CK Fellers Potato Crisps Business Plan
CK Fellers Potato Crisps Business Plan
Business Plan
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1 EXECUTIVE SUMMARY................................................................................................................. 4
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13 KEY ASSUMPTIONS ...................................................................................................................... 25
13.1 MACHINERY ASSUMPTIONS ....................................................................................................... 25
13.2 OPERATING ASSUMPTIONS ......................................................................................................... 25
13.3 ECONOMY RELATED ASSUMPTIONS ........................................................................................... 25
13.4 CASH FLOW ASSUMPTIONS ........................................................................................................ 25
13.5 REVENUE ASSUMPTIONS ............................................................................................................ 26
13.6 RAW MATERIAL ASSUMPTIONS .................................................................................................. 26
13.7 FINANCIAL ASSUMPTIONS .......................................................................................................... 26
13.8 EXPENSE ASSUMPTIONS ............................................................................................................. 27
14 ANNEXURES ...................................................................................................................... ................ 28
14.1 MAJOR MACHINERY SUPPLIERS ................................................................................................. 28
14.2 MAJOR COLD STORAGE FACILITY IN NTCHHEU AND SURROUNDING AREAS ............................... 28
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1 EXECUTIVE SUMMARY
In this Project, CK Fellers intends to set up a Potato Crisps Production Facility in
Lilongwe the capital city of Malawi. We intend to produce premium quality potato crisps
aimed at the local market, where there are a few competing products. The business
intends to use modern semi-automatic machinery for its processes, ensuring that quality
checks throughout the production process are being conducted. The finished product will
be packaged in metallized film packets.
The opportunities for production of snacks in Malawi was nonexistent up until the late-
eighties and early nineties. Subsequently, the investment in this sector has been
reasonable. During this time, the Malawi snacks market was characterized by biscuits,
candies and corn-based products. Potato crisps later appeared on the snacks market and
took up a major share. Over the last few years the demand for potato crisps has seen a
considerable rise, triggering a gap between demand and supply. This gap opens a chance
to set up a business to produce good quality crisps at ideal production level. Most of the
snack business units are set-up in Lilongwe and Blantyre.
The total project cost for setting up the plant is estimated at US$10,000.00 and will be
financed through 100% o w n e r s ’ equity. The legal status of this venture is proposed
as a Sole Proprietorship.
The planned production capacity of the plant is 50 kg potato crisps per hour. The plant
will work in shifts and operate at 90% capacity in the potato season and 75% off season
all achievable in within six months of operation. The maximum capacity expected is 95%
and the plant should operate at this capacity by the second year.
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2 INTRODUCTION TO CK FELLERS
CK FELLERS was created to provide fresh motivation to medium and smallholder farmers
and the economy through the launch of an aggressive SME businesses and consulting
programs.
Upon its inception CK Fellers espoused a sectorial Small and Medium Enterprise
development approach. Limited significant segments of the economy were selected on the
principle of SME presence which included smallholder agriculture and production. A
comprehensive research was conducted, and all-inclusive progress strategies were framed
after identification of weaknesses and retardants. The sectorial development strategy
involved recommending changes in the regulatory environment by taking into account
other important aspects including finance, promotion, technology and human resource
development.
CK Fellers will formulate its sectorial focus on a wide range of business development
ideas including identification of feasible business openings for potential SME investment.
This business plan consists of data required to make well-researched venture decisions.
Practicability assessments and development of business plans are some of the services
being carried out to enhance the capacity of individual SMEs to exploit workable business
opportunities in an improved way.
This document is an internal white paper in the persistence of the effort to enable CK
Fellers make educated investment decisions.
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WEAKNESSES
• There will be a need for firm m oni t ori ng t o enhance em pl o ye e prod uc t i vi t y by
reducing wastage.
• Losses will be experienced at the beginning of production
• Increased market costs to promote the product increasing operating costs
• Low initial sales returns
• Inexperienced technical staff which will need a longer learning curve and increased
training costs.
OPPORTUNITIES
• Changes in the recent consumption habits of the people has seen a rise in buying of
snacks
• About 90% of the Potato Crisps Market share comprises of non-Malawian brands
that are produced outside of Malawi. The company intends to take advantage of
the buy Malawi initiative currently being promoted by the government
• The lure of products which are identified with western lifestyles and tastes and the
general trend towards more snacking among youngsters
• Many people that have no specific preference regarding potato crisps brands can be
targeted through marketing campaigns.
• Export opportunities will be available as production stabilizes
THREATS
• Established Multinational corporations that are already in the business of Potato
Crisps production.
• Unstable Malawi economy which has seen fluctuations in Irish potato prices
• Lack of proper storage facilities resulting in wastage of potato production of potatoes.
• Quality of the Potato Crisps is to be monitored very closely as people are more
directed towards health and safety issues.
• Strong competition and high promotional activity by competitors who are already
established
• Monopolies that will be played by the established companies might try keep the new
merchandise out of market.
4. PROJECT PROPOSAL
4.1 Prospect Motivation
With the beginning of globalization, African consumption behaviors are changing to rival
those of the West. In the recent years, eating of foods with a western influence is on the
rise. Due to this, the latent market size of potato products is also increasing at an
exponential rate.
Recently, biscuits, corn-based and other snacks constituted the Malawi snacks market. The
business of a local manufacturer of premium quality and internationally recognized potato
crisps did not appear on the Malawi snacks scenario. There are a very few local potato
crisps manufacturers on the market that the customers are aware of and 3 international
player Lays (South Africa) Crackles (Kenya) and Amigo (Zambia). The potato crisps
market is therefore still in the growing stage and new players can enter the market. An
original high-quality product can seize substantial market share in the current rising
market, contingent on their marketing approach and product superiority.
5.2 Project Transitory
CK Fellers plans on setting up a Potato Crisps Production facility in Lilongwe, Malawi.
The unit is expected produce different varieties of finest quality potato crisps in different
flavors, initially in one standard packet size of 20gms, later as business progresses, 50 and
120 grams.
5.3 Proposed Business Legal Status
The legal status of the planned business is sole proprietorship, with a provision to register
under the Companies Ordinance once business has developed.
5.4 Project Capacity and Rationale
Determining the project capacity is another critical factor. After systematic research, the
manufacturing capacity of the plant was decided to be 30 - 50 kg per plant hour of finished
potato crisps. There is huge demand of Potato Crisps (Snacks) in and outside Malawi. A
considerable production size is therefore required. The unit will be working in two 8-hour
shift/day
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5.5 Venture Investment
Initial Cost of the Venture has been worked out as follows:
Table 5-1: Project Cost
USD MWK (1:750)
Principal Investment Required 10,000.00 7,500,000.00
Startup &Working Capital 5000.00 3,250,000.00
Total Requirement 15,000.00 10,750,000.00
This proposal assumes that owners have 100% equity. The composition of debt and equity
will be adjusted on a need basis.
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6 MARKET INFORMATION ABOUT POTATOES
Malawi is one of the big potato growing countries in Sub Sahara Africa, ranked second
from South Africa. There is, however, very inadequate storage and production facilities
which leads to a substantial quantity of production to be wasted. The combination of lack
of storage facilities and an undeveloped processing industry leads to price instability,
because of the inability to store and/or process surplus for consumption during off-season.
The following analysis attempts demonstrate the current state of the potato growing in
Malawi.
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6.2 Potato Wholesa
ale Price Trends
Due to inadequate storage facilities, there is a substantial supply of potatoes during the
harvesting period, leading to reduction of prices. If storage services are available, price
volatility can be moderated through constant supply all year around.
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Additional advantage to the investor is that in Malawi, the life style is improving with the
coming of suburbanization. Similarly, due to satellite invasion and effect of foreign
media, the demand for snacks is certain to register a substantial improvement.
There is also a possible market for the Snacks in the neighboring nations which can be
explored. Forecasting for the ensuing decade, export prospects are very optimistic
considering the continued and continuous expansion of the Fast Food Industry overseas.
Additionally, Tariff cuts under Trade Agreements are projected and can be used as a
platform to export.
8.1 Demand and Supply
According to the industry conclusions, the Market Subdivisions with respect to age is as
follows:
Table 8-1: Market Segmentation
Age Group (Years) Percentage Share
5 – 12 30 %
13 – 19 35 %
20 – 35 20 %
Above 35 15 %
Based on statistics acquired through market surveys conducted, the demand in the present
market is met by the combination of patented and unbranded crisps that are readily
available on the market. Around 70% of the population has brand loyalty and the
remaining 30% of the un-branded market can be attracted through heavy advertisement
campaigns.
Table 8-2: Segmentation - Snacks Industry
Segments Share %
Branded 70
Unbranded 30
Total 100
Currently, Lays is the market leader with nearly twice the share of its closest competitor,
Amigo. Decent possibilities exist for a new product to compete and lure a market share
provided the product has:
• Good quality internationally accepted product
• Exclusive packaging that can attract consumers visually
• Customer oriented flavors at affordable prices
Additionally, there’s also a need for the company to have:
• Wide distribution networks
• Industry knowledge
• Financial standing (capacity)
• Proper feedback mechanisms (reverse logistics)
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The share of current market Competitors is given below:
The process flow of Potato Crisps production requires the following machinery:
The machine has a soft brush which helps in removing the thin peel
completely and efficiently.
2. Slicing/Cutting
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3. Blanching machine
4. Dewatering machine
5. Frying machine
The potato slices are then placed in this machine for deep
frying into crisps.
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6. De-oiling machine
7. Flavoring machine
Potato crisps can be added with various flavors for taste. The
machine is drum type flavoring.
8. Packing Machine
The potato crisps are packaged quickly before going bad. They
are sealed in bags full of nitrogen so that they should not react
with oxygen.
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9.5 Proposed Product Mix
CK Fellers will be making branded potato crisps in different f l a v o r s a n d packet sizes.
Half of the product will be flavored with salt, a n d the other half will have other
assorted flavors. The product blend according to packet size is given in the table below.
Table 9-1: Product Mix
Packet Size Production Mix Factory selling price
(MWK)
20 grams 50 100.00
50 grams %
30 250.00
120 grams %
20 600.00
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9.7 Other asset requirements
The following supplementary immovable assets are required for the factory and
management offices.
TOTAL 2,270,000.00
Table 10-2: U t i l i t y r e q u i r e m e n t s / m o n t h
Electricity 2000kwh
water 250L
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Business Plan Potato Crisp Manufacturing Unit
12 FINANCIAL ANALYSIS
12.1 Project Detail
Initial Investment
Capital Investment Rest. in
actuals
Land 5,000,000.00
Buildings and Infrastructure 8,525,000.00
Machinery & equipment 18,753,930.00
Furniture, fixtures & fittings 1,266,000.00
Office vehicles 765,000.00
Office equipment 650,500.00
Pre-operating costs 1,866,000.00
Legal costs 50,000.00
Total Capital Costs 36,876,430.00
Working Capital Rest. in
actuals
Replacement parts inventory 187,539.00
Raw materials 18,763,321.00
Storage facility rent 5,616,000.00
Transportation 108,000.00
Insurance 975,946.00
Cash on hand 1,000,000.00
Total Working Capital 26,650,807.00
Total Investment 63,527,236.00
Initial Financing Rest. in
actuals
Debt 50% 31,768,618.00
Equity 50% 31,768,618.00
Project Returns
EQUITY PROJECT
Net Present Value 175,711,106.00 211,063,976.00
Internal Rate of Return 65% 45%
Payback Period (Yrs.) 3.55 4.18
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Financing activities
Project Loan - principal repayment (2,681,816) (3,110,907) (3,608,652) (4,248,985) (4,928,823) (84,704) (98,257) (113,978) - -
Working Capital Loan - principal repayment (13,325,403) - - - - - - - - -
Short term debt principal repayment - (25,023,586) (14,314,906) - - - - - - -
Additions to Project Loan 18,443,215 - - 432,908 - - - - - - -
Additions to Working Capital Loan 13,325,403 - - - - - - - - - -
Issuance of shares 31,768,618 - - 432,908 - - - - - - -
Cash provided by / (used for) financing activities 63,537,236 (16,007,220) (28,134,493) (17,057,742) (4,248,985) (4,928,823) (84,704) (98,257) (113,978) - -
Investing activities
Capital expenditure (36,886,430) - - (865,816) - (1,232,040) (1,152,400) - - (1,533,845) -
Cash (used for) / provided by investing activities (36,886,430) - - (865,816) - (1,232,040) (1,152,400) - - (1,533,845) -
NET CASH 1,000,000 (26,023,586) (14,314,906) 8,422,170 43,158,202 72,064,068 110,664,484 142,065,267 176,657,297 214,856,901 346,302,073
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Shareholders' equity
Paid-up capital 31,768,618 31,768,618 31,768,618 32,201,526 32,201,526 32,201,526 32,201,526 32,201,526 32,201,526 32,201,526 32,201,526
Retained earnings 2,293,494 19,785,805 55,121,814 112,885,841 200,257,907 319,613,871 468,396,893 651,430,499 874,845,021 1,147,560,240
Total Equity 31,768,618 34,062,112 51,554,423 87,323,340 145,087,367 232,459,433 351,815,397 500,598,419 683,632,025 907,046,547 1,179,761,766
TOTAL CAPITAL AND LIABILITIES 63,537,236 86,144,846 94,021,307 115,143,144 171,737,201 257,355,593 378,304,906 527,651,399 711,289,283 935,481,417 1,205,248,413
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POTATO CRISPS PLANT INSTALLED CAPACITY - AT ACTUAL UTILIZATION 50% 50% 50% 50% 50% 50% 50% 50% 50% 50%
Expected Annual Growth Rate 10% 10% 10% 10% 10% 10% 10% 10% 10%
Capacity Utilization Rate 50.00% 60.00% 70.00% 80.00% 90.00% 95.00% 95.00% 95.00% 95.00% 95.00%
Utilized Production Line Capacity in Kgs per Plant Hour 75 90 105 120 135 143 143 143 143 143
Expected per day Production in Kgs 1,200 1,440 1,680 1,920 2,160 2,280 2,280 2,280 2,280 2,280
ANNUAL POTATO CRISPS PLANT PRODUCTION CAPACITY - AT ACTUAL UTILIZATION BASED ON 300 WORKING DAYS
Finished Production in kgs
Potato Crisps 360,000 432,000 504,000 576,000 648,000 684,000 684,000 684,000 684,000 684,000
Waste Production in kgs
Burnt Crisps 792,000 950,400 1,108,800 1,267,200 1,425,600 1,504,800 1,504,800 1,504,800 1,504,800 1,504,800
Chura Crisps 288,000 345,600 403,200 460,800 518,400 547,200 547,200 547,200 547,200 547,200
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13 KEY ASSUMPTIONS
13.1 Machinery Assumptions
Processing plant capacity (Kg/hr) 150
Potato crisps production (% of potatoes) 55%
Burnt and under-fried crisps (% of potatoes) 25%
Chura Crisps (% of potatoes) 20%
First Year Production ( Increasing @ 7.5% each successive Year) 50%
Machine maintenance expense (% of machine cost) 2%
Machine maintenance growth rate 5%
Equipment spare part inventory (% machinery cost) 1%
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Business Plan Potato Crisp Manufacturing Unit
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Business Plan Potato Crisp Manufacturing Unit
14 ANNEXURES
Following is the list of major Potato Crisps Machinery suppliers and Cold Storage
rental facilities.
14.1 Major Machinery Suppliers
No. Suppliers Web Address
1 Alisha Machines (Private) Limited www.alishamachines.com
2 Campbell Wrapper Machinery www.campbellwrapper.com
3 Xuzhi Equipment Co. Limited www.lucy.168.com
4 Seoju Engineering Co. Ltd. www.ec21.net/foodmachinery.com
5 Mundra Engineering works www.mundraengineering.com
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Business Plan Potato Crisp Manufacturing Unit
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Business Plan Potato Crisp Manufacturing Unit
REFERENCES:
East African Standards Journal, 2010, Poptato Crisps Specifications, 1 st Edition, EAS745:2010
Kateta S.V., Kabambe V, Lowole M.W, Nalivata P.C, 2015, African Journal of Agricultural Research Volume
10: Production Practices of Potato by Farmers in Mzimba Districts, PP797-802, Article 6A8839B50629
Sangster A and Wood F, 2018, Frank Wood’s Business Accounting Volume 1, 14 th Edition, Pearson uk
Shelton H, 2017, The secrets to writing a successful business plan, 2 nd Edition, Summit Valley Press
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