Change in MSME definition: Does it help the sector?

The union cabinet recently approved a change in the definition (see Table 1) of Micro, Small and Medium enterprises (MSME), to base it on their turnover as against investment in fixed assets. The Micro, Small and Medium Enterprises Development Act, 2006 will be amended accordingly to reflect the new definition. A change in definition of MSME assumes significance as it is used to provide a number of incentives such as capital, interest and technology/market promotion subsidy by the central and state governments.

Table 1: MSME definition
EnterpriseEarlier definitionNew definition
MicroManufacturing enterprises: Investment in plant and machinery< INR 25 lakhs
Service enterprises: Investment in equipment/machinery<INR 10 lakh
Annual Turnover< INR 5 crore
SmallManufacturing enterprises:Investment in plant and machinery between INR 25 lakhs and INR 5 crore
Service enterprises:Investment in equipment between INR10 lakhs and INR 2 crore
Annual turnover between INR 5 crore and INR75 crore
MediumManufacturing enterprise: investment in plant and machinery between INR 5 crores and 10 crore
Service enterprises: investment in equipment between INR  2 crores and 5 crores
Annual Turnover between INR 75 croreand 250 crore
Note: Turnover of enterprises is likely to be calculated based on GST returns

The new classification may result in many medium enterprises being classified as small enterprises (or small getting classified as micro) based on their turnover. Such reclassification would be positive for enterprises in sectors such as engineering, machine fabrication, apparel, construction contractors etc, where a large number of MSMEs are vendors to public sector enterprises (PSUs). These PSUs reserve 20 per cent of their procurement requirements for micro and small enterprises.

Further, a turnover based definition coupled with incentives for filing GST will encourage MSMEs to file taxes and transact through bank accounts, resulting in improved information availability on the sector for the policy makers. The GST filings of 2017-18, already show an increase of almost 50 per cent in the number of unique indirect tax payers.

The most significant impact though would be on state governments who would now have to revise their industrial policies that currently offer incentives to new enterprises based on their investment in plant and machinery. These policies could broadly be divided into two categories:

  • Capital investment subsidies (subsidies on machinery, building); and
  • Interest related subsidies where loans given to micro and small enterprises attract lower interest rates.

For example Government of Telangana offers Interest subsidy under Pavala vaddi on the term loan taken for fixed asset by new micro and small enterprises. The amount of loan is currently governed by the investment guidelines as defined by the MSME Development Act, 2006. This scheme may have to beredesigned to reflect the new MSME definition. Similarly, central government schemes such as PMEGP (Prime Minister Employment Generation Programme) that provide subsidy to micro and small enterprises will also have to be revised accordingly.

As such, the change to a more transparent mechanism based on turnover is a welcome step as it would make it easier for MSMEs to grow and transition from micro to small and medium enterprises. Further, unlike earlier definition which incentivised enterprises to remain small (as the incentive decreased with the increase in fixed assets), the new definition would likelystimulate investment in the sector.

Share This:

Green products: How to set up Compostable Plastic bags business?

Compostable plastic bags are plastic bags that decompose into natural components such as carbon, water and biomass upon their contact with soil. As per DS6400, the most widely recognised international standard for compostable plastics, such plastics should completely disintegrate into natural components within 180 days in composting environment.

India generates huge amount of plastic waste (nearly 15,000 tonnes per day). It is estimated that only around 60 per cent of this waste is recycled and remaining gets dumped in the landfills and other places. Prominent among non-recyclable plastics are poly bags made from Polyethylene (PE), which can take up to 100 years to disintegrate.

Plastic bags have been completely banned in Maharashtra[1] (except for milk packets and some specific applications). Further, 17 States and Union Territories in the country have imposed partial ban on these bags with restriction on the thickness of the bags to minimum 50 microns. Increasing awareness about environmentally sustainable products along with restrictions on the usage of plastic bags have improved the prospects of compostable bags.

What are compostable Plastics?

Compostable plastics can be made out of bio based or petroleum based compounds (Resins) as shown below.

Figure1: Types of compostable plastics

Currently, the market for compostable resins is small, at around 1 million tonnes[2] (less than 0.5% of world’s annual plastic consumption of 320 million tonnes). These resins are patented by large multinationals such as BASF, NOVAMONT and have to be purchased from them or their dealers, thus resulting in higher price and limited availability. However, their consumption is predicted to grow at a CAGR of 20% over the next five years[3], and with the rise in demand, the availability of such plastics is likely to increase and their prices would become competitive.

How do compostable bags compare with conventional bags?

Compostable resins’ tensile strength, printability and weight bearing capacities are similar to that of conventional polymers such as Polyethylene (PE). In fact, in some specific applications, compostable resin may offer higher density and tensile strength as compared to  PE, thus resulting in requirement of less tonnage of the resin vis-à-vis PE.

However, currently, the compostable plastic resin is 2-3 times costlier than the conventional resins. Further, the costs of processing these resins into products such as bags are also higher due to smaller size of the processing capacities. As a result, these bags are 3 times as costly as conventional bags. For example, a medium size compostable garbage bags is currently priced at Rs. 220 (for a pack of 30 bags) as compared to a price of Rs. 70-80 for similar conventional bags.

What are the international and domestic standards for compostable Plastics?

There are a number of standards for compostable plastics including ASM D6400 (USA) and EN 13432 (Europe) and ISO 17088.

An Indian manufacturer of compostable plastic bags has to obtain a certification from Central Pollution Control Board (CPCB) for selling compostable bags and related products. The certification process requires the product to be tested in a government authorised lab to check its compliance to ISO 17088.

Table 1. International Standards for compostable bags
S.NoStandardization BodyStandard
1ASTM – American Society for Testing and MaterialsASTM D6400
2European StandardsEN 13432, EN 14995
3ISO – International Organization for StandardizationISO 17088

Is manufacturing compostable bags complex?

No, the manufacturing is very simple and is a two-step process; first the resin is processed into a film through a blown film manufacturing machine, the film is then cut, printed and sliced as per the bag sizes. Currently most Indian manufacturers use conventional LDPE blown film machinery for sheet extrusion. The resin is either directly imported from the manufacturers (list of bioplastic resin manufacturers is available in Table.2), or their dealers.

Table 2. Bio Resin manufacturers
S.NoCompanyCountry
1BASFGermany
2Bio-FedGermany
3CarbioliceFrance
4FKuR KunststofGermany
5NatureWorksNetherland
6NovamontItaly

Is there a market for compostable bags?

The demand for compostable bags is rising driven by growing concern about the environment and changing regulatory landscape. The waste management regulations in India are getting more stringent about handling and disposal of all types of waste including plastic. Therefore, specific segment of the market such as trash bags, bags for nurseries are witnessing a lot of interest from supermarkets, retail chains etc.

Given the demand, a number of new manufacturers have entered the market in past two years. The number of CBCB registered manufacturers of compostable bags has increased to 12 from just 2/3 a couple of years back ( a list of CPCB approved vendors is available here ).

The usage of other biodegradable/environmentally sustainable products is also increasing. Recently McDonald’s India has proposed to replace its plastic cutlery with a combination of wooden and biodegradable plastic cutlery ( available in this link: McDonald’s India kicks out plastics )

How much capital is required and what will be the profitability?

The capital requirements would depend on the machinery and the scale of operations. For example, a blown film machine of a capacity of 15-20 tonnes a month available for around Rs. 30 lakhs. However a European machinery (smallest capacity of 400 kg per hour) specifically made to handle bioplastics can cost more than Rs. 3 crores.

The minimum capital requirement including working capital is likely to be over Rs. 60 lakhs. The overall profitability and return on investment would be contingent on the manufacturer’s ability to secure regular orders and keep processing costs under control.

What are the key challenges?

  • Most states do not have a policy on regulation of usage of compostable plastic bags currently. The guidelines on allowing such bags in retail market would be critical for the growth of the industry.
  • The processing machinery is designed for conventional plastic, which can withstand higher temperature as compared to compostable plastics. Therefore getting the right product requires a number of trials.
  • The certification process for compostable bags is time consuming and can take up to 6-8 months.

[1] As per the circular, dated 10th July 2018 of Maharashtra Environment department, the compostable plastic bags are allowed for horticulture, agriculture, and handling of solid waste.
[2] Source: Global production of bioplastics, a publication by European bioplastics
[3] Source: European-bioplastics.org

How can we help?

We can help you start a compostable plastic bags manufacturing unit through a number of services including viability assessment, market landscaping and technical consultation

Reach us @

Write to us: bchhatre@finetrain.com , admin@finetrain.com
Call us: 800 888 4932

Share This:

Business Opportunity in Turmeric Processing

Business Opportunity in Turmeric Processing

Turmeric (botanical name-Curcuma Longa), one of the most important spice crops in India, is used to colour and flavour the food products.The yellow pigmented fraction of Turmeric (Curcumin,)is used as a colourant in food products and also as an anti-inflammatory agent in medicinal formulations.

India is the largest Turmeric producer in the world, with an annual production of nearly 10 lakh tonnes, accounting for nearly 80 per cent of world’s production. In India, Telangana is one of the largest producers of Turmeric, followed by Andhra Pradesh, Tamilnadu and Maharashtra (see picture 1).

In FY 17, India produced 10.51 Lakh tonnes[1] of Turmeric, of which nearly 1.1 lakh tonnes valued at Rs. 1200 crores was exported. Additionally, India exported Turmeric based oleo resins and Turmeric oil, valued at around Rs. 400 crores.

 

 

Turmeric processing technology

Turmeric can be processed into two products Turmeric powder and Turmeric extracts including oleo resins and Turmeric oils.Turmeric oleo resins/oils are extracted through solvent extraction of turmeric powder. The solvent extraction plant can process a variety of spices including Capsicum, Pepper, Amla, Marigold etc. A plant of a capacity of 500 kg per day requires land of 20,000 square ft. and power load of 60 HP.

Since the extracts (oleo resins) are used in food preparation/pharmaceuticals and largely cater to exports, the oleo resin extraction operations have to be compliant with the USFDA, and European food safety guidelines. The companies that manufacture extracts usually obtain certifications such as HCAAP, Kosher, and Halal.

Key Players

Turmeric powder

The Turmeric power manufacturing is mostly done by micro enterprises and there are a number of players in each region. Additionally, most large spice powder manufacturers such as MDH spices, Everest Spices, Aachi Masala also sell turmeric powder.

Turmeric oleoresins and oils

This segment has a number of large players as well as SMEs.  The large companies extract oils from a number of spices and their products are targeted at export market. (See table 1). These are mostly based in Kerala, due to easy availability of spices. In addition to these large players, there are a number of SMEs that are spread across spice growing states such as Tamilnadu, Andhra Pradesh, Karnataka, Gujarat etc.

Table 1: Spice Extract manufacturers in Kerala
S. No.Company NameProduct RangeLocation
1.SynthiteValue added spice extracts and natural spice powderKolenchery, Kerala
2.Universal OleoresinsSpice Oils, Spice Oleoresins, natural coloursKochi, Kerala
3.Arjuna Natural ExtractsFormulations based on spice extractsAluva, Kerala
4.VD flavoursEssential oils from spicesKochi, Kerala
5.Plant LipidsSpice oils and oleoresinsKochi, Kerala
6.Kancor IngredientsOleo Resins, Essential Oils & Isolates, Mint, Menthol & Isolates, Floral Extracts, Speciality Ingredients, Organic Ingredients.Ernakulam, Kerala,
7.Plant Lipids.Spices and other Essential Oils.Kochi, Kerala
Source : FineTrain research

Key consumers of oleoresins in the domestic market include FMCG companies such as Hindustan Lever, Godrej, Colgate Pamolive, herbal products manufacturers such as Ayur Herbals, Dabur, Himalayan Drug Company, cosmetics product manufacturers such as Garnier Laboratories and pharmaceutical companies such as Dr. Reddys, Cipla etc.

Profitability and return on investment

The capital investment required for a Turmeric powder unit would be under Rs. 50 lakhs for a capacity of up to 2 tonnes per day. Since there is limited value addition in the powder manufacturing process and the manufacturer has to pay large commissions to distributors and retailers, the operating margins of such manufacturers would be thin and profitability would depend on their ability to sell large volumes.

Capital investment in Turmeric extraction capacity of 500 kg per day could be up to Rs. 2 crores. The profitability would depend on the spread between the oleo resin and Turmeric price and the yield of the extraction process.  A tonne of turmeric can yield anywhere 4-5% of extracts. Assuming that a tonne of turmeric yields 40 kgs of Curcumin (95%) and 30 litres of oil, the gross margin calculation is as under

Table 2. Turmeric Oleoresin Processing: Profitability
kgsPrice (Rs/kg)Value (Rs.)
Turmeric10009393,000
Solvents46,500
Total Raw material cost1,39,500
Oleo Resin4044981,79,920
Oil301003,000
Total revenue1,82,920
Spread (Oleoresin-Turmeric)43,420
Spread (%)24

Note: The prices of Turmeric and its Oleo resin are based on export data of 2017 provided by DGFT

The overall profitability and return on investment would depend on the producer’s ability to secure regular orders. Further, any value addition to the products by developing formulations based on the extracts can improve revenues as well as profitability.

Why Turmeric processing may be an attractive opportunity

Demand for Turmeric extracts is growing rapidly in foreign and domestic market. For example, India’s Turmeric extract exports have tripled over the past three years from Rs. 150 crores in FY 15 to Rs. 500 crores[2] in FY 18.

The infrastructure availability (cold storage, common infrastructure for grading and sorting of agri products) for food processing industry is improving as government is providing incentives for development of food parks/spice parks etc.  Further, food processing units are also being given incentives in the form of capital subsidies to set up and expand their businesses.

[1] Source: report on state wise/spice wise production by Spice Board Of India

[2]  DGFT data base: http://commerce-app.gov.in/eidb/ecomq.asp

How we can help

We can help you start a “Turmeric Processing Unit” through a number services including business viability assessment, market landscaping, technical consultation and project execution support.

Reach Us:

Write to us:bchhatre@finetrain.com, admin@finetrain.com

Call us: 800 888 4932

Share This:

Business Opportunity : Corrugated Boxes

1. Introduction

Corrugated box refers to the ubiquitous brown box that brings your online shopping home. Such boxes are also extensively used by manufacturers of consumer and industrial goods to transport their products to their dealers. These boxes keep the contents safe and also serve as a marketing medium for the brand manufacturers.

Corrugated boxes are made from Kraft paper –  several layers of Kraft paper are glued together to make the board.  The board is then cut, folded and stitched/glued to make boxes. The boxes are called three ply, five ply, seven ply etc, depending on the number of layers of Kraft paper.Since the corrugated box manufacturers convert the Kraft paper into a box, they are also called convertors.

The quality of a box is measured by a number of parameters including BF (Burst factor that measures tear resistance of the box), RCT (Ring Crush Test that measures ability to withstand load) and a COBB value (which is its ability to absorb moisture).Quality requirements differ across customers: For example, while a FMCG customer may require the box to have high RCT (the boxes are carried in a truck and a box should be able to withstand the load of boxes placed on it) and low COBB values, the Consumer Appliance industry would need a box with a high BF that can protect valuable electronic parts.

2. Market

The Indian corrugated box industry converts about 4.7[1] million tonnes of Kraft paper per annum and the industry has been growing at a rate of 8-10% annually, which is the fastest among various segments of the paper industry.  Key end users include FMCG, textile, beverages, glass, tobacco and lately e-commerce. Since corrugated boxes are bulky products, they are typically transported within 300 kilometers of the production center, thereby making the industry very local/regional in nature.

The industry is divided into two types of players: automatic plants with a capacity of 1000 tonnes per month and above, and semi-automatic plants with a capacity of under 1000 tonnes per month. At present, there are over 375 automatic plants in the country and more than 10,000 semi-automatic plants[2]. Automatic plants have almost 40% of the share in the corrugated box market. Some of the large corrugators that have operations across the country include Horizon Packs Private Limited, Khemka Containers Limited, TGI Packaging Limitedand MNMTriple Wall Containers. In addition, there are local players that have both automated and semi-automated plants in each state.

The corrugation customers broadly fall into two categories:large corporate consumers such as FMCG, distillery, textile companies and SMEs(fruits and marine products exporters, injection moulded component manufacturers, food processors and consumer products manufacturers). The large customers are gradually shifting their purchases to automatic plants as they require lower lead time and can provide a product with better finish as compared to semi-automated plants.

3. Production process

The corrugated box manufacturing process comprises two steps: board manufacturing and converting the board into the box (See Figure 1).

Figure 1. Corrugated box Manufacturing Process

The capacity of a corrugation plant is defined by the length/width of the machine and its speed and thickness of paper that can be handled by the machine. A 350 meters per minute plant can churn up to 4,000 tonnes of corrugated board per month, when run continuously (24 hours).

There are a number of machinery suppliers both from within India and abroad. Typically, automated corrugation plants use machinery from China or Europe. Some of the popular international machinery manufacturers include BHS(Germany) and Fobster Group(China) for corrugation board and Bobst(Switzerland) and Dongfang(China) for conversion machinery.

4. Capital requirements and profitability

The capital requirements would depend on the capacity and automation levels of the plant. A European plant of capacity of 4000per tonne per month would require an investment of INR 20 Crore in machinery alone. Further as much capital would be needed for meeting other requirements including working capital, factory building, ware house etc.

The corrugation is a volume driven business and profitability would depend on the company’s ability to find bulk/anchor consumers who can buy in large volumes. The pricing flexibility (ability to raise the price) of the corrugators is limited as their customers are large corporates who work with a number of vendors and therefore enjoy high bargaining power. Additionally, the end users/customers have dedicated purchase departments that keep track of Kraft paper prices and cost structure of corrugators thus leaving little room for corrugators for margin expansion.

In order to breakeven, a corrugator should be able to run its plant at more than 30-40% capacity, which can be easily achieved if it has some anchor customers who can provide assured volumes.

5. Why corrugation may be an attractive opportunity

  • Corrugated boxes are environment friendly and currently do not have many substitutes except for shrink films (which are not as environment friendly but cheaper), which are mostly used only in case of PET bottles.
  • The demand for corrugation products is growing at over 9 per cent per annum. The demand growth is expected to remain strong in the near future given the growth in end user industry including FMCG, electronics, e-commerce etc.
  • Customer preference is shifting to large automated plants as these are able to meet the quality requirements and need lower lead time to supply the products as compared to smaller plants, thus resulting in a demand for large corrugation units.

However, before starting a unit, it is critical to study the local demand for corrugated products, potential customers and performance of the existing corrugators. The location of the plant should be chosen carefully keeping in mind the current and potential customers.  Second tier industries cities (that have textile, edible oil, distilleries) seem more attractive as compared to large cities as these already have a number of automatic corrugation plants.

6. How can we help?

If you are interested in starting a corrugated box manufacturing unit, we can assist you in the following

  • Market research to understand local demand supply
  • Viability study for entering a particular market
  • Assistance in developing the project proposal for funding and land allotment
  • Connecting you to technical experts who can offer execution support

[1] Source: Print week and Indian Paper Manufacturers Association (IPMA)

[2] Source: Print week, article dated 14th Sep 2017

Call us/reach us

Call us: 800 888 4932

Write to us: bchhatre@finetrain.comadmin@finetrain.com

Visit us: www.finetrain.com

Share This:

Plastic Products export:Opportunities for SMEs

Introduction

Plastics are the 6th largest traded products, globally.  Indian plastic exports are estimated to be around $ 7.6 billion[1] (Rs. 45,000 crores), accounting for around 3 per cent of our total exports. Top destinations for Indian plastics include USA, China, UAE and United Kingdom. There are over 2300 exporters[2] in India, largely located in Maharashtra and Gujarat. The exporters include both large manufacturers such as Garware-Wall Ropes Ltd, Supreme industries Limited and a number of small and medium enterprises.

Figure 1: Plastic exports-product wise and country wise breakup

Source : Plastics Export Promotion Council

[1] In FY 16

[2] There are around 2300 exporters registered with the Plastics Export Promotion Council

Raw materials (polymers) account for around 30 per cent of our plastics export and value added products for the remaining 70 per cent. Among value added products, plastic sheets, woven sacks, table and kitchenware are the key products.  The exports of these products have increased at a CAGR of around 12-20 per in the past decade (Table 1)

Table 1.  Growth in key categories  of Plastics (INR crs.)
HS codeItem2006-072016-17CAGR (%)
39269099Miscellaneous plastic products315.822,093.4120.82
39232990Plastic sacks bags439.731,964.3116.15
39269080PP articles such as woven sacks226.711,191.7318.05
39239090Plastic articles for conveyance and packaging such as crates160.16615.8114.42
39219099Plastic sheets, films, foils strips, plates, etc.30.33575.6934.22
39241090Tableware Kitchenware55.58505.7824.71
39219096Laminated Flexible packaging items (plates, sheets, films, foils, strips. Etc.)58.93393.8420.92
3917Tube , Pipes and Hoses and fittings284.99947.1912.76
39241010Plastic insulated Tableware Kitchenware89.81386.2415.71
Source : Directorate General of Foreign trade

How To Tap The Export Market

Entering the foreign requires a lot of preparation towards market research and product development, as the products have to meet the requirements of new customers, who may have different standards of quality, design and product packaging.  Also, diversifying into exports entails extensive documentation of company’s processes related to quality, purchase and sales, thus requiring a few dedicated resources. As such, venturing into export market comprises following steps:

Select The Market

Markets can be selected based on size of the opportunity, ease of entry and company’s competitiveness vis a vis other suppliers. The below given graph highlights key markets for various plastic products.

Table 2. Top  export markets  for key Plastics products
HS codeItemCountryCountry’s share in Indian plastics  exports
39269099Miscellaneous plastic productsU. S.21%
Canada6%
UAE4%
39232990Plastic sacks & bagsU.K13%
U.S.A8%
Canada6%
39239090Plastic articles for conveyance and packaging such as plastic cratesU K12%
U A E10%
U S A9%
39269080PP articlesU S A61%
Spain5%
Brazil5%
Source : Directorate General of Foreign trade

As can be seen, the key markets are different for each category of product, for example in FY16, UK accounted for the highest share in exports for plastic bags and sacks, whereas USA was the largest buyer for polypropylene (PP) products.  One can do a detailed market analysis to understand the key consumer countries as well as other suppliers that are supplying to the same market and the competitiveness of your goods vis a vis other suppliers.The competitiveness of the product also gets impacted by the trade and non-trade barriers as explained below.

Trade Barriers

These refers to custom related tariffs, anti-dumping duties that are imposed on the imported products by the countries so as to protect their domestic industry. For example, recently Govt of USA announced its plans to levy a tariff of 25% on imported steel and a 10% of Tariff on imported Aluminium products from a number of countries except Canada, Mexico.

However, the import tariffs are typically lower among trading partners who are party to different agreements such as Free Trade agreements (FTA), Comprehensive Economic Agreement (CEA) etc.   For example, India has trade agreementswith a number of countries including ASEAN, whereby the tariff on a number of products among the ASEAN countries is gradually being brought down to zero. Many of ASEAN members are importers of plastics (HS code 39) and India currently has very limited share in these markets (see Table 4), thereby presenting an opportunity.

Table 3. Plastic imports by ASEAN countries , 2016
CountryCountry wise Plastic imports from the world ($ mn)Country wise plastics imports from India ($ mn)Share of India  in plastic  imports
Indonesia6999.8096.801.40%
Malaysia6827.6032.100.50%
Myanmar582.608.301.40%
Philippines3061.6014.000.50%
Singapore6687.3049.300.70%
Thailand8034.2081.001.00%
Vietnam9614.6087.800.90%
Source : Strengthening ASEAN-India Partnerships: Trends and Future prospects, a report by Export-Import bank of India
Non Trade Barriers

These refers to legislations/other technical requirements that make it very expensive for Indian products to access a particular market. For example the cost of certifications of food grade plastics products in US and Europe are high at around $ 4000-5000 per product per year[1], thus making it very difficult for Indian SMEs to target these markets.

As such it may be easier for a new exporters to start with Asian markets, where the customers’ preferences are similar to India. However a detailed analysis of market size and competitiveness of our products vis a vis other suppliers is a must.

Market Entry Strategy

Having selected the market, a company can choose to enter the market by directly contacting the buyer, selling to a local distributor or participating in a joint venture with a local partner.The trade fairsand buyer’s sellers meet are commonly used by SMEs to identify the buyers as well as test market their products. Some of the trade fairs related to plastics industry include National Plastics Exhibition (NPE), USA, Chinaplas (a plastics and rubber trade fare in China) and Plastindia (Plastic trade fare in India).

The ministry of MSME offers a number of schemes to exporters for market development assistance including exposure visits to foreign markets and concessions in stall charges and air fare to participate in exhibition. These schemes are administrated by Plastics Export Promotion Council (PLEXCONCIL) or Federation of Indian exporters (FIEO), who also organise trade fares in India and facilitate meeting with international buyers.

Meet The Technical Requirements

The exporters need to comply with the technical requirements of the destination country and obtain relevant product certifications. These certifications can be broadly divided into two parts: certifications related to process and safety such as ISO and product related certifications.In general, product certifications required for US and Europe markets are more stringent than those needed for Asian, African and other markets. A summary of important certifications across plastic products is provided below.

Table 4. Technical Certifications  for plastics products
CountryCertifications
Injection moulded productsISO  and product certification based on applications
Pipes and fittingsWater Regulation Advisory Scheme (WARS) for UK, NSF for USA, DVGW for Germany
Food grade plasticsUS FDA guidelines, European Commission (EC ) guidelines
ToysConsumer product safety improvement act (CPSIA) in USA,  EU Toy Safety Directive in Europe
Woven sacksLabour data certificate for FIBC (Flexible intermediate bulk container)
Source : Discussion with NSF officials  and FineTrain research

Estimate The Capital Investment And Profitability Of Export Market

The costs can be divided into two categories:  fixed cost and variable costs. The fixed cost or capital investment required for the export market would depend on the product adaptations/customisations, certification costs and working capital requirements.The working capital cycle can be up to 3 months including the time realised in getting the payment from the buyers as well as for claiming refunds/incentives from the government.

The price of the product in foreign markets should factor the costs such as   commercial costs (shipping, packaging, and duties, insurance), marketing costs over and above the product cost.The marketing expenses such as cost of catalog, samples and visits to the destination country can add up to a significant chunk.

Some of the common costs that are incurred by the exporters include transport cost from factory to port of departure, import duty and taxes, custom clearance, ground transportation from port to customer’s warehouse and marketing agent’s commission.

As such the exporter needs to factor in both fixed and variable before quoting the price and also estimate the minimum volumes they need to sell to recover their costs.

Secure The Order And Finalise Trade Terms

Once the buyer is interested in your product, the next steps would be to finalise the trade terms also known as Incoterms. These typically define the responsibilities of buyers and sellers and costs and risks undertaken by each party.  Some of the commonly used terms include EXW (pricing is ex-factory and buyer is responsible for the transport/insurance), FOB (Free on Board, pricing includes cost of transport till the port of origin) and CIF (Cost insurance and freight, the pricing includes the freight costs and insurance required for transporting the goods to destination).

How Can We Help?

If you are interested in exporting your plastics products, we can assist you in the following

  • Identifying potential markets for your products
  • Viability study for entering a particular market
  • Assistance in generating a list of potential buyers and in scheduling meetings

[1] Based on discussions with NSF International’s office in India

Call us/reach us

Call us: 800 888 4932

Write to us: bchhatre@finetrain.comadmin@finetrain.com

Visit us: www.finetrain.com

Share This:

ECONOMICS OF DAIRY FARMING

India is world’s largest producer of milk, with a production of around 155 million tonnes per annum, contributing to 20 per cent of the world’s milk output. The dairy sector is one of the fastest growing sectors in India, growing at a CAGR of over 15-20 percent, largely driven by the growth of value added products such as yogurt, cheese, ice-cream etc.

The demand growth in dairy industry has also spurred an interest in dairy farming by entrepreneurs from rural as well as urban India. This blog discusses factors that influence profitability and sustainability of a dairy farm.  These include macro factors such as international and domestic prices of milk, and farm level factors such as size of the dairy farm,its cattle management practices and its marketing strategies.

How are local milk prices linked to international milk prices?

While milk is a perishable commodity mostly sold locally, Skimmed Milk Powder (SMP) is traded in the global market and international prices of SMP influence India’s SMP exports. SMP is a large end user of milk, asalmost 11 tonnes of milk is needed to make 1 tonne of milk powder.  Since SMP has a long shelf life as compared to milk, dairy companies keep their surplus milk stock as SMP, and also use it to manufacture milk based products such as ice-cream and yogurt. Adecline in international prices of SMP reduces the export of SMP from India and therefore increases domestic milk availability. Increased domestic availability can sometimes impact the prices at which dairies procure milk from farmers.

For example, India’s SMP exports declined to 15,930 tonnes (INR 293.01 crore) in 2015-16 from a peak of 1.3 lakh tonnes (valued at INR 2,717.56 crore) in 2013-14 due to a steep decline in global SMP prices. During the same time, milk procurement prices declined by as much as INR 10 per litre in North India and Maharashtra.

As can be seen from Figure 1, the prices of SMP tend to fluctuate, which can lead to volatility in the domestic milk prices as well.

Source: https://www.globaldairytrade.info/en/product-results/skim-milk-powder/

Why is marketing strategy for milk so crucial to the profitability of my milk farm?

Dairy farmerstypically sell their milk to a number of customers including public and private sector dairies milk traders, milk processors and directly to consumers. Dairies are the largest bulk buyers accounting for over 20 per cent of milk procurement. They currentlyprocure the milk at around INR 25-35 per litre across the country and the product is sold at a retail price of INR 35-45 per litre.  However, the retail prices for branded, farm fresh milk are higherINR 60-70 per litre.Over the past decade, there has been a spurt in dairy farms that sell their milk as farm fresh milk, desi cow milk, chemical free milk or A2 milk etc. directly to the customers. Some of these players are shown in Table 1

Table 1: Dairy farms selling branded fresh milk
Company nameProductValue proposition
Vrindavan Milk, BangalorePure Natural cow milk, Desi A2 milkDelivered directly from farm, no chemicals used to inject cows.
Klimom, HyderabadCow milk, A2 milkDelivered in eco-friendly glass bottles within a few hours of milking
Astra Dairy, ChennaiCow milk and dairy productsFrom farm to your home in 12 hours
Pride of cows, Pune (aventure of Parag Milk Products)Pasteurized cow milkFarm to home fresh milk, completely untouched by human hands

As a dairy farmer, you have many choices; you can choose to find an assured market  in a large dairy or milk processing companies, sell  fresh milk under your brand name or sell value added products such as flavoured milk, yogurt etc.Therefore, market related choices should be made first and then you can work backwards to make decisions related to animals, location, investment and farm automation.

What are other profitability drivers?

The success of a dairy farm is aligned with the productivity of its animals and the following elements play an important role in determining a farms profitability:

  1. Milk yield: Milk production over the productive life of the dairy animals is one of the most important drivers of the profitability of a dairy farm. It depends on many factors such as animal’s age at first calving, number of lactations and yield per lactation. Further, milk production can be enhanced by providing adequate amount of green fodder and keeping animals disease free.
  2. Self-sufficiency in Fodder:The cost of feed accounts for majority (about 70%) of the costof running a dairy farm. The fodder can broadly be divided into three parts: Green fodder, Dry Fodder and Concentrated Feed. Of the three, Green fodder, which is needed in large quantities, remains most scarce, due to gradual reduction in the green cover of our landscapes. Further, the fodder prices can be volatile and do not move in line with the milk prices. Therefore, in order to be sustainable, a dairy farm must be self-sufficient to meet its green fodder needs. The fodder requirements for a farm with 20 cows are illustrated in Figure 2.

 

Figure 2: Fodder Requirements of a dairy farm

Since fodder cultivation requires a lot of space, several dairy farmers have now shifted to silage, which refers to green fodder preserved under anaerobic conditions. Silage provides benefits similar to that of fodder but is needed in lesser quantities.  Feeding your animal silage, lowers the area needed for fodder cultivation and frees up the land, which can be used to generate income through cultivation of grain/horticulture crops.

  1. Best practices in animal management: Good farm management practices that improve animal productivity are shown.
Figure 3: Best Dairy management practices

How much investment is required for a dairy farm?

A dairy farm requires investment towards land, construction of shed, milking equipment and purchase of animals.Land and animals are the two largest investment heads.

  • Land: The land is needed for the cattle shed and milking operations and also for growing fodder. Minimum 2-3 acres of land would be required for a 20 animal farm.
  • Animal: The cost of animal depends on its age, milk yield, breed etc. As per NABARD’s dairy entrepreneurship development scheme (DEDS), the cost of 10 animals of desi cows is INR 6 lakh.
  • Civil construction: Shed for animals to provide them protection from heat/rain etc. and storage room for feed and housing for labour if needed
  • Equipment:Milking machines, chaff cutter, tipper for cutting the crop.

As such, the investment in animals should be about INR 12 lakhs for a 20 cow dairy farm. Assuming that investment in animals is about 50% of the cost of the farm (excluding land), the investment in the dairy farm with 20 animals should be about INR 25 lakh.

Why is dairy farming an attractive opportunity?

The Indian dairy market is expected to continue  grow at a rate of over 15%, over the next five years, mostlydue to a growth in the consumption of value added products such as cheese, curd, flavoured milk etc. Anticipating the growth, Indian dairy companies have planned significant investments in capacity expansion as given below in table 2.

Table 2: Capacity expansion plans of Indian Dairy majors
CompanyCapital expenditure plansBrandBudget(INR crore)
Heritage Foods Ltd.Addition in the existing capacities in curd and whey products segmentHeritage70 – 75(for FY18)
Gujarat Cooperative Milk Marketing Federation Ltd (GCMMFL)Additional capacities in cheese and chocolatesAmul3000(Upto 2020)
Kwality Ltd.Additional capacities in value-added product categories like Cheese, Paneer, UHT Milk, Flavoured Milk and Table ButterDairy Best520(forFY18 and up to mid FY19)
Parag Milk Foods Ltd.Expansion and modernization of existing plants and improvement in marketing and distribution infrastructureGo, Gowardhan, Topp Up64.5(for FY18)
Prabhat Dairy Ltd.Upgradation of plant and machineryPrabhat40
Source: Indian Dairy Industry – driven by value added products, a report by CARE Ratings

Also, there have been a number of acquisitions in the dairy sector by large private equity companies, and multinationals   who are acquiring local dairy companies to strengthen their operations in India.

Table 3:Acquisitions in the dairy sector
Acquired CompanyInvesting CompanyYear
Kwality LimitedKKR India(a private equity firm)2016
Tirumala MilkLactalis , a France based multinational dairy corporation2014
Anik IndustriesLactalis2016
Creamline DairyGodrej Agrovet Limited2015
Dairy business of Reliance RetailHeritage foods2017
Source:Indian Dairy Industry – driven by value added products, a report by CARE Ratings and FineTrain research

In order to meet the demand growth of the dairy industry, a strong and sustainable dairy farming sector needs to be developed. Dairy farming is currently dominated by a small farmer who has two animals and uses dairy income to supplement his/her agriculture income.  Given the bright prospects of dairy sector and lack of professionally run dairy farms, there is an opportunity for entrepreneurs who can set up dairy farms with scientific feed management practices. These farms can also forward integrate into manufacturing of milk based products.

How can we help?

We can help you set up a dairy farm or a milk product business through a number of services including:

  • Market feasibility assessment
  • Development of project proposal for loans/credits
  • Technical consultation
  • Project execution support

Call us/reach us

Call us: 800 888 4932

Write to us: bchhatre@finetrain.comadmin@finetrain.com

Visit us: www.finetrain.com

[1] Source: India’s milk production in 2015-16,

[2] Source: Indian Dairy Industry-driven by value added products-by Care Ratings, June 30, 2017

[3] Source: http://indianexpress.com/article/india/india-news- india/global-dairy- price-recovery- to-benefit- indian-
farmers-3019391/

[4] Source: http://indianexpress.com/article/india/india-news- india/why-milk- prices-have- fallen-by- rs-10litre- for-
farmers/

Share This:

Business Opportunity: Injection Moulded Products

The injection moulding technology is used for mass production of plastic products. Plastic material, in the form of granules, is melted and injected under pressure to fill a mould to create different types of rigid shapes.

Injection moulding is a popular way of manufacturing both industrial as well as household products. The most common examples of injection moulded products include PET bottle caps, plastic containers, parts of washing machine, cooler and agricultural pipe fittings.

The table below enlists a number of products that can be made through injection moulding.

Capture6

Markets

The PET preforms and bottles/container segment is more crowded as compared to industrial/agri components. The quality specifications of industrial components are more stringent vis-a-vis household segment and therefore require more investment in machinery and experience in plastic technology.

The players in the injection moulding market can be divided into the following categories –
  1. Manufacturers who also market their products: For example, Plast-O-Pack India, Mumbai manufactures and markets various designer house hold products such as microwave containers, pencil boxes, fridge bottles, containers and corporate gift items.  Bangaru Irrigation systems, Telangana manufactures and markets the sprinklers and drips and other irrigation system components.
  2. Contract manufacturers: These players manufacture goods or rigid packaging material for others. In contract manufacturing, there are two models: A) complete job work price model, and B) conversion only price model.

Under the conversion price model, the clients provide the raw material (resins/pellets) and they are billed only for conversions of resins to products, thus protecting injection/blow moulding companies from price fluctuations of the raw material. The clients in such cases usually demand stringent quality standards. However, this consumer segment is difficult to enter for a new injection moulding company as the clients specifically look for imported machinery, in house testing facility and large operational capacity.

Some of the Hyderabad based contract manufacturers include Baba Group of companies (clientele includes Asian paints, Berger paints).  Innocorp Ltd. (clientele includes furniture brands such as Neelkamal and Polyset). Nano polymers (clientele includes Neelkamal, Wipro, HBL, Acme, Asian paints).

PROCESS & TECHNOLOGY

Figure 1: Process flowchart

injection molding process
Injection machine is the heart of the whole process, as it is responsible for turning resins into melted free-flowing liquid and injecting the same into mould cavities.  The capacity of the machine is measured in terms of the pressure it exerts to inject the melted material into the mould and it is measured in either Tonnes or KiloNewton. The capacity of the machine may also be referred to as “shot weight”. Basically, Shot weight/ Injection rate of any machine is the grams of the melted raw material injected to the mould at one shot of pressure. The popular injection moulding machinery suppliers in India include Windsor Machines Ltd., Ferromatik Milacron India Pvt. Ltd., Haitian Huayuan Machinery (India) Pvt Ltd, etc.

Moulds are the most critical part of the process, apart from the injection machine. Mould designs are critical for the shape and texture of the output and also for ascertaining the required injection rate and consequently the capacity of the machine.  Mould designs are typically mentioned in terms of cavities. As such, higher the cavity, higher the production speeds.

BUDGET

While   minimum budget to start an injection moulding unit would be more than Rs 3 Crores, including land, building, and working capital, the overall cost of plant would depend on the quality standards and complexity of the final product. The cost of an injection moulding unit has four components: injection moulding machine, blow moulding machine, auxiliary equipment and working capital. Moulds are the costliest part of the plant, more so because for each different shape, a different mould will be required and the moulds are priced based on the number and complexity in design of the cavities.

The table below depicts a sample plant cost for making containers, the process involves injection moulding as well as blow moulding.

Capture7

How Can We Help You?

If you are interested in setting up an injection moulding unit, we can assist you in starting one. Our services include

  1. Market & Financial viability assessment
  2. Technical consultancy
  3. Detailed project report preparation
  4. Support in project execution

Reach Us

Call us @ 800 888 4932,

Write to us- bchhatre@finetrain.com

Visit us- www.finetrain.com

Share This:

Business Opportunity: PET Sheets

PET sheets provide a convenient way of packaging product across a number of industries – consumer products, pharmaceuticals, food & beverages, etc. PET sheets are increasingly getting popular as a preferred option for packaging of food and pharma products, due to their visual appeal, their ability to keep the product safe from moisture and easy thermoform-ability.

The table below depicts various types and forms of packaging made out of PET sheets:

Capture4

Types of PET Sheets

Various PET sheets, based on their properties, are used in different applications. For example, CPET which has a very high working heat resistance (can withstand a temperature of up to 220 degree Celsius for more than 25 minutes) is used for microwaveable containers. The table below depicts the application of various types of PET Sheets.

Capture1

Market

PET sheet market is currently small, comprising just 1.5% of PET resin consumption in India. However, this market is rapidly growing and the resin consumed by PET sheet industry has nearly doubled from 6,400 tonnes/year in FY-14 to 11,150 tonnes/ year[1] in the FY 17.

Presently most of the PET sheet is manufactured by companies that make different kinds of packaging material. Two of the Hyderabad based players include Nirmala Pet A Pack Pvt Ltd and Spear Pet Pvt Ltd.

Process &Technology

Process
The process of PET sheet making broadly involves: Raw material pre-treatment, Extrusion and Drying & Winding/ Cutting the finished sheet

Fig1: Process flow

Capture

Sometimes, the final product requires one more layer of PET or coatings, in such cases a co extruder will be required.

Single Versus Double Screw Extrusion

Screw is the most important part of any extruder. The screw is divided into three equal zones; feeding, transition, and metering. The primary functions of the three zones are:

  • Feed – taking in the resins and feeding it forward in the screw
  • Transition – compressing and melting the resin
  • Metering/ Pumping– homogenizing/ blending the melted resins and pumping out through the extruder at a constant rate.

There are mainly two types of extruders; Single screw and Twin screw.The single screw extruders typically cost less than twin screw, however they offer less operational flexibility.

Budget

The overall budget for starting a PET sheet extrusion unit with a minimum viable capacity i.e. 300 KG/hr would be Rs. 5 Crores. The machinery cost of twin screw and single screw alone would approximately be Rs. 3 Crores and Rs. 2 Crores respectively[2].

How Can We Help You?

If you are interested in setting up a PET sheet manufacturing unit, we can assist you in starting a processing unit. Our services include

  1. Market & Financial viability assessment
  2. Technical consultancy
  3. Detailed project report preparation
  4. Support in project execution

Reach Us

Call us @ 800 888 4932,

Write to us- bchhatre@finetrain.com

Visit us- www.finetrain.com

 

[1]Source: PRESENTATION OF RELIANCE INDUSTRIES LTD. – March1,2016

 

[2] Source: Based on discussion with extrusion machinery suppliers

Share This: