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ROTOMOLDING PRODUCTION START UP PROJECT IN RUSSIA MOSCOW REGION
Section I. Brief description of the project
There is a decryption of staring up project in the very new industry with high efficiency and great potential in Russia - rotomolding production. This sector has been developing in Russia since 2007. Rotomolding production gives an opportunity to do great variable products which are in high demand on the market. In Moscow region there are three real competitors, one of which focuses on products for the construction (not our case), other has an obsolete and not efficient equipment for the time being
Our competitive advantages are: Romomolding production, modern equipment, managerial skills of partners and possibility to work on its own assets. The place (Moscow region) is also a great plus to the future of the business.
All these guarantee that the business will have a sustainable development for many years. And even with very conservative attitude, the company will have a 10 -15% the market share in 3 years.
The partners on the business are looking for a loan of 3 500 00 USD for 6 years. ROI 200 % And offer collaterals in the form of building and equipment for investor to minimize investor’s risks. Before putting into operation building (supposed to build it from scratch) and equipment, Investor will control all expenses for the first 6 months. The research is already made. 150 000 USD was spent. The company is ready to operate.
Pls. write: [email protected] skype: julia935g
Section II. Description of the sector of the company, its products
Sector description: recently on the Russian market increased demand for products obtained by rotational molding (Russian Federation), including large-size containers of various purposes. The method of the Russian Federation can be recycled thermoplastic polymeric materials (PM), originally located in powder. With these method polyethylene goods, polypropylene, nylon, polycarbonate and polyurethane are produced. For processing of thermoplastics the most popular methods are pressure die casting, extrusion. Rotational molding is used much less frequently. According to experts, the share of plastic products received by Russian manufacturers using this method, does not exceed 5%, while mastered only 20% of the existing needs of the market products. Use of the method of the rotational molding for the production of products is prevented by the significant cost of their transportation. It can be argued that this technology is focused mainly on local markets, so in different regions naturally there is a need to organize such production.Features of the production of products from thermoplastic materials produced by the method of rotary forming:Application of the rotational molding method makes it possible to produce products, which are impossible to obtain in other ways: capacity for individual sewage facilities, small-size and large capacity (up to 30 m3, containers of various purpose, garden furniture, guardrails, children's playgrounds, the goods for winter recreation. It is known that hollow products from thermoplastics can also be read by extrusion blow molding. But the drawback of this method are the thickness of the products due to the heterogeneous draft degree procurement in various places; significant waste material in the form of a matrix, inevitable under this method; periodic mode of operation of the extruder.
Method of rotational molding has a number of advantages compared with other types of plastics processing: the ability to manufacture products of a complex configuration; the multiple layers of products; the ability of reinforcement products metal and plastic parts; regulation of wall thickness of the product, varying quantity of the loaded in the shape of the material (the method of the RF can obtain a product with a wall thickness of 5-20 mm) and non-waste production;
Raw material market.Raw materials is the low density polyethylene (LLDPE - linear).The basic manufacturers of raw materials in the world are:
Main suppliers India Petrotech Internationalhttp://www.petrotechgroups.com
China Aishuibao
Jushui http://www.jushui.com Korea LG Chem Daelim http:www.daelimchem.co.kr Sam-A C&I Co. http:www.samacolor.com Hyosung
SK Honam Petrochemical http://english.hpc.co.kr
Hyundai Engineering Plastics http://www.hyundai-ep.com
Russia Ufaorgsintez
Kazanorgsintez http:www.kazanorgsintez.ru Nizhnekamskneftekhim http://www.nknh.ru
During the 1st and 2nd years of existence the company is planning to buy raw materials from local wholesale sellers at an average price of 2,3 USD /kg Largest wholesale supplier of imported raw materials is the company «Ecoplastik» (http://www.ecpl.ru). Traditionally wholesale suppliers begin to work on an advance payment, in the future, there may be a small installment payment. In the future, when the company's turnover will increase, possibly to buy raw materials from direct producers, both Russian and imported, depending on the market value.
Section III. Market analysis and marketing plan
Business competitorsName Regions of activities Production Functional
activitiesAd, PR, marketing activities
The estimated market share Moscow region 2013 in %
The estimated market share in the Central Federal district of the Russian
Federation (50% of the Russian Federation) 2013. in %
Anion, Ltd + Kation, Ltd
Moscow(The branch and warehouse on the leased premises.), Moscow region(In Klin is manufacturing, warehouse and head office in the area of the property), Saint-Petersburg(Warehouse on the leased premises), Ekaterinburg (Warehouse on the leased premises), Krasnodar (Warehouse on the leased premises), Nizhny Novgorod, Dzerzhinsk (Manufacturing, warehouse and branch in the area of the property)
Septic tanks (up to 14500 liters, caissons, wells+products of polyamide
Engaged in rotomolding and casting polyamide (PA 6). Lately seen activity in development of agriculture in the Orenburg region. Work on Rotomolding since 2006 (the equipment of the joint Assembly with the English Nylacast). According to unconfirmed information, the founders of 2009 are in conflict on the grounds of the so-called "Case of Chemists" (Illegal shipment of ethyl ether). Main market: state order and distributors.
As such - are not engaged. All media activity given the chance Directors objects.
10% 5%
Triton plastik, Ltd + Elit Story Invest, Ltd
Moscow (The Head office, Manufacturing, Warehouse), the Moscow region: Mytishchi (A Warehouse of raw materials and manufacturing), Turaevo (Warehouse, manufacturing)
Septic tanks, caissons, and wells.
Actively promoted in the Central regions of Russia. Business in shares (75% husband and 25% by the wife).
There is no specialist . The founder is engaged in advertising activity personally. A superficial analysis allows to do assumptions this is not effective.
15% 8%
Rotoprom, Ltd
City Vladimir Russia
Rotomolding forms production, septic tanks, caissons, and wells.
Rotomolding production was organized as a subsidiary of the production at processing of metal rolling. The basic profile of the company is metal-roll.
Minimum, because consider it is not necessary. Media work - no. Production Manage is engaged in Media activity
5% 3%
Ekopol, Ltd City Vladimir (Warehouse and Office), Moscow (Warehouse)
Septic tanks(up to 6000 liters), caissons, and wells.
Rotomolding production was organized in 2002. Currently experiencing difficulties with sales.
The lack of activity since 2012.
5% 3%
Group of companies Mefodiy
Moscow region, Ramensky district, Ostrovci
Boats, Canoeing, pontoons, cast forms for rotomolding.
Was established as a subsidiary enterprise engaged in the manufacture and installation
Activity is observed in the promotion of boats by web.
5% 3%
of plastic and aluminium profiles.
Elgad Polimer, JSC
Moscow Septic tanks, caissons, and wells.
Formed as a subsidiary company of building holding "Elgad".
Carry out the activities in the framework of the overall communication strategy of the parent company.
10% 5%
Group of companies EcoProm
Moscow region ,Mytischi and another 10 objects in the Central Federal district
Rotomolding equipment. Septic tanks, caissons, and wells.
High activity in the framework of media activities of the main Holding.
Activities in the framework of the functioning of the group of companies.
30% 15%
Rotoplast Moscow region ,Mytischi
Septic tanks(up to 6000 liters), caissons, and wells.
Created to support the needs of a building complex of Moscow
According to the analysis of sites for job seekers, the has positions in marketing. No advertising neither PR.
10% 5%
Others 10% 55%
Basic groups of products to be manufactured by the company, received by rotomolding:
1. Tanks of different shapes and sizes, designed for different variants of their use, with the volume from 100 to 10000 litres, i.e. the possibility to receive by rotoformation products without seams and consequently without the danger of weak sections allows containers guaranteed to withstand a pressure of liquid filled. All of the tanks on customer request can be equipped with fittings. Material containers usually polyethylene, this material has a very high resistance to most aggressive chemicals and allows the use of polyethylene tanks for storage of the most aggressive chemicals. The polyethylene absolutely non-toxic, and allowed for contact with food products, that allows to use it in the food industry.
2. Products for private household plots. This group includes a wide range of products from tanks, mobile showers and mobile peat toilets to small children's pools and garden furniture.
3. Sanitary-technical products. Mainly in the CIS are widely used septic tanks for wastewater treatment, it is much easier and economically more advantageous than the use of traditional wells
of concrete rings. However, in addition to septic tanks rotomolding produce a large range of funded systems of purification of underground systems, all kinds of oil catchers, integrated sewage system for the device of canalization in the scale is not only one house, but of the whole village.
4. As a separate group of products, toilets must be selected. Rotomolding get all the details of portable toilets from the tank to the walls and the roof. In the toilets in this arrangement there is no metal frame and other metal elements that, when installing a cabin under the open sky, are the most vulnerable components and limit the service life of the product. The lack of such elements makes the toilets produced by rotomolding, most appropriate to use in the any weather conditions.
5. For agriculture - products for cattle-breeding complexes and poultry farms (bins, drinkers, houses for calves and so on).
6. Products for river and sea complex - pontoons, buoys. While having a simple design, low cost and high buoyancy pontoons can be collected in the design of any shape and size for a variety of needs.
7. Special containers for installation on agricultural equipment, under any order can be developed and released the necessary capacity of any size and shape.
Classification of clients of our company:
Retail clients - terms of payment - prepaid.
Corporate, wholesale clients - terms of payment: prepaid, special promotions and discounts
Large retail chains, hypermarkets DYF - terms of payment - factoring
Dealers - variety of instruments- prepayments, factoring (the banking Commission by the dealer) (no risk on no payments)
Conditions of work with clients: work with minimal risks for the prepayment for dealers and large networks, it is planned to use factoring. In the result the company will have more liquidity, high turnover, the minimum difference, there is virtually no client receivables.
The prospects for our company: for the successful implementation of instruments of PR, advertising and marketing possibly permanent increase of sales. Increase instrumentation settlement and reduction of delivery terms of the distributor or end user gives competitive advantages. Progressively growing demand for capacity over 10,000 liters for agriculture and industrial production. Prospects of opening of branches and warehouses in the Central Federal district. When solving the transport issue - shipment railroad transport, open storage in more remote towns with population over one million, where this type of business is almost not represented. The prospects for the CIS in the area of the single customs Union: the Opening of the Belarus production to work on a foreign market, the resource base is present, Kazakhstan opened a warehouse - virtually no competition, also in Kazakhstan, there is no resource base.
Section IV. Start up of production
Start up of production: analyzing the market on the available proposals on the market for land, leasing of manufacturing spaces, the company's Partners have come to the conclusion about its own industrial spaces. Companies in Moscow are actively developing industrial sites in the Moscow region. The selected plot of land is near the central gas and electricity.
Own assets of the company will ensure the stable, sustainable development of the company for many years. Furthermore, by building a production premises at cost, the market value will increase by 2-3 times after putting into operation. That is, when necessary area of 2000 sq. m. the cost of construction will be 1 201 030 USD + cost of land 300 000 USD for 0.5 hectares. Total cost of the production complex without equipment will be equal to about 3, 5 million USD.
According to the schedule the following are needed: approval of the project, construction, connection of communications, equipment installation and launch of production. It is planned to start the project in October 2013, One (1) month for the development and coordination of the project. Construction will take three (3) months, and the connection of communications take another three (3) months, at the end of this period, installation of equipment. Total project on putting into operation of the production complex is 1+3+3= 7 seven (7) months. The company is interested in entering the market next year.Production: the Company will produce mainly mid-size products.
Section V. the Characteristic of the equipment and production plan
For the cost-effective rotational formation of intermediate products is advisable to use a rotary- moulding machine with independent conveyors PRM 3500-2C (VAT $400000). Basic equipment includes: the burner connected with furnace, cooling chamber, the central column, 6 PLC controls, moving conveyors, conveyors holder levers, electrical control equipment.
PRM 3500-2С
PRM 3500-2С
Also, it is advisable to consider the full cycle of processing of raw material (granules and re-granules). For the preparation of the fine fraction HDPE need mill. To maintain the volume of production and provision of high maintainability you must use common HDPE mill MF-600 (27 000 $ with VAT).
MF-600
For processing of defective products, overflow and low-quality raw materials necessary complex of equipment for processing of solid waste, consisting of: Schroeder, combined with the crusher (YMSC-4080 cost of $ 50,000 with VAT) and granulation line (TR-VS cost of $70,000 with VAT).
YMSC-4080
TR-VS
This equipment allows processing 3 % of spoilage and, beyond that, to give 100 kg of granules per hour, which covers the needs of equipment for rotomoulding.
Thus, the full cycle will be as follows. HDPE granules goes to the bunker mill, next goes the small fraction that is loaded in a prepared form for casting. Form is sealed and sent to the burner. After rotation of the form in the oven it moves in the cooling chamber, where goes the process of crystallization. Then the form is opened, the product is removed and is handling by flexible cutter. After that we have the overflow and finished product. When the accumulation of sufficient amount of waste they are sent to the shredder and mill where fraction is prepared for recycling into granules.
The very conservative assumption is made that during 1st year - 1 shift and 25% of loading of capacities, 2nd year – 1 shift and 25% of loading of capacities 52 % of loading capacities. From the 3-d year there is increase in sales and production by 35 % each year.
Seasonal business: June-August – maximum loading capacity, September-October – 80 %, November – March – 50 %, April-May – 80 %. This factor is included in calculation. All this assumption are made on the analysis of competitor’s activity, but our figures are extremely conservative.
During the offseason, the company makes a small stock of finished products ( up to 10 days) , as well as working on the state orders, molding produces, develops a product, looks for ways to corporate
orders, enters the markets of the CIS countries with a milder climate, engaged in preparation for an extensive advertising campaign in the next year.
Section VI. A technical modification of the product.
List of the additional equipment:Cutters on flexible shaft;Disc saw;Angle grinder;Pressing cutter;Measuring instruments.
Additional processing
During production, when the withdrawal of the finished product from the form, there is a removal of formed overflow. It is carried out with the use of cutters on flexible shaft. If necessary to countersink the edges of the holes, toothed disc saws carbide and good free cut are used, or cutters installed in the auxiliary tools. Cost of the equipment for technical modification is about USD 3000 in 2013. Calibration of finished products is not required, since the chiller is used.
For some types of products, it has to mount the flexible fittings (septic tanks) and/or pour working fluids (septic tanks, toilet cabins). Also, after implementation of the technology of production of electric septic tanks, the wiring and filling of the chemical reagents are needed.
Under these tasks it is planned to use the work shift, consisting of 3 people. As this work does not require special permits and carried out by people who do not require degree of a specialist, these works can be made during the day or the night shift. A maximum efficiency of the technological equipment, when on the production of 1(One) form was spent 20 minutes, in parallel shifts in the daytime and in the case of seasonal congestion production, night shift will be created.
Section VII. Management team
There are two main blocks: the commercial and industrial, each partner is responsible for the relevant blocks with extensive experience in these areas.
Commercial unit is responsible for the daily operations and creation of promising solutions (sales, planning, the marketing strategy on the market, logistics).
The manufacturing unit is responsible for the production, provision and operation of the complex as well as for developing new products. In the diagram below show all staff required for this type of production and sales, with mutual replacement of staff.
Section VIII. Risk assessments
Country risk. Russia as a country for investments. Acceptable investment climate settled and clear the current legislation. Russia remains attractive for investments due to the highly profitable projects, stable political and economic situation.
Industry and raw materials risks. Minimal. Rotational molding is developing in Russia since the 2006-2007 year. The industry itself is very young and promising. Product range is practically excludes foreign competition due to transportation limitations for large-sized products. Raw material risks practically does not exist, because there are Russians and import manufacturers on the market.
Regional and production risks. Sales are scheduled to begin in area of Moscow (12 million) and Moscow region (7 million). This region of Russia is the most numerous, with high purchasing power and with a constant migration of people from other places in Russia. The competitive environment in the region mainly consist of 3 (three) companies described above, the company Ecoprom http://www.ekopromgroup.ru/, Triton Plastic http://triton-plastik.pulscen.ru/ and Rotoplast www.rotoplast.ru, with approximate market shares of 30%,15% and 10% respectively. All these three companies are not performing active PR active marketing policy and till now, only one company Ecoprom uses modern high-performance equipment of the company Rotomachinery Group, Italy http://www.rotomachinery.com . The company Triton Plastic owner - a former worker who is facing difficulties with the competent organization of business. The company Órotoplast - limited range of product, mainly for the construction market.
The company will use only the gas equipment. The planning spot location ( 25 km from Moscow) is fully equipped with Central communication, thus operational risks are absent, staff is always available in the_region.Our company with a competent top management, high-performance equipment, good location (about 25
km from MKAD East) and a good advertising budget in the next 2-3 years will win up to 15 % market share in Moscow and Moscow region while building a dealer network in the Central Federal District.
Financial risks:
Minimization of risks: property on land, building, equipment and transport. Collaterals on building and equipment are suggested on these assets. Building – construction cost: 1 201 030 USD (with utilities), after putting into operation, market value of the building would be higher in 2, 5 times i.e. 3 002 575 USD (durability 40 years). Cost of equipment is 700 000 USD (durability 25 years). In business plan insurance of these assets is included. Collateral would be 3 002 575+ 700 000 = 3702 575 USD
Land (300 000 USD for 0, 5 Ga.) is appreciated each years by 6-8 %. Transport - 262 000 USD (durability 7 years)
As a suggestion: Before having the collaterals (in 6 month after start up), Investor would control all expenses (by approving all payments).
Section IX. Finance plan
One shift 25 % One shift 52 % by 35% by 35% by 35% by 35%P&L for 6 years USD USD USD USD USD USD 1-st year 2-nd year 3-d year 4-th year 5-th year 6 year Sales manufacturing: 910 000 1 892 800 2 555 280 3 449 628 4 656 998 6 286 947 Main product 910 000 1 892 800 2 555 280 3 449 628 4 656 998 6 286 947 Costs: 256 688 533 111 719 700 971 595 1 311 654 1 770 732 Basic component Material 244 183 507 901 685 667 925 650 1 249 628 1 686 997 Other component Material 10 000 20 000 27 000 36 450 49 208 66 430 Сolorant 2 505 5 210 7 033 9 495 12 818 17 305 Utility payments 28 864 56 818 62 598 70 402 80 936 95 158 Diesel for heating 15 152 30 303 30 303 30 303 30 303 30 303 Electricity 5 455 10 000 10 000 10 000 10 000 10 000 Water supply 1 818 3 636 4 909 6 627 8 947 12 078 Gas for equipment 6 439 12 879 17 386 23 472 31 687 42 777 Expenses Production Sales 1 151 610 1 143 050 1 163 908 1 210 378 1 268 564 1 341 091
AdminAdvertising 309 091 309 091 309 091 309 091 309 091 309 091 Diesel for transport 26 364 35 152 47 455 64 064 86 486 116 756 Lease of land - - - - - - Office rent for sales 7 576 7 576 8 000 8 000 8 000 8 000 Salary ( inc.taxes) 536 615 536 615 590 277 649 304 714 235 785 658 Communications expenses 20 000 21 818 21 818 21 818 21 818 21 818 Property Tax ( equipment) 5 455 10 909 10 909 10 909 10 909 10 909 Property Tax ( building) 4 545 9 091 9 091 9 091 9 091 9 091 Insurance building 1,5% 16 364 16 364 16 364 16 364 16 364 16 364 Insurance transport % 13 433 13 433 13 433 13 433 13 433 13 433 Transport Tax 804 804 804 804 804 804 % loan agreement 175 000 145 833 116 667 87 500 58 333 29 167 Unforeseen expenses 36 364 20 000 20 000 20 000 20 000 20 000 Total expenses 1 437 162 1 732 979 1 946 207 2 252 375 2 661 154 3 206 982 EBITDA - 527 162 159 821 609 073 1 197 253 1 995 843 3 079 965 EBITDA, % -58% 8% 24% 35% 43% 49% Depreciation 39 394 39 394 39 394 39 394 39 394 39 394 Income before tax - 566 556 120 427 569 679 1 157 859 1 956 449 3 040 571 Income Tax 20 % - 24 710 231 572 391 290 608 114 Net income - 566 556 120 427 544 969 926 287 1 565 160 2 432 457 Volumes for suppliers 118 149 Volumes sales manufact. (Units) 1 181 2 458 3 318 4 479 6 046 8 163 avg. Sales price 770 770 770 770 770 770 Cost of materiala of Sales, % 28% 28% 28% 28% 28% 28%Total cost of Sales % 158% 92% 76% 65% 57% 51%
In the above table P& L for 6 years all income, expenses and taxes for 6 years are included. As an expense a probable interest on loan is shown as well. The sum of net income for 6 years is equal to
5 022 743 USD. The very conservative assumption: 1-st year 25 % loading o f capacities, one shift, 2-nd year 52 % loading of capacities, one shift, and from the 3-d year the company is shown 35 % increase in sales each year.
USD USD USD USD USD USDCash flow 1-st year 2-nd year 3-d year 4-th year 5-th year 6 year Cash per bank - beginning balance 3 500 000 282 551 62 625 261 986 498 037 Investor borrowing drawdown beginning balance 2 300 000 2 916 667 2 333 333 1 750 000 1 166 667 583 333 Interest payments beginning balance 175 000 145 833 116 667 87 500 58 333 29 167
Operating cash receipts Sales - collection from 3rd parties customers 910 000 1 892 800 2 555 280 3 449 628 4 656 998 6 286 947 Total operating cash receipts 910 000 1 892 800 2 555 280 3 449 628 4 656 998 6 286 947 Operating disbursements Regular payroll (net salaries) 536 615 536 615 590 277 649 304 714 235 785 658 Rent and lease payments 7 576 7 576 8 000 8 000 8 000 8 000 Utilities (energy), telecom, direct debits 28 864 56 818 62 598 70 402 80 936 95 158 Advertising 309 091 309 091 309 091 309 091 309 091 309 091 Insurance building 1,5% 16 364 16 364 16 364 16 364 16 364 16 364 Insurance transport % 13 433 12 090 9 672 6 770 4 062 2 031 Raw materials suppliers 256 688 533 111 719 700 971 595 1 311 654 1 770 732 Monthly tax payments (VAT) - 391 077 - 215 046 43 822 370 785 521 874 725 844 Monthly payments - other 57 168 77 774 90 077 106 686 129 108 159 378 Other 36 364 20 000 20 000 20 000 20 000 20 000
Total operating disbursements 871 085 1 354 393 1 869 600 2 528 998 3 115 324 3 892 257 Total operating cash flows 38 915 538 407 685 680 920 630 1 541 674 2 394 690 Non-operating disbursements Capex payments land incl VAT 300 000 0 0 0 0 0Capex payments building incl VAT 1 090 909 Capex payment building's utilities incl VAT 110 121 Capex payments equipment include 700 000 Transport include 262 000 Corporate income tax payments - - 24 710 231 572 391 290 608 114 Other non-operating payments Non-operating disbursements 2 463 030 - 24 710 231 572 391 290 608 114 Funding-related flows Investor borrowing drawdown / (re-payment) 583 333 583 333 583 333 583 333 583 333 583 333 Interest payments income / (expense) 175 000 145 833 116 667 87 500 58 333 29 167 Withholding Tax 20% on loan interest 35 000 29 167 23 333 17 500 11 667 5 833 Capital & dividends in-flow / (outflow) - - - - - - Funding-related flows 793 333 758 333 723 333 688 333 653 333 618 333 Net change in cash - 3 217 449 - 219 926 - 62 364 725 497 050 1 168 243 Ending balances Cash per bank - ending balance 282 551 62 625 261 986 498 037 1 666 279
In the above table Cash Flow for 6 years all inflows and outflows for 6 years are included. As an outflow a probable loan and interest on loan is shown as well. The very conservative assumption is taken for the base. Cash Flow table shown: loss for the first year reduced net profit for the 2-nd year. VAT as usual - during the first 2-3 years – is a receivable and after than payable. After the third year we can see a stable increase in cash.
Section X. Proposals on the terms of financing
Loan 3 500 000 USD for 6 years. In tables P&L and Cash Flow loan repayment and possible interest on loan are included.
ROI 1 year 2year 3 year 4 year 5 year 6 year Total USD Profit - 566 556 120 427 544 969 926 287 1 565 160 2 432 457 5 022 743
Purchase price 3 500 000 Sales price: Assets at market value: Land 300 000 324 000 349 920 377 914 408 147 440 798 440 798 Building 3 603 091 3 513 014 3 422 936 3 332 859 3 242 782 3 152 705 3 152 705 Equipment 700 000 672 000 644 000 616 000 588 000 560 000 560 000 Tranport 262 000 224 571 187 143 149 714 112 286 74 857 74 857 total: 4 228 360
ROI = 2
NPV is not shown because in Table Cash Flow loan repayment and possible interest on loan are included.