Honey Production, Processing, Packaging

HONEY PRODUCTION, PROCESSING

&

PACKAGING
Submitted by:
M.Adnan.Akram Sajid Majeed Abida Yousuf M.Junaid

Submitted to:
Akbar Saeed
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Honey Production, Processing, Packaging

TABLE OF CONTENT
Executive Summary -------------------------------------------------------------------03

Company Introduction ----------------------------------------------------------------04

Project Profile --------------------------------------------------------------------------05

Sector and Industry Analysis---------------------------------------------------------08

Market Information--------------------------------------------------------------------12

Production Process --------------------------------------------------------------------15

Land and Building Requirement-----------------------------------------------------18

Human Resource Requirement-------------------------------------------------------19

Key Assumptions ----------------------------------------------------------------------20

Annexure -------------------------------------------------------------------------------24

Honey Production, Processing, Packaging

EXECUTIVE SUMMARY
Honey is the natural sweet substance, produced by honey bees from the nectar of flowers. It has been regarded a food with high nutritional value and enigmatic healing and preserving powers. Honey has been used both as a food product and medicine in Pakistan. We are setting up a business of Honey Production, processing and packaging. Production would be started in Punjab. Processing, packaging and marketing would be accomplished in Karachi. The business will start around 1500 hives which will be settled in Punjab. A contract would be signed with the local farmers or the land owners to get the permission for the placement of beehives in their locality. The site owners charge rent against this facility. Production capacity of the Honey production, processing and packaging business would be around 200,000 Kilogram during first year. The total project cost of the Honey production, processing and packaging business would be approximately Rs. 20.8 million. Debt and equity ratio will be 50:50. Debt will be paid back in 5 years by equal installment method. The distribution network desirable for marketing and distribution of Honey products will be one which provides complete solution from pickup of product from the manufacturers premises, distribution and ensuring space availability for the product on the retail outlets. This kind of distribution solutions can be availed at the cost of 30 to 35% of the gross sales. This type of distribution network is proposed for the reason that being a new business setup, it would be difficult for the manufacturer (owner) to handle logistics involved in managing distribution; therefore commissioning such kind of solution will make it possible for the manufacturer to concentrate on product development and broaden market niche. Our primary target market would be children and the old people which are more than 50% of the total current population. Production capacity of the honey would be around 200,000 Kilogram during first year.

Honey Production, Processing, Packaging

COMPANY INTRODUCTION
It is a newly established company with a name of PURE HONEY. We work hard and would use modern techniques to collect and pack honey for our clients to relish it in its pure & natural form. With a client centric approach, the company diverts all its efforts in assuring the maximum satisfaction of the clients. For this purpose, our team will pay keen attention to assure high Quality until the product is delivered to the clients. We believe that selling the best quality is the right way to cultivate a long term relationship with customers. We will provide Honey at market leading prices so that all our clients can afford it. All these efforts have turned out to be fruitful for making our place amongst the well-reputed companies in Pakistan. Buy with confidence!

VISION:
To see people benefit from the health-giving properties of pure honey of the highest quality....because we care!"

MISSION:
We are committed to achievement of our goals to produce the most nutritious natural honey as a divine service to mankind in the name of Allah the Almighty .

Honey Production, Processing, Packaging

PROJECT PROFILE
Honey is a sweet and viscous fluid produced by honeybees from the nectar of flowers. Honey has been regarded a food with high nutritional value and enigmatic healing and preserving powers. Religion, human civilizations and history all have regarded honey a valuable and sacred food. It has been used by the ancient civilization for the purpose of mummification. Medicinal use of honey was very common among all nations of the ancient civilizations. Honey was also one of the favorite appetites of Muhammad (PBUH) and his disciples. Besides, we see that in Quran, both honeybee and honey are referred to as a wholesome food and a great healer for diseases. Human beings have been relying on wild honey historically; however, there are some ancient evidences suggest that in Chinese reared honeybees for the first time, producing honey for their personal use, not commercial purposes. By the introduction of modern agricultural techniques in different areas in order to increase productivity and meet growing human requirement of food, farming of livestock became an extremely attractive and financially profitable business in rural areas. Honeybee farming is also one of the areas where impressive achievements were noticed globally as well as locally. Through research and development efforts of Pakistan Agriculture & Research Council, European honeybee was introduced in Pakistan in 1980s for the purpose of commercial bee farming. Currently there are more than 300,000 bee colonies exist in Pakistan DEFINITION OF HONEY (According to Pakistan Standards Quality Control Authority - PSQCA) Honey is the natural sweet substance produced by honey bees from the nectar of flowers. It is also produced from blossoms or secretions of living parts of plants or excretions of plant sucking insects, however, honeybees collect, transform and combine nectar with specific substances of their own, store and leave in the honey comb to ripen and mature. Bees produce blossom honeys from nectar and honeydew honey from honeydew. Honeydew is the product of small plant sucking insects. Honey is significantly sweeter than table sugar and has attractive chemical properties for baking. Honey has a distinctive flavor which leads some people to prefer it over sugar and other sweeteners. Liquid honey does not spoil. Because of its high sugar concentration, it kills most bacteria by crenation. Natural airborne yeasts cannot become active in it because the moisture content is too low. Moisture content in natural raw honey varies from 14% to 18%. As long as the moisture content remains under 18%, virtually no organism can successfully multiply to significant amounts in honey, though, importantly, enough bacteria survive to make honey dangerous for infants (especially Clostridium botulinum).

Honey Production, Processing, Packaging

Honey consists essentially of different sugars, predominate glucose and fructose. The color of honey varies from nearly colorless to dark brown. The consistency can be fluid, viscous or partly to entirely crystallized. The flavor and aroma vary, but usually derive from the plant origin. It should not contain any sweetening agents and additions. OPPORTUNITY RATIONALE In Pakistan, honey has been used both as a food product and medicine. Particularly, aging people and children are considered to be in more need of honey and its products. However, food table particularly of children and the older people is considered incomplete without the bottle of honey. The proportion of children and the old people would be the primary target market, which is, more than 50% of the total current population. Unlike other countries where honey is consumed throughout the year irrespective of the fact that how far they are located from North Pole and what weather conditions are there, in Pakistan, use of honey is traditionally discouraged during summer due to a perception about honey that it is hot in nature and should not be used during hot weather or in excess quantities which is perhaps not true at all as Arab countries where weather conditions are even more severe, honey is consumed in larger quantities both in winter and summer seasons. Nevertheless, in Pakistan and abroad, the consumption of honey increases substantively during winter and remain limited during summer (Except for medicinal use). Honey being an expensive item is purchased by a limited number of households in limited quantity. On the other hand, both eastern and western pharmaceutical companies extensively use honey for the manufacturing of medicines. Particularly, eastern pharmaceutical companies are the largest consumer of the honey using it in almost all major medicine. It is suggested that honey business as a trader would best be suitable for those operating other food products business i.e. spice, pickle, jam & jellies etc. Pakistan has a large agricultural base. During different cropping seasons, honeybee farming can be adopted as a side business to produce honey on commercial level. Honeybees also serve as agents for the crop pollination. It helps for gaining high yield rate and healthy production. Crop pollination: The share of honeybees in crop pollination is 80 %. It improves the quality of fruits, vegetable and yield of seed crops. Bee hives value-added by-products: Royal jelly, Pollen and Propolis are used as health food and beeswax in cosmetics. The production and value addition of by-products would supplement the income of beekeepers. PROJECT BRIEF The project of honey production, processing, packaging and envisages the farming of honeybees, extraction of honey, its processing in the factory, followed by packaging and then distribution or supply to the consumer market. The proposed business will start with around 1500 hives which will be settled in Punjab in the farming areas where wild plantation or crop farming is common. In such areas, we sign a contract with the local farmers or the land owners to allow the placement of beehives in the locality and their subsequent movement from one place to another so that bees find enough flowers in the apiary site to fill the honey comb. The site owners charge rent against this facility.

Honey Production, Processing, Packaging

Once the hive is ready and filled with honey, it will be extracted using prevalent extraction technique and will be stored in large plastic drums. Processing and packaging will be performed in the production facility while Quality Testing will be outsourced to third party. In the end, packaged honey of different grades will be supplied to the local market through distributors. MARKET ENTRY TIMING Honey is used as food mostly during winter season which lasts almost three to four months in the entire country. Honey demand increases during chilly winter when children and aged people need honey to keep them warm and protected from cough and other seasonal diseases. This is the best time to market the product. On the other hand, when we assess supply side of honey, it was informed by the honey producers that March, April, May, September, October and November are the months when honey is produced by the bees, while during rest of six months production is either stopped or so small that can only feed bees of the hive. Therefore, it would be appropriate to start production from September and bring the product in the market from November. This would help business integrate its production and marketing operations. BUSINESS LEGAL STATUS The legal status of business tends to play an important role in any setup; the proposed Honey Processing and Packaging Unit is assumed to operate on partnership basis. CAPACITY Production capacity of the Honey production, processing and packaging business would be around 200,000 Kilogram during first year. Project will utilize 60% of its total production capacity (only for processing and packaging plant and machinery) which will increase @10% every year. PROJECT COST Honey processing and packaging involves a simple process of refining and packaging which needs necessary equipment and machinery. Most of the honey producers use local equipment and machinery, however, for this project we have assumed Indian honey processing plant, while, other equipment and machinery would be procured from local sources. The total project cost of the Honey production, processing packaging and marketing business would be approximately Rs. 20.8 million. LOCATION Honey production and processing procedures are simple and can be performed in a small facility. Honey processing unit will be located in Karachi, while, production facility will operate across Punjab as production is a mobile activity in which hives are moved according to weather and availability of flowers.

Honey Production, Processing, Packaging

SECTOR & INDUSTRY ANALYSIS

SECTOR CHARACTERISTICS AND OVERVIEW Honey extraction, processing, packaging and marketing is considered to be a small scale business in Pakistan. There are two types of honey known in the market, one is wild honey for which the largest source is FATA areas and Changa Manga (Punjab), while, farm honey is produced largely in Punjab and some areas of NWFP. Following areas have extensive opportunities for honeybee farming: Mustard (Sarso) Honey Areas Bahawalpur Multan Lodhra Sahiwal Kusur Acacia (Pholai) Honey Areas Jhelum Attock Islambad Bhalwal Haripur Tallagang Azad kashmir Swat Gujar khan Hundi Kahota Bannu Chakwal Sahiwal Mani bahauddin Plum (Beri) Honey Areas Bannu Karak Noushehra Attock Kohat Orange and Barseen Honey Areas Sargodha Kot momin Bhalwal Shaheen abad Faislabad Mani bahauddin Gujrat Sheikhupura Gujrat Sheikhupura Gujranwala Duska Sialkot

Sargodha is the only identified location where Sunflower honey is produced. On average 15 kg honey is produced from one hive of the size 22x17. Average time it takes to be filled in the peak season (March to May) is mentioned to be 12-20 days. However, during Monsoon the production is almost zero and farmers may require feed honeybees in this season. Leftover honey in the hive primarily used by the honeybees and farmers avoid extract honey in this season. Tarnab farm market in Peshawar is considered to be the center of honey business. Honey machinery suppliers [except for processing machinery which is generally imported from India, China and Germany] and traders are located in this market. Honeybee farming is a quite interesting work. Hives which are used as honey combs are transported to the apiary sites in vehicles. During night time hives are placed at different locations (generally along the river banks, beside main highways within the safe distance) with reasonable distance between two hives. Sliding panes of the hives remain closed and removed early morning before sunrise so that bees are free to fly. Side panes of the hive are shut down after sun sets in the evening. In every two three days beehives are moved three to four kilometers ahead from their existing position in the apiary territory selected by the farmer in order to get rid of empty flowers sucked by the honeybees. The purpose of this relocation is to provide honeybees with a new field full of fresh flowers. The process

Honey Production, Processing, Packaging

continuous till the time farmer finds the hive completely filled with honey. Honey is extracted using extractors from the mature hives in large sized tumblers or pots in the field. The extracted honey is then gathered on a site and transported to the processing and packaging factory, while apiary site operations continuous till the end of season. It has been suggested by the existing operators that with the radius of 3 km, a maximum of 50 to 100 hives of standard size can be settled effectively. The sector is largely operating informally and no specific data is available as to how many extractors (honey producers) are in the industry; and who are the main suppliers. However, according to Ministry of Food, Agriculture and Livestock, Pakistan, there are 300,000 apiary sites currently operating in Pakistan. While looking at the FATA honey suppliers who are the biggest wild honey suppliers, they collect honey from a number of small scale bee keepers who have 25 to 50 hives within a radius of 3-4 kilometer. Generally, the honey collectors are Khans and Maliks of the area and use their social and political influence to raise financial benefit from the natural resources. Collected honey is packed in large sized plastic drums which are stored in natural caves for a certain time period until all honey is collected. The stored quantity is then supplied through trucks and heavy vehicles to the traders who pay the highest prices. Peshawar is the main market for the procurement of honey. COMPOSITION OF HONEY Honey is a mixture of sugars and other compounds. The specific composition of any batch of honey will depend largely on the mix of flowers consumed by the bees that produced the honey. As a natural product, the composition of honey is highly variable; however, standards as general reference are provided in the following table
Average Fructose/Glucose ratio Fructose % Glucose % Minerals (ash) % Moisture % Reducing sugar % Sucrose % Ph Total acidity ,mg/kg 1.23 38.38 30.31 0.169 17.2 76.75 1.31 3.91 29.12 Range 0.76 - 1.86 30.91 - 44.26 22.89 -40.75 0.020 - 1.028 13.4 - 22.9 61.39 - 83.75 0.25 - 7.57 3.42 - 6.10 8.68 - 59.49

True protein mg/100g

168.6

57.7 - 567

The analysis of the sugar content of honey is used for detecting adulteration.

Honey Production, Processing, Packaging

HONEY AS PRODUCT Honey processing Comb honey is a popular honey product in the western countries. Comb honey was once packaged by installing wooden framework in special supers, but this labor intensive method is dying, and is being replaced by plastic rings or cartridges. After removal from the hive, a clear cover is usually fitted onto the cartridge so customers can see the product. Raw honey - Honey as it exists in the beehive or as obtained by extraction, settling or straining without adding heat above 120 degrees Fahrenheit. Raw honey contains some pollen and may contain small particles of wax. Local raw honey is sought after by allergy sufferers as the pollen impurities are thought to lessen the sensitivity to hay fever. Most of the honey suppliers and marketers in Pakistan offering this type of honey as modern processing techniques are either out of reach or costly for rural producers. Chunk honey - Honey packed in wide-mouth containers consisting of one or more pieces of comb honey surrounded by extracted liquid honey. This type of honey is preferred in the USA. Strained honey or filtered honey - Honey which has been passed through a mesh material to remove particulate material (pieces of wax, propolis, and other defects) without removing pollen. Preferred by the health food trade - it has a cloudy appearance due to the included pollen, but it also tends to crystallize more quickly than ultra-filtered honey. Ultra-filtered honey - Honey processed by very fine filtration under high pressure to remove all extraneous solids and pollen grains. Ultra-filtered honey is very clear and has a longer shelf life, because it crystallizes more slowly. Preferred by the supermarket trade. Honey products Products which do not meet the compositional criteria for honey, but are products consisting in whole or in part of honey. Imitation or artificial honey is a mixture of sweeteners, colored and flavored to resemble honey. This product does not meet the definition of honey or honey products. As such, it is inappropriate to include the word honey on the label of such a product. This is a partial and constantly growing list intended to standardize the vocabulary used in the honey trade. Deionized Honey: A honey product where honey has been processed to remove selected ions. Deproteinized Honey: A honey product from which protein has been removed by appropriate processing. Dried Honey: Honey which has been dehydrated and in which edible drying aids and processing adjuncts may be included to facilitate processing and improve product stability. Honey Extract: Any product formed by removing selected components from honey. The nature of the component (flavor, color, etc.) determines the type of extract.

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Honey Production, Processing, Packaging

Honey Spread: A variety of edible, extremely viscous honey products made from honey or creamed honey. Honey spread is sometimes blended with other ingredients (such as: fruits, nuts, flavors, spices or margarine but excluding refined sweeteners). Natural Honey Flavor: A substance obtained (often by extraction) only from honey that contains the flavor constituents of honey. Ultra-filtered Sweetener Derived from Honey: Honey from which all materials not passing a specified submicron membrane pore size have been removed. Materials removed include most proteins, enzymes and polypeptides. Evaporation required in the processing may also remove some volatile flavor and aroma constituents. PRECAUTIONS Honey is not always edible. Because it is gathered from flowers in the wild, there are situations in which it may be toxic. Therefore, it is recommended to test the honey received from the honey collector and ensure that it is not injurious for the human health. Benefits of honey and its uses in daily life Honey is an important nutritive food containing various kinds of sugar, protein, free amino acids, minerals, trace elements, enzymes and vitamins with a fairly high caloric value. Its main sugars - laevulose and dextrose are absorbed directly into the blood and provide rapid energy. Species of honeybee are available in Pakistan Four species of honeybees are found in Pakistan. Three are indigenous and one is imported and established in Pakistan. These species are present in different ecological areas of the country. The indigenous species are Apis dorsata, Apis cerana, and Apis florea. The occidental species is Apis mellifera. Department of Agricultural Research of Pakistan may be contacted for further information on honey and honey bee.

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Honey Production, Processing, Packaging

MARKET INFORMATION
Majority of the honey producers are operating in the informal sector, therefore, no precise data on the annual production of honey is available; Industry stakeholders, researchers and Ministry of Food, Agriculture and Livestock, Pakistan report different data. Through research and development efforts of PARC, European honeybee was introduced in Pakistan in 1980s. Now more than 300,000 bee colonies exist in Pakistan, producing well over 3000 metric ton valued at Rs. 600 million honey annually, making Pakistan an exporter of honey earning US $ 220-250 million annually. However, according to the estimates of Honey Research Center, Islamabad, annual production of farm honey is around 7500 metric ton annually. On the other hand, honeybee farmers report an annual production of about 3500 metric ton. While looking at major honey markets and honey demand, Karachi is considered to be the biggest urban market which consumes about one-third of the total production. However, it is not possible to say as to how much is supplied to the industrial users (Pharmaceutical companies), what quantity is further shipped to interior Sindh and what volumes are left for the retail users. MARKET POTENTIAL Pakistan is basically an Agri base economy and major portion of the population still lives in rural areas and beekeeping can be a profitable business for them. About 7,000 beekeepers are now rearing exotic species, Apis mellifera in the modern beehives. There are about 300,000 colonies producing 7,500 metric ton honey annually. Congenial climate conditions and bee flora in the country provide excellent opportunities for the expansion of beekeeping. Honeybee flora is present on vast areas in all the provinces including Northern areas, FATA and AJK and can support 1,000,000 honeybee colonies. Pakistan Agricultural Research Council (PARC) can provide training to the individuals and groups of various organizations and also arrange special training courses on request. The investment and income is worked out for beekeepers for honey production having 50,100 and 200 colonies. These colonies need to be migrated to different locations depending upon the availability of honeybee flora. Future of Honey The bee farming industry is the basic industry on which the whole honey supply chain depends. This sector is becoming progressively more mechanized. Migratory farming is getting more efficient as trucks, complete with loading devices and portable extracting equipment become more prominent. Beekeepers are accepting that they need to travel huge distances each year to work the nectar resource. They possess a phenomenal knowledge that allows them to apply the principles of beekeeping to the climate and vegetation around them. Apiculture can provide a comfortable living, provided the apiarist is willing to become a producer. A successful beekeeper will need plenty of experience, energy and a good location.

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Honey Production, Processing, Packaging

Herbal medicine has now become a recognized industry in the developed countries. Besides that, in the western pharmacopeias use of honey is increasing leading to a huge industrial demand of honey. Current Market Players with Product Prices Weight(In gm) 125 250 500 1000 Retail price (In Rs.) Salman's langnese Al-Shifa 220 200 225 400 325 325 670 600 610 1300 1100

Retailer and Distributor Role Distributor and retailers are of primary importance in marketing Honey products. Easy availability of alternatives and very low per capita consumption of honey across the country makes life difficult for a new entrant. That is the reason, unlike other consumer goods, distribution and retailer margins are relatively higher on Honey Products. For distributor and retailer, around 25% profit margins are normally given by the manufacturer, especially by those with small to medium sized operations. The distribution network desirable for marketing and distribution of Honey products will be one which provides complete solution from pickup of product from the manufacturers premises, distribution and ensuring space availability for the product on the retail outlets. This kind of distribution solutions can be availed at the cost of 30 to 35% of the gross sales. This type of distribution network is proposed for the reason that being a new business setup, it would be difficult for the manufacturer (owner) to handle logistics involved in managing distribution; therefore commissioning such kind of solution will make it possible for the manufacturer to concentrate on product development and broaden market niche. Once the product become successful, the distribution cost will gradually be reduced. Demand On average, total demand of the honey and its products in Karachi is around 50-100 metric ton per month which also includes industrial demand of honey. Honey is more demanded in winter. Target Market-Segment Children less than 12 years and old population of age above 50 year are considered to be the target for honey and honey products. People of all age and demography like to use honey. However, as it is an expensive item, low purchasing power of general consumer in Pakistan sets limit to the potential market for honey.

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Honey Production, Processing, Packaging

Channel of Distribution:

PRODUCER

INDUSTRIAL USER WHOLE SELLERS USER RETAILERS

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Honey Production, Processing, Packaging

PRODUCTION PROCESS
Following production process is followed: EXTRACTION The honeycombs are inserted into an extractor, a large drum that employs centrifugal force to draw out the honey. Because the full combs can weigh as much as 5 lb (2.27 kg), the extractor is started at a slow speed to prevent the combs from breaking. As the extractor spins, the honey is pulled out and up against the walls. It drips down to the cone-shaped bottom and out of the extractor through a spigot. Positioned under the spigot is a honey bucket topped by two sieves, one coarse and one fine, to hold back wax particles and other debris. The honey is poured into drums and taken to the processing facility. PROCESSING/REFINING Modern processing facilities include heating and cooling units, filter presses and pumps that deliver the finished product to the packing line. Following are the key steps during refining process of honey: Liquification Pre-Heating and Straining Micro-filtration Inactivation of Yeast Cells (Processing) Vacuum Evaporation/moisture reduction Cooling of Honey

FILLING Lines include bottle cleaning, filling, capping, front and back labeling and packing. All finished goods are delivered to storage areas by a system of conveyors. LABELING Pre-printed front and back labels are pasted through machines to make certain that accurate names and sizes match up with every bottle turns out. WAREHOUSING Finally, the finished products are stored in the warehouse and distributed according to the plan throughout the year as shelf life of honey is generally higher then other perishable items. Product Mix Offered Following product mix will be offered by the business:
Grams 250 375 500 1000 %age of total 27 31 26 16 Retail price (Rs) 150 200 300 600

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Honey Production, Processing, Packaging

RAW MATERIAL REQUIREMENT Honey and the packaging material will be the main raw material required for the honey business. For the packaging purpose, following material will be required: Bottles with stickers and labels and Packing Cartons Honey will be packaged in bottles in the quantities of 125, 250, 500 and 1000 gram. Glass bottles will be used for this purpose which will provide cost efficiency. The glass bottles will be packed in cardboard boxes or cartons which will then be shipped to the customers (wholesalers). Honey will be supplied from business own production facility; however, for the procurement of other material, following suppliers may be contacted. For labels and cartons Akmal print house A-70 Manghopir Road Opp. Kulsoom Bai Valika Hospital Karachi. PH. 2595301 For Glass Bottle Ghani Glass Ltd 12- D/3 Chandni Chowk KDA Scheme # 7 & 8 Karachi Bottle Market Bottle Gali, Light House, Karachi TECHNOLOGY OPTIONS Honey Processing Machinery Honey being a biological substance and intended for food & pharmaceutical use, needs greater attention in quality and its handling. The moisture content in honey plays an important role in deciding the quality of honey. Honey with more than 20% moisture is thinner in consistency. The moisture content in honey increases due to hygroscopic nature of honey in which the surrounding atmosphere moisture is absorbed by honey. If the moisture content is more than 20% the honey is liable to spoilage due to fermentation & granulation. Considering the present practice of collection, storage & handling of honey under uncontrolled conditions including climatic factors, honey needs processing, reduction of moisture & packing by utmost care to protect the valuable natural properties. Machinery Requirement Both local and imported machinery is required for the processing of honey. Local machinery reportedly gives good quality output. Following machinery will be required for setting up a Honey production, processing and packaging business:

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Machine/Equipment Hive Standard Langstroth Comb Foundation Nucleus Hives Pollen traps Miscellaneous tools Packaging machine Processing Plant with Moisture Reduction Unit Capping unit Steel fabrication and support structure Honey extractor Total cost

Capacity 15 kg

No. of units 1480

Unit cost 5500 4500 200 500 200 100 250000 950000 24000 150000

Total cost 8140000

15 - 22 bottles/minute 1000 kg/8 hour 2500-8500/8 hour

1 1

250000 950000 72000 150000 120000 9682000

60

2000

Honey extractors and hives can easily be procured from Tarnab Farm market Peshawar. Honey processing plant is not readily available in Pakistan. For the proposed project Indian honey processing plant has been proposed and following supplier can be contacted for the supply of machinery: Mr. Tanveerul Hasan Cosmos Inernational S-6, A-206, Block 13-C Gulshan-e-Iqbal Karachi Ph: 021-4209680 & 021-4816594 Email: [email protected] [email protected] There are many local suppliers of Honey packaging machinery working at Karachi and other cities who could be contacted for obtaining packaging machinery; however, during the course of study for this pre-feasibility we have contacted the following local manufacturer: Bizko Tech Engineering Orangi No. 5, Near Police Station, Karachi. Phone +9221-5427334 Machinery Maintenance Machinery is expected to be serviced on an annual basis. Maintenance expenses are estimated to be around 3% of the total cost of machine.

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Honey Production, Processing, Packaging

LAND AND BUILDING REQUIREMENT

Site Development The honey processing, packaging and marketing project is estimated to require a total area of 200-300 yards plot. This area will be used for setting up the Processing facility, Packaging, storage and office. Renovation and Customization Cost 200300 Sq. Yards area is sufficient on rent for the processing and packaging facility. The factory would be located at any place in Karachi, where basic industrial infrastructure is available. Factory space will be obtained on rent and some customization and alteration in the facility will be required. For this purpose approximately Rs. 400,000/- has been assumed.

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HUMAN RESOURCE REQUIREMENT

Honeybee farming is a labor intensive business if done on commercial scale. Operations of the honey processing unit (factory) do not require specialized and skilled staff; however, farming is the area where specialized and trained staff would definitely be needed. For this a total of 250 bee attendants will be required to look after 1480 hives. Whereas, 26 staff will be required for processing and packaging purposes. Total approximate manpower requirement for the business operations along with the respective salaries are given in the table below:
Staff title Business unit manager/owner Production staff Quality controller Marketing manager Supervisor Packaging staff Processing staff Bee attendants Total production staff General administration/ selling staff Accountant Assistant accountant Other administrative staff Guard Driver Total g a/s staff Total 1 1 3 2 6 13 291 25,000 15,000 10,000 9,000 12,000 25,000 15,000 30,000 18,000 72,000 160,000 2,188,000 300,000 180,000 360,000 216,000 864,000 1,920,000 26,256,000 2 1 12 7 6 250 278 20,000 30,000 18,000 9,000 9,000 6,500 40,000 30,000 216,000 63,000 54,000 1,625,000 2,028,000 480,000 360,000 2,592,000 756,000 648,000 19,500,000 24,336,000 No of Individual persons salary Monthly salary Annual salary

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KEY ASSUMPTIONS
The projections cover the cost of land, machinery and equipment including office equipment, fixtures etc. The specific assumptions relating to individual cost components are given as under. LAND & BUILDING Land for setting up the proposed Honey Processing and Packaging unit would be on rental basis which will cost around Rs. 35,000/- per month for a 300 Sq. Yards area. It has been assumed that it would be a developed land with basic infrastructure available. However, for the necessary alteration and customization of the facility, Rs. 400,000/- will be required, straight line method is used for depreciation FACTORY / OFFICE FURNITURE A lump sum provision of Rs. 130,000/- for procurement of office/factory furniture is assumed. This would include table, desk, chairs, and office stationery. The breakup of Factory Office Furniture & Fixtures is as follows:
ITEM Table & chair for owner Table & chair for Qc Incharge & marketing Waiting chair Curtain & interior decoration for office Electrical fittings & lights Other Total Number 1 2 8 1 1 1 Cost 30,000 18,000 2,000 15,000 30,000 7,000 Total cost 30,000 36,000 16,000 15,000 30,000 7,000 134,000

DEPRECIATION TREATMENT The treatment of depreciation would be on straight line method on the following. 1. Machinery 2. Land & Building Construction 3. Vehicles 4. Furniture and Fixtures etc.
Cost 1,542,000 8,140,000 400,000 2,000,000 134,000 12,216,000 Life 10 10 10 10 10 Depreciation per year 154,200 814,000 40,000 200,000 13,400 1,221,600

Machinery Capital Expenditure Land & Building Construction Vehicles Furniture & Fixture Total

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Honey Production, Processing, Packaging

UTILITIES Honey processing and packaging unit will be operated using electricity for packaging purposes, while water is required for processing of honey. The cost of the utilities including electricity, Gas, and telephone is estimated to be around Rs. 2300000/- per month. Approximate cost of utilities has been given below: Utility Electricity Gas Water Telephone Total Total Monthly cost (Rs) 80,000 50,000 35,000 30,000 195,000 Total annual cost (Rs) 960,000 600,000 420,000 360,000 2,340,000 Annual % age increase 5% 5% 5% 5%

WORKING CAPITAL REQUIREMENTS It is estimated that an additional amount of Rs. 6 Million (approximately) will be required as cash in hand to meet the working capital requirements. These provisions have been estimated based on the following assumptions for the proposed business. Description First Three Months Salaries (Production staff) First Three Months Other Utilities Charges First Three Months Misc. Expenses First Three Months Rent Expense Raw Material Inventory 03 month Total VEHICLE FOR SUPPORT AND MAINTENANCE SERVICES At-least four loading vehicle would be required for providing services for the transportation of production and material. For this purpose a transportation vehicle has been proposed which will cost of a vehicle is around Rs. 500,000. SELLING & DISTRIBUTION EXPENSES It has been assumed that the Honey processing and packaging unit is engaged in local sales. For the purpose of increasing awareness about its product, we place some advertisements in local publications. These arrangements would result in additional cost to the business for which an amount equivalent to 5% of the annual sales has been assumed. Amount in Rs 6,084,000 465,000 24,000 105,000 1,586,410 8,264,410

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Honey Production, Processing, Packaging

DISTRIBUTION AND RETAILER MARGIN Distributor and retailers are of primary importance in marketing Honey products. This is the reason that, unlike other consumer goods, distribution and retailer margins are relatively higher on Honey Products. For distributor and retailer, around 30% profit margins are normally given by the manufacturer, especially by those with small to medium sized operations. MISCELLANEOUS EXPENSES Miscellaneous expenses of running the business are assumed to be Rs. 8,000 per month. These expenses include various items like office stationery, daily consumables, traveling allowances etc. and are assumed to increase at a nominal rate of 10% per annum. RAW MATERIAL INVENTORY Based on our assumptions for the processing facility and orders, it would be necessary to maintain three month raw material i.e. unprocessed honey, glass bottles, labels and cartons in order to cover any urgent order requirement. FINISHED GOODS INVENTORY The proposed setup is assumed to maintain finished goods inventory to meet any unforeseen demand. For this purpose finished products equivalent to 15 days finished honey would be maintained. REVENUE PROJECTIONS The Proposed business setup would be able to process around 200,000 kilograms honey in a year. Entire production of the facility will cater the demand of local market of Pakistan, particularly Karachi. For the projection purpose, annual revenue growth rate of 10% has been assumed which would cover anticipated growth in the industry as well price. Revenue Projections By Products Following table presents product mix with total annual sales for each product for the proposed project:

Grams 250 375 500 1000 Total

No of Units 114074 133333 109630 66667

Retail Price 150 200 300 600

sales price 17111100 26666600 32889000 40000200 116666900

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Honey Production, Processing, Packaging

ACCOUNTS RECEIVABLES It has been assumed that 80% of the sales will be on cash, whereas, remaining 20% sales will be on credit. A provision for bad debts has been assumed which is equal to 2% of the annual credit sales. FINANCIAL CHARGES It is assumed that long-term financing for 5 years will be obtained in order to finance the project investment cost. This leasing facility would be required at a rate of 18%. The installments are assumed to be paid at the end of every year.
Year 0 1 2 3 4 5 Balance 10,395,205.00 10,395,205 8,316,164 6,237,123 4,158,082 2,079,041 Interest Payment 1,871,137 1,496,910 1,122,682 748,455 374,227 Repayment of Principle 2,079,041 2,079,041 2,079,041 2,079,041 2,079,041 Total Payment 3,950,178 3,575,951 3,201,723 2,827,496 2,453,268 Remaining Balance 10,395,205.00 8,316,164 6,237,123 4,158,082 2,079,041 -

TAXATION We assume tax rate 30 % OWNERS WITHDRAWAL It is assumed that the owner will draw funds from the business once the desired profitability is reached from the start of operations. The amount would depend on business sustainability and availability of funds for future growth.

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Honey Production, Processing, Packaging

Annexure

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