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Complex NPK Fertilizer Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Wednesday, December 28, 2016

Complex NPK Fertilizer Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue, Plant Economics, Production Schedule, Working Capital Requirement, Plant Layout, Process Flow Sheet, Cost of Project, Projected Balance Sheets, Profitability Ratios, Break Even Analysis

 

Fertilizer is a material that is added to the soil to supply one or more elements required for plant growth and productiveness. Plants need to be fertilized because most soil does not provide the essential nutrients required for optimum growth.

The three numbers on fertilizer represents the value of the three macro-nutrients used by plants. These macro-nutrients are nitrogen (N), phosphorus (P) and potassium (K) or NPK for short. All plants need nitrogen, phosphorus and potassium to grow. Without enough of any one of these nutrients, a plant will fail. An NPK fertilizer provides those three nutrients in ratios particular to the plant being grown.

Nitrogen (N), the main constituent of proteins, is essential for growth and development in plants. Supply of nitrogen determines a plant’s growth, vigour, colour and yield

Phosphorus (P) is vital for adequate root development and helps the plant resist drought. Phosphorus is also important for plant growth and development, such as the ripening of seed and fruit

Potassium (K) is central to the translocation of photosynthesis within plants, and for high-yielding crops. Potassium helps improve crop resistance to lodging, disease and drought

They are all important to photosynthesis, the process by which plants manufacture their food.

NPK fertilizers can be in the form of powder and liquid. There may also be a granular structure. These fertilizers can be used dripping and leaves.NPK fertilizer production is not very difficult. You need to know what materials will be used and in what amounts. Therefore, there is need for a good NPK fertilizer formulations and manufacturing methods.

 

Components of NPK Production Line:

 

Weighing & Blending System

Belt conveyor

Furnace

Rotary drum granulator

Rotary dryer

Rotary cooler

Rotary coating machine

Packing machine

Cyclones & dust collector

Vibrating screen

Bucket elevator

Scrubbers

 

The demand for fertilisers is divisible into three nutrients: nitrogen (N), phosphates (P2O5) and potash (K). Potash is used in the mineral form and is mainly imported for India's fertiliser requirements. Some plants produce only nitrogenous fertilisers, a few phosphatic and others mixed.

NPK fertilizer plants are used for production of complex with different concentrations and types, such as inorganic fertilizers and biological fertilizers. The agriculture industry relies heavily on the use of NPK fertilizer.

There are in the country some 56 large fertilizer plants (29 producing urea, 21 producing DAP and complex fertilizers, 5 producing straight nitrogenous fertilizers), while the rest 9 units produce ammonium phosphate. Besides, another 72 medium and small units are producing single super phosphates (SSP). The sector has grown to attain a market size of around Rs. 300 bn

India is the 3rd largest fertilizer producer in the world. In India chemical fertilizers played a significant role which is well recognized and established for the success in agriculture sector, not only in terms of meeting total requirement of food grains but also generating exportable surpluses.

The Indian Fertilizers industry is the most energy intensive sectors according to the context of environmental discussion. As there is increasing productivity through the implementation of competent and pollution free technologies in the manufacturing sector it would be desirable in combining economic, environmental and social development. Today the Indian fertilizer Industry has grown in size and stature as it ranks 3rd in the world.

Importance of fertilizers in yield improvement, which is essential for achieving increased agricultural production, further increases because there is little scope for bringing more area under cultivation as well as majority of Indian soils are deficient in many macro and micro nutrients.

 

Table of Contents

1.       District Profile & Geotechnical Site Characterization

1.1.    General

1.2.    Climate & Rainfall

1.3.    Map

1.4.    Transportation and Communications

1.5.    Economy & Industry

2.       Introduction

3.       Nutrient Based Subsidy (NBS) Policy

4.       Types of Subsidy given under NBS Policy

5.       Properties

6.       Market Survey

6.1.    Nitrogenous Fertilisers

6.2.    Urea

6.3.    Di-ammonium Phosphate (DAP)

6.4.    Biotechnology Products

6.5.    India’s Position in Global Fertiliser Market

6.6.    Agricultural Outlook

6.7.    Demand for Fertilizer Nutrients

6.8.    List of Manufacturers of Granular/Physical Fertiliser Mixture

7.       Financials & Comparison of Major indian Players/Companies

7.1.    About Financial Statements of CMIE Database

7.2.    Profits & Appropriations

7.3.    Total Liabilities

7.4.    Total Assets

7.5.    Net Cash Flow from Operating Activities

7.6.    Section – I

7.6.1.Name of Company with Contact Details

7.6.2.Name of Director(S)

7.6.3.Plant Capacity

7.6.4.Location of Plant

7.6.5.Name of Raw Material(S) Consumed with Quantity & Cost

7.7.    Section – II

7.7.1.Assets

7.7.2.Cash Flow

7.7.3.Cost as % ge of Sales

7.7.4.Forex Transaction

7.7.5.Growth in Assets & Liabilities

7.7.6.Growth in Income & Expenditure

7.7.7.Income & Expenditure

7.7.8.Liabilities

7.7.9.Liquidity Ratios

7.7.10.    Profitability Ratio

7.7.11.    Profits

7.8.    Return Ratios

7.8.1.Structure of Assets & Liabilities (%)

7.8.2.Working Capital & Turnover Ratios

8.       Export &Import Statistics Data of India

8.1.    Export Statistics Data for NPK Fertilizer

8.2.    Import Statistics Data for NPK Fertilizer

9.       Present Manufacturers

10.   Raw Material

11.   Manufacturing Process

12.   Process Flow Diagram

13.   Suppliers of Plant & Machinery

13.1.Complete Machinery Suppliers

14.   Suppliers of Raw Material

15.   Machinery, Raw Material & Product Photographs

16.   Plant Layout

17.   Quotation of Plant, Machinery and Equipments from Supplier

 

PROJECT FINANCIALS

·         Project at a Glance

Annexure

·         Assumptions for Profitability workings ….…………………………………………....................... 1

·         Plant Economics…………………………………………………………………………….................... 2

·         Production Schedule……………………………………………………………………….................... 3

·         Land & Building…………………………………………………………………………….................... 4

§  Factory Land & Building

§  Site Development Expenses

·         Plant & Machinery………………………………………………………………………….................... 5

§  Indigenous Machineries

§  Other Machineries (Miscellaneous, Laboratory etc.)

·         Other Fixed Assets………………………………………………………………………….................... 6

§  Furniture & Fixtures

§  Pre-operative and Preliminary Expenses

§  Technical Knowhow

§  Provision of Contingencies

·         Working Capital Requirement Per Month………………………………………………................. 7

§  Raw Material

§  Packing Material

§  Lab & ETP Chemical Cost

§  Consumable Store

·         Overheads Required Per Month and Per Annum ……………………………………................. .8

§  Utilities & Overheads (Power, Water and Fuel Expenses etc.)

§  Royalty and Other Charges

§  Selling and Distribution Expenses

·         Salary and Wages ……………………………………………………………………………................. 9

·         Turnover Per Annum ………………………………………………………………………................ 10

·         Share Capital…………………………………………………………………………………................ 11

§  Equity Capital

§  Preference Share Capital

 

•        Annexure 1            ::        Cost of Project and Means of Finance

•        Annexure 2            ::        Profitability and Net Cash Accruals

§  Revenue/Income/Realisation

§  Expenses/Cost of Products/Services/Items

§  Gross Profit

§  Financial Charges    

§  Total Cost of Sales

§  Net Profit After Taxes

§  Net Cash Accruals

 

•        Annexure 3            ::        Assessment of Working Capital requirements

§  Current Assets

§  Gross Working Capital

§  Current Liabilities

§  Net Working Capital

§  Working Note for Calculation of Work-in-process

 

•        Annexure 4            ::        Sources and Disposition of Funds

•        Annexure 5            ::        Projected Balance Sheets

§  ROI (Average of Fixed Assets)

§  RONW (Average of Share Capital)

§  ROI (Average of Total Assets)

 

•        Annexure 6            ::        Profitability ratios

§  D.S.C.R

§  Earnings Per Share (EPS)

§  Debt Equity Ratio

 

•        Annexure 7            ::        Break-Even Analysis

§  Variable Cost & Expenses

§  Semi-Variable/Semi-Fixed Expenses

§  Profit Volume Ratio (PVR)

§  Fixed Expenses / Cost 

§  B.E.P

 

•        Annexure 8 to 11   ::        Sensitivity Analysis-Price/Volume

§  Resultant N.P.B.T

§  Resultant D.S.C.R

§  Resultant PV Ratio

§  Resultant DER

§  Resultant ROI

§  Resultant BEP

 

•        Annexure 12          ::        Shareholding Pattern and Stake Status

§  Equity Capital

§  Preference Share Capital

 

•        Annexure 13          ::        Quantitative Details-Output/Sales/Stocks

§  Determined Capacity P.A of Products/Services

§  Achievable Efficiency/Yield % of Products/Services/Items 

§  Net Usable Load/Capacity of Products/Services/Items   

§  Expected Sales/ Revenue/ Income of Products/ Services/ Items   

 

•        Annexure 14          ::        Product wise domestic Sales Realisation

•        Annexure 15          ::        Total Raw Material Cost

•        Annexure 16          ::        Raw Material Cost per unit

•        Annexure 17          ::        Total Lab & ETP Chemical Cost

•        Annexure 18          ::        Consumables, Store etc.

•        Annexure 19          ::        Packing Material Cost

•        Annexure 20          ::        Packing Material Cost Per Unit

•        Annexure 21          ::        Employees Expenses

•        Annexure 22          ::        Fuel Expenses

•        Annexure 23          ::        Power/Electricity Expenses

•        Annexure 24          ::        Royalty & Other Charges

•        Annexure 25          ::        Repairs & Maintenance Expenses

•        Annexure 26          ::        Other Manufacturing Expenses

•        Annexure 27          ::        Administration Expenses

•        Annexure 28          ::        Selling Expenses

•        Annexure 29          ::        Depreciation Charges – as per Books (Total)

•        Annexure 30          ::        Depreciation Charges – as per Books (P & M)

•        Annexure 31          ::        Depreciation Charges - as per IT Act WDV (Total)

•        Annexure 32          ::        Depreciation Charges - as per IT Act WDV (P & M)

•        Annexure 33          ::        Interest and Repayment - Term Loans

•        Annexure 34          ::        Tax on Profits

•        Annexure 35          ::        Projected Pay-Back Period And IRR

 

 

 

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