Chips Manufacturing Cost Guide
Chips Manufacturing Cost Guide
Written By:
Master of Commerce
Submitted To:
Master of Commerce
                                        Master
                                          In
                                       Commerce
Submitted By
                                      Mr.
                                      Mubashir
                                      Hassan
                                      Khan
                            Table of Contents
      Topic                                                                  Page No
Acknowledgment..................................................................……….07
Executive Summary………………………………………………...08
Cost Accounting ……………………………………….....................08
Cost Classifications………………………………………………….08
                                                                                         4
Characteristics Of Good Cost System……………………………...11
Machinery Requirements…………………………………………...16
Fixed Assets Requirements…………………………………………17
Raw Material Requirements………………………………………..18
Land & Building Requirements…………………………………....19
Human Resource Requirements……………………………………20
Key Assumptions…………………………………………………….21
Operating Assumptions……………………………………………..22
Revenue Assumptions……………………………………………….22
Expense Assumptions……………………………………………….23
Turnover Assumptions……………………………………………...23
References…………………………………………………………....26
                                                              5
6
                  Acknowledgement
                                                               7
Executive Summary:
                          Cost Classifications
Costs are classified into fixed costs, variable costs or mixed costs (based on
behavior); product costs or period costs (for external reporting); direct costs or
indirect costs (based on traceability); and sunk costs, opportunity costs or
incremental costs (for decision-making).
                                                                                             8
Product Costs vs Period Costs
                                9
Product costs (also called inventoriable costs) are costs assigned to the manufacture of
products and recognized for financial reporting when sold. They include direct materials,
direct labor, factory wages, factory depreciation, etc.
Period costs are on the other hand are all costs other than product costs. They include
marketing costs and administrative costs, etc.
    Direct materials: Represents the cost of the materials that can be identified directly
     with the product at reasonable cost. For example, cost of paper in newspaper printing,
     etc.
    Direct labor: Represents the cost of the labor time spent on that product, for example
     cost of the time spent by a petroleum engineer on an oil rig, etc.
    Manufacturing overhead costs: Represents all production costs except those for
     direct labor and direct materials, for example the cost of an accountant's time in an
     organization, depreciation on equipment, electricity, fuel, etc.
Conversion costs are all costs incurred to convert the raw materials to finished products and
they equal the sum of direct labor, other direct costs (other than materials) and
manufacturing overheads.
Variable costs are costs which change with a change in the level of activity. Examples
include direct materials, direct labor, etc.
In contrast to sunk costs are opportunity costs which are costs of a potential benefit
foregone. For example the opportunity cost of going on a picnic is the money that you
would have earned in that time.
1. Simplicity: It must be simple, flexible and adaptable to the changing conditions. And it
must be easily understandable to the personnel. The information provided must be in the
proper order, in right time and to the right persons so as to be utilized fully.
3. Economy: The costing system must suit the finance available. The expenditure must be
less than the benefits derived from the system adopted.
7. Less Clerical Work: Printed forms will involve less labor to fill in, as the workers
may be a little educated. They may not like to spend much time in filling the forms.
9. A Sound Plan: There must be proper and sound plans to collect, to allocate and to
apportion overhead expenses on each job or each product in order to find out the cost
accurately.
                                                                                               12
(b) Control of labour cost
It can be controlled if workers complete their work within the standard time limit.
Reduction of labor turnover and idle time to help us, to control labor cost.
(e) Budgeting
Now-a-days detailed estimates in terms of quantities and amounts drawn up before the start
of each activity. This is done to ensure that a practicable course of action can be chalked out
and the actual performance corresponds with the estimated or budgeted performance. The
preparation of the budget is the function of Costing Department.
(h) Expansion:
Cost Accounts may provide estimates of production of various levels on the basis of which
the management may be able to formulate its approach to expansion.
                                                                                              13
(i) Arriving at decisions
Most of the decisions in a business undertaking involve correct statements of the likely
effect on profits. Cost Accounts are of vital help in this respect. In fact, without proper cost
accounting, decision would be like taking a jump in the dark, such as when production of a
product is stopped.
Rupees
The proposed plan is based on the assumption of 50% Debt and 50% Equity. However this
composition of Debt and Equity can be changed as per the requirement of the Investor.
                                                                                               14
Table: Project Viability
           IRR % - age                                       23.41 %
          NPV @ 20 %                                      Rs. 4,662,111
        Pay Back Period                                       4-Years
Proposed Location: The said project can be started in any Industrial Area. It is
recommended to establish the Project in an area where Raw Material is easily available. It
may have any Industrial Area of Islamabad. The location of this proposed plan
recommended at Humak Model Town, Islamabad.
                                                                                              15
PRODUCTION PROCESS:
                                                              Washing and
                                                            rinsing of potato
  Flavoring/ salt                                              chips in hot
                                 Potato Frying
  on fried chips                                                water for
                                                            excessive starch
                                                                 removal
     Packing of
     Crisps into
     packets of
   different sizes
Machinery Requirement:
Following table shows the machinery & equipment requirement for setting up a Potato
Chips Manufacturing Unit imported from China. (HS Codes 84.38.)
Machine              Price $            Make             Unit                   RUPEES
Description
 Washing Machine         2,450                   China          1                 146,982
 Peeling Machine         2,723                   China          1                 163,350
 Slicing Machine         1,991                   China          1                 119,460
  Chips Washing          5,240                   China          1                 314,424
     Machine
                                                                                            16
  Frying Machine        13,885             China               1                  833,118
 Flavoring machine       5,280             China               1                  316,800
   Chips Cooling         4,574             China               1                  274,428
     Machine
 Packing Machine         5,718             China               1                  343,068
    Gas Burning         17,992             China               1                 1,079,496
       Boiler
  Frozen Machine        51,051             China               1                 3,063,060
      Total            110,903                                                6,654,186
  Other charges
    Income Tax            6%                                                      399,251
     Freight &            5%                                                      352,672
 Handling Charges
 as % of CIF price
    Installation          1%                                                      74,061
  Charges as % of
       Price
 Cost of Imported                                                                7,480,170
     Machinery
   Cold Storage                                                                  3,000,000
   Equipments &
    Accessories
TOTAL                                                                         10,480,170
Major Suppliers:
                                                                                             17
Office Equipment
Computers           6      3         180,000
                           0
                           ,
                           0
                           0
                           0
Printers            3      2          75,000
                           5
                           ,
                           0
                           0
                           0
Photocopy Machine   1     10         100,000
                          0,
                          00
                          0
Fax Machine         1      1          10,000
                           0
                           ,
                           0
                           0
                           0
Telephone Sets      10          5      5,000
                                0
                                0
                                     370,000
Fittings &
Installations
Air Conditioners    4      2          80,000
                           0
                           ,
                           0
                           0
                           0
Generator           1    1,50       1,500,000
                         0,00
                         0
Air Compressor      1    1,20       1,200,000
                         0,00
                                                18
                                           0
 Transformer                      1        450,                   450,000
                                           000
 Electric Installations                                           300,000
 & Charges
 Water Pump                                                       500,000
 including boring
                                                                4,030,000
 Furniture & Fixtures
 Office Furniture                 1        250,                   250,000
                                           000
TOTAL 4,650,000
Motor Vehicles:
   The proposed project will also be using two Loader truck for transportation purposes.
   The truck will be costing Rs. 1,100,000 and the depreciation will be charged at the
   rate of 20% on written down value basis. In addition to the above the proposed project
   will also be using two Cars costing Rs. 1,000,000/- each.
   Pakistan is a Potato growing country and has a major advantage of availability and
   lower prices. Potatoes produced in Pakistan are appropriate and ideal to produce
   Quality Potato Chips.
       Potatoes
       Vegetable Ghee / Cooking Oil
       Flavors
Utilities Requirement:
                                                                                     20
  Utilities required for a Chips Manufacturing Unit are Electricity, Water and
  Telephone.
                                                                         22
                   Marketing Cost                           2,052,000
                    Other Benefits                            524,000
                         TOTAL                              2,576,000
KEY ASSUMPTIONS:
Project Assumptions
                                                        %
  Equity                                                5
                                                        0
                                                        %
  Annual Mark Up Rate (Short Term & Long Term)          1
                                                        5
                                                        %
  Debt Tenure in Years                                  5
  General Inflation Rate                                5
Operating Assumptions:
                                                                        23
  Maximum capacity utilization                                                                      95 %
Revenue Assumptions
                                           Distribution                          Distributi
                                           price to                              on price
                                                                                 to
                                           Retailer
                                                                                 Consume
                                                                                 r
                                                     Rs.                            Rs.
  Sales Price per
  15 gm packet                                      3.75                                  5
Raw Material Costs during the 1st Year of Operation Cost (Rs./kg)
  Potatoes per Kg                                                                                            18
  Frying Oil per Liter                                                                                       60
  Flavors per kg                                                                                             392
Region wise Average Annual wholesale prices of Potato (Rs. per 40 kgs)
  *
      Potato price per kg is Rs. 18 average out by taking different Mandi rates. [Source Market Committee]
Expense Assumptions
Turnover Assumptions
                FINANCIAL ANALYSIS:
                Projected Income Statement:
                            2               2                2               2                2               20
                            0               0                0               0                0               26
                            2               2                2               2                2
                            1               2                3               4                5
    Current
    Assets:
       Stock in                      6,494,226         7,346,6         8,080,70          8,897,996       9,809,325         10,822,260
       Trade                                                90                9
                                                                                                                                    26
   Stores &                        1,979,913   2,830,2   3,121,93    3,445,748   3,804,076     4,199,922
   Spares                                           64          1
   Advances,                        537,000    590,70    649,770      714,747     786,222       864,844
   Deposits &                                       0
   Other
   Receivables
   Accounts                        8,726,659   10,040,   11,116,4   12,302,963   13,621,39    15,082,652
   Receivable                                     063          35                        7
   Cash in                           64,243    8,064,2   17,272,1   28,630,897   42,332,72    62,281,375
   Hand / Bank                                      38         73                        7
Owner’s
Equity:
   Capital                        22,000,000   27,341,   36,995,6   47,179,089   59,957,56    75,495,816
   Introduced                                     483          64                        3
   Profit for the                  5,327,398   9,654,1   14,183,4   17,178,474   20,378,25    24,891,002
   Year                                             82         24                        3
                                  27,341,483   36,995,   51,179,0   64,357,563   80,335,81   100,386,818
                                                  664          89                        6
   Less ;                                -         -     4,000,00    4,400,000   4,840,000     5,324,000
   Drawings                                                     0
                                  27,341,483   36,995,   47,179,0   59,957,563   75,495,81    95,062,818
                                                  664          89                        6
Long Term                         13,200,000   8,800,0   4,400,00          -           -             -
Loan                                                00          0
Current
Liabilities:
   Current                         4,400,000   4,400,0   4,400,00    4,400,000         -             -
   Portion of                                       00          0
   Long Term
   Loan
   Accounts                        5,728,202   6,259,1   6,919,63    7,658,077   8,478,879     9,388,502
   Payable                                          63          3
   Provisions &                    4,990,501   5,489,5   6,038,50    6,642,357   7,306,593     8,037,252
   Accrued                                          51          6
   Charges
                                                                                                         27
References:
[1] https://xplaind.com/209931/cost-classifications#:~:text=In%20managerial%20accounting%2C%20costs%20are,
(for%20decision%2Dmaking).
[2] https://freebcomnotes.blogspot.com/2017/03/an-ideal-costing-system-characteristics.html
[3] https://www.preservearticles.com/cost-accounting/importance-of-cost-accounting-to-business-concerns/3085
[4] http://amis.pk/pdf/feasibilities/potato%20chips%20manufacturing%20unit.pdf
28