MAKING BANANA FABRIC POLYMER
Introduction
A cost- effective substitute for glass fibre, banana fibre polymer composite can be a very good fibre-reinforced plastic to make a variety of products. Products such as trays, mirror-casings, voltage stabilizer covers and electrical panels are now made from this material. The envisaged project is therefore to set up a plant for making banana fabric polymer. The project cost is US$ 56,972 with a capacity of 10,000kg per annum yielding estimated revenue of US$ 61,998 per year.
Production Process, capacity and
technology
The process starts with preparing moulds of metal, wood or plaster of Paris, followed by mixing of resin with dye in requisite proportion, shaping the banana fabric by placing it on the mould and reinforcing the polymer over banana fabric. Later these are cured, de-moulded and cut. Finally these are trimmed and polished for market. The proposed plant would have a minimum capacity of 10 tonnes per annum on the basis of 312 working days.
Market Analysis
The cost effective nature of this product has made it a perfect substitute for glass fibre. Today, the demand for banana fabric polymer is gaining ground as a variety of products can be made from this, with a potential market growth. Therefore most of the manufacturing industries should be targeted so as to tap forward and backward linkages as the fibre is normally used in the manufacture of other products. In Uganda, this Industry is not yet established.
Capital Investment Requirement in US $
|
Item |
Units |
Qty |
Price |
Total |
|
Moulds |
No |
5 |
500 |
2,500 |
|
Weighing balance |
No |
2 |
25 |
50 |
|
Other tools & equipment |
No |
1 |
750 |
750 |
|
Mixing Machine |
No |
1 |
500 |
500 |
|
Total cost of Machinery & Tools |
3,800 |
Production and Operation costs in US $
Direct materials, supplies and costs
|
Cost Item |
Unit |
Unit |
Qty |
Prod |
Prod |
Prod |
|
|
Direct Costs |
|
|
|
|
|
|
|
|
Banana Fibre |
kgs |
2 |
32.5 |
64.10 |
1,666.7 |
20,000 |
|
|
Cotton fabric |
mtrs |
3 |
16.03 |
48.08 |
1,250.0 |
15,000 |
|
|
Polyester resin |
mtrs |
1.5 |
9.62 |
14.42 |
375.0 |
4,500 |
|
|
Catalyst, dyes, |
Ltrs |
6 |
0.22 |
1.3 |
35 |
420 |
|
|
Mould release |
Ltrs |
1.5 |
1.50 |
2.3 |
59 |
702 |
|
|
Packaging |
packets |
2 |
6.41 |
12.8 |
333 |
4,000 |
|
|
Sub-total |
143 |
3,718.5 |
44,622 |
||||
|
General Costs (Overheads) |
|||||||
|
Labour |
300 |
3,600 |
|||||
|
Selling & distribution |
100 |
1,200 |
|||||
|
Utilities (Water, power) |
200 |
2,400 |
|||||
|
Administration |
100 |
1,200 |
|||||
|
Rent |
150 |
1,800 |
|||||
|
Miscellaneous expenses |
100 |
1,200 |
|||||
|
Depreciation |
79 |
950 |
|||||
|
Sub-total |
1,029 |
12,350 |
|||||
|
Total Operating Costs |
4,747.5 |
56,972 |
|||||
1. Production costs assume 312 days per year with daily capacity of 32.1 Kgs.
2. Depreciation (fixed asset write off) assumes 4 year life of assets written off at 25% per year for all assets.
3. Direct costs include: materials, supplies and all other costs incurred to produce the product.
4. A production month is 26 work days
5. Currency used is US Dollars.
Project product costs and Price structure in US $
|
Item |
Qty |
Qty |
Unit |
Prod |
Unit |
Total |
|
Banana |
32.1 |
10,000 |
5.70 |
56,972 |
6.20 |
61,998 |
Profitability Analysis in US$
|
Item |
Per |
Per |
Per year |
|
Revenue |
199 |
5,166 |
61,998 |
|
Less: Production and operating costs |
183 |
4,748 |
56,972 |
|
Profit |
16 |
419 |
5,026 |