877

49,700,571

COST OF GOOD SOLD


Raw Material Cost
Other Overhead (Ink)
Direct Labor
Direct Electricity
Carriage and Freight (Inward)
Repair & Maintenance

12,528,064
250,561
1,080,000
42,624
125,281
160,187

16,443,098
328,862
1,188,000
58,608
164,431
210,246

19,731,715
394,634
1,306,800
77,363
197,317
264,909

23,020,336
460,407
1,437,480
99,282
230,203
324,514

26,308,957
526,179
1,581,228
124,812
263,090
389,417

26,308,957
526,179
1,739,351
137,293
263,090
408,888

26,308,957
526,179
1,913,286
151,022
263,090
429,332

26,308,957
526,179
2,104,614
166,124
263,090
450,799

26,308,957
526,179
2,315,076
182,737
263,090
473,339

26,308,957
526,179
2,546,584
201,010
263,090
497,006

Total

14,186,716

18,393,244

21,972,738

25,572,222

29,193,682

29,383,757

29,591,866

29,819,763

30,069,377

30,342,825

1,831,985

2,631,321

4,518,210

6,879,191

9,748,016

11,505,026

13,341,356

15,260,120

17,264,500

19,357,746

546,000
360,000
80,094
67,392
48,056
25,000
201,560
18,000

600,600
396,000
105,123
74,131
63,074
27,500
181,404
18,000

660,660
435,600
132,455
81,544
79,473
30,250
163,264
18,000

726,726
479,160
162,257
89,699
97,354
33,275
146,937
18,000

799,399
527,076
194,708
98,669
116,825
36,603
132,244
18,000

879,338
579,784
204,444
108,535
122,666
40,263
119,019
18,000

967,272
637,762
214,666
119,389
128,800
44,289
107,117
18,000

1,064,000
701,538
225,399
131,328
135,240
48,718
96,406
18,000

1,170,399
771,692
236,669
144,461
142,002
53,590
86,765
18,000

1,287,439
848,861
248,503
158,907
149,102
58,949
78,088
18,000

Gross Profit
GENERAL ADMINISTRATION & SELLING EXPENSE
Administration Staff
Building Rent
Communication Expense (Telephone,fax, Postal etc.)
Fixed Electricity Expense
Entertainment Expense
Professional Fee (Legal, Audits, etc.)
Depreciation expense
Amortization of pre-operating costs
Total Operating Expenses

1,346,102

1,465,832

1,601,246

1,753,408

1,923,523

2,072,050

2,237,295

2,420,628

2,623,578

2,847,849

Earning Before Interest & Taxes

485,883

1,165,489

2,916,964

5,125,783

7,824,493

9,432,976

11,104,061

12,839,492

14,640,923

16,509,897

Interest expense on long term debt

211,200

166,737

122,274

77,810

33,347

Sub Total

211,200

166,737

122,274

77,810

33,347

Earning Before Taxes

274,684

998,752

2,794,691

5,047,973

7,791,146

9,432,976

11,104,061

12,839,492

14,640,923

16,509,897

13,734

174,782

698,673

1,261,993

1,947,786

2,358,244

2,776,015

3,209,873

3,660,231

4,127,474

260,950

823,971

2,096,018

3,785,979

5,843,359

7,074,732

8,328,046

9,629,619

10,980,692

12,382,423

260,950
260,950

260,950
1,084,920
1,084,920

1,084,920
3,180,938
3,180,938

3,180,938
6,966,918
6,966,918

6,966,918
12,810,277
12,810,277

12,810,277
19,885,009
19,885,009

19,885,009
28,213,055
28,213,055

28,213,055
37,842,674
37,842,674

37,842,674
48,823,366
48,823,366

48,823,366
61,205,788
61,205,788

Taxes
Net Profit After Taxes
Balance brought forward
Total profit available for appropriation
Balance carried forward

21
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Pre-Feasibility Study

Printing Press

10.2 Projected Balance Sheet

SMEDA

Project Balance Sheet


Const. Year

Year 1

Year 2

Year 3

Year 4

Year 5

Year 6

Year 7

Year 8

Year 9

Year 10

180,000

(17,687)
1,601,870
198,000

367,374
2,102,457
217,800

1,926,363
2,649,095
239,580

5,107,402
3,245,141
263,538

10,275,748
3,894,170
289,892

17,263,802
4,088,878
318,881

25,480,633
4,293,322
350,769

34,974,914
4,507,988
385,846

45,796,387
4,733,388
424,431

58,462,660
4,970,057
-

980,336

1,782,183

2,687,631

4,815,038

8,616,081

14,459,810

21,671,561

30,124,724

39,868,749

50,954,206

63,432,717

FIXED ASSETS
Machinery & Equipment
Office Equipment

1,625,000
390,600

1,462,500
351,540

1,316,250
316,386

1,184,625
284,747

1,066,163
256,273

959,546
230,645

863,592
207,581

777,232
186,823

699,509
168,140

629,558
151,326

566,602
136,194

Total Fixed Assets

2,015,600

1,814,040

1,632,636

1,469,372

1,322,435

1,190,192

1,071,172

964,055

867,650

780,885

702,796

INTANGIBLE ASSETS
Pre-Operational Costs

180,000

162,000

144,000

126,000

108,000

90,000

72,000

54,000

36,000

18,000

Total Intangible Assets

180,000

162,000

144,000

126,000

108,000

90,000

72,000

54,000

36,000

18,000

3,175,936

3,758,223

4,464,267

6,410,411

10,046,516

15,740,002

22,814,734

31,142,779

40,772,398

51,753,090

64,135,513

638,931

838,598

1,006,317

1,174,037

1,341,757

1,341,757

1,341,757

1,341,757

1,341,757

1,341,757

638,931

838,598

1,006,317

1,174,037

1,341,757

1,341,757

1,341,757

1,341,757

1,341,757

1,341,757

OTHER LIABILITIES
Long Term Debt

1,587,968

1,270,374

952,781

635,187

317,594

Total Long Term Liabilities

1,587,968

1,270,374

952,781

635,187

317,594

SHAREHOLDER'S EQUITY
Paid-up Capital
Retained Earnings

1,587,968

1,587,968
260,950

1,587,968
1,084,920

1,587,968
3,180,938

1,587,968
6,966,918

1,587,968
12,810,277

1,587,968
19,885,009

1,587,968
28,213,055

1,587,968
37,842,674

1,587,968
48,823,366

1,587,968
61,205,788

Total Equity

1,587,968

1,848,917

2,672,888

4,768,906

8,554,885

14,398,245

21,472,977

29,801,023

39,430,642

50,411,333

62,793,756

TOTAL CAPITAL & LIABILITIES

3,175,936
-

3,758,223
-

4,464,267
-

6,410,411
-

10,046,516
-

15,740,002
-

22,814,734
-

31,142,779
-

40,772,398
-

51,753,090
-

64,135,513
-

CURRENT ASSETS
Cash in Bank
Accounts Receivable
Pre-paid Building Rent
Total Current Asset

TOTAL ASSETS

800,336

CURRENT LIABILITIES
Accounts Payable
Total Current Liabilities

22
PREF-69/December, 2007/2

Pre-Feasibility Study

Printing Press

10.3 Projected Cash flow Statement


Projected Cash Flows

SMEDA
Year-0
Operating activities
Net profit
Add: depreciation expense
amortization of pre-operating costs
amortization of training costs
Accounts receivable
Finished goods inventory
Pre-paid building rent
Accounts payable
Cash provided by operations

Year 1
-

260,950
201,560
18,000

Year 2
823,971
181,404
18,000

Year 3

Year 4

Year 5

Year 6

Year 7

Year 8

2,096,018
163,264
18,000

3,785,979
146,937
18,000

5,843,359
132,244
18,000

7,074,732
119,019
18,000

8,328,046
107,117
18,000

9,629,619
96,406
18,000

Year 9

Year 10

10,980,692
86,765
18,000

12,382,423
78,088
18,000

(1,601,870)

(500,586)

(546,638)

(596,047)

(649,028)

(194,708)

(204,444)

(214,666)

(225,399)

(236,669)

(180,000)
-

(18,000)
638,931

(19,800)
199,667

(21,780)
167,719

(23,958)
167,720

(26,354)
167,720

(28,989)
-

(31,888)
-

(35,077)
-

(38,585)
-

424,431
-

(180,000)

(500,429)

702,655

(317,594)

(317,594)

(317,594)

(317,594)

(317,594)

(317,594)

(317,594)

(317,594)

(317,594)

(317,594)

1,876,583

3,498,632

5,485,940

6,988,054

8,216,831

9,494,281

10,821,473

12,666,272

Financing activities
Long Term Debt Repayment
Additions of New Long Term Debt
Issuance of shares

1,587,968
1,587,968

Cash provided by / (used for) financing activities

3,175,936

Investing activities
Capital expenditure
Minimum Cash Balance
Cash (used for) / provided by investing activities
NET CASH
Cash balance brought forward
Cash available for appropriation
Cash balance
Short term loan requirement
Cash carried forward

(2,195,600)
(2,195,600)

800,336

(818,023)

385,061

1,558,989

3,181,038

5,168,347

6,988,054

8,216,831

9,494,281

10,821,473

12,666,272

800,336

800,336
(17,687)

(17,687)
367,374

367,374
1,926,363

1,926,363
5,107,402

5,107,402
10,275,748

10,275,748
17,263,802

17,263,802
25,480,633

25,480,633
34,974,914

34,974,914
45,796,387

45,796,387
58,462,660

800,336

(17,687)

367,374

1,926,363

5,107,402

10,275,748

17,263,802

25,480,633

34,974,914

45,796,387

58,462,660

23
PREF-69/December, 2007/2

Pre-Feasibility Study

11

Printing Press

KEY ASSUMPTIONS

Table 11-1

Operating Assumptions

Hours operational per day


Days operational per month
Days operational per year
Table 11-2

8
25
300

Production Assumptions

Capacity of printing machines(Impression/Hour)


Capacity utilization (1st Year)
Capacity growth rate (yearly)
Maximum attainable capacity utilization
Table 11-3

14,000
40%
10%
80%

Economy Assumptions

Electricity growth rate


Wages growth rate
Building rent growth rate
Raw material price growth rate
Finished product price growth rate
Table 11-4

10%
10%
10%
5%
5%

Cash Flow Assumptions

Accounts Receivable cycle (in days)


Accounts Payable cycle (in days)
Cash at the start of Operations (Rs)
Table 11-5

30
15
800,336

Product Mix Assumptions

Solna 125 Machine


Financial reports
Brochures
Books
Pamphlets
Letterheads
Rota Machine
Vouchers
Visiting cards
Packaging material
Invitation cards

Production
percentage
25%
15%
50%
5%
5%

Impressions/
Unit
103
12
135
2
0.5

Production/Units
Year 1 @ 40%
18,640
93,203
28,520
188,235
752,940

40%
5%
35%
20%

0.5
0.5
4.1
3

4,539,901
556,521
496,551
378,324

24
PREF-69/December, 2007/2

Pre-Feasibility Study

Table 11-6

Printing Press

Order Size Assumptions

Product Mix
Financial reports
Brochures
Books
Pamphlets
Letterheads
Vouchers
Visiting cards
Packaging material
Invitation cards
Table 11-7

Order Size
5,000 units
5,000 units
10,000 units
5,000 units
5,000 units
15,000 units
1,000 units
10,000 units
500 units

Sale Price Assumptions

Product Mix
Financial reports
Brochures
Books
Pamphlets
Letterheads
Vouchers
Visiting cards
Packaging material
Invitation cards
Table 11-8

Price Per Unit (Rs)


100.00
13.00
72.00
2.50
1.00
0.30
0.75
1.10
15.00

Expense Assumptions

Direct overhead (Ink)


Carriage and freight (Inward)
Machine maintenance cost
Pre-paid building rent (months)
Communication expense (Telephone, fax, Postal etc.)
Entertainment expense
Legal & professional fee (1st Year)
Growth rate in legal charges
Tax Rate
Table 11-9

2 % of Raw Material Cost


1% of Raw Material Cost
1% of Revenue
6
0.5% of Revenue
0.3% of Revenue
25,000
10%
Sole proprietorship tax slabs

Depreciation Assumptions

Machinery
Other Equipment

10%
10%

25
PREF-69/December, 2007/2

Reducing Balance Method


Reducing Balance Method

Pre-Feasibility Study

Printing Press

Table 11-10 Financial Assumptions


Project life (Years)
Equity
Debt
Interest rate on Long term Debt
Debt repayments (Installment per year)
Debt Tenure (Year)
Discount rate for calculation of NPV (WACC)

10
50%
50%
14%
2
5
18.5%

Table 11-11 Material Cost Details of Financial Report


Description
Plates
Image setting
Plate developing
Paper
Lamination/Garnishing
Binding cost
Packing cost
Total Cost Per Financial Report

Cost Per Unit


3.33
25.83
1.04
43.03
1.15
5.00
0.08
79.46

Table 11-12 Material Cost Details of B rochure


Description
Plates
Image setting
Plate developing
Paper
Lamination/Garnishing
Binding cost
Packing cost
Total Cost Per Brochure

Cost Per Unit


0.51
3.97
0.16
6.17
0.20
0.25
0.04
11.30

26
PREF-69/December, 2007/2

Pre-Feasibility Study

Printing Press

Table 11-13 Material Cost Details of Book


Description
Plates
Image setting
Plate developing
Paper
Lamination/Garnishing
Binding cost
Packing cost
Total Cost Per Brochure

Cost Per Unit


1.11
8.68
0.35
41.25
0.10
10.00
0.04
61.53

Table 11-14 Material Cost Details of Pamphlet


Description
Plates
Image setting
Plate developing
Paper
Packing cost
Total Cost Per Pamphlet

Cost Per Unit


0.26
1.99
0.08
0.71
0.004
3.04

Table 11-15 Material Cost Details of Letterhead


Description
Plates
Image setting
Plate developing
Paper
Packing cost
Total Cost Per Letter

Cost Per Unit


0.06
0.50
0.02
0.61
0.004
1.19

Table 11-16 Material Cost Details of Voucher


Description
Plates
Image setting
Plate developing
Paper
Binding cost
Packing cost
Total Cost Per Voucher

Cost Per Unit


0.002
0.003
0.002
0.590
0.02
0.004
0.62

27
PREF-69/December, 2007/2

Pre-Feasibility Study

Printing Press

Table 11-17 Material Cost Details of Visiting Cards


Description
Plates
Image setting
Plate developing
Paper
Packing cost
Total Cost Per Visiting Cards

Cost Per Unit


0.07
0.23
0.05
0.15
0.02
0.52

Table 11-18 Material Cost Details of Packaging Material


Description
Plates
Image setting
Plate developing
Paper
Binding cost
Cutting Dye
Packing cost
Total Cost Per Packaging Material

Cost Per Unit


0.01
0.02
0.01
0.59
0.05
0.17
0.02
0.87

Table 11-19 Material Cost Details of Invitation Card


Description
Plates
Image setting
Plate developing
Paper
Packing cost
Total Cost Per Invitation Card

Cost Per Unit (Rs)


0.21
0.30
0.15
7.76
0.02
8.44

28
PREF-69/December, 2007/2

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