4. Mr. ADEEL AKHTAR
Submitted By:
MUHAMMAD JAVED 59
M.COM 4th session (2010-2012)
THE ISLAMIA UNIVERSITY BAHAWALPUR
5. MY PARENTS
AND
TEACHERS
And also to
ALL MY
WELL WISHERS.
6. Almighty ALLAH is the entire source of knowledge and wisdom endowed to
mankind and His dearest Nabi, MUHAMMAD (PBUH) is a light of guidance and
knowledge for humanity as a whole.
Everyone has a long list of individuals to whom he is indebted. We are no
exception. We are firstly, with humble gratitude bow our heads before Almighty
ALLAH for giving us strength, courage, patience and inspiration, and enable us to
complete this project. To work for this project, was a difficult task, because it is
about
NEW PIZZA HUT BRANCH
We acknowledge with thanks and admiration, our dependence on all of our
respondents on their nice co-operation and giving us their loyal time. We feel
Great pleasure and honors to express our gratitude from the citadel of hearts to our
respected and dignified instructor
SIR.ADEEL AKHTAR
Without whose guidance it would have been difficult for us to achieve
Our objectives He provide us, his in-depth approach of the subject
“Project Management“
And taught us a lot of tell analysis techniques which we have applied during data
analysis. His sympathetic behavior has an ever lasting impression on the page of
our memory.
9. The Project:
Most of areas of Pakistan have long duration of summer due to which demand for ice is high for
more than six months of the year. As in India demand for ice is more due to GOLAWALA
during summer. Other growing markets for ice plant are industries linked to FOOD PRODUCTS
i.e. fish, dairy, packaged food, restaurants etc. With this growing demand a large number of ice
plants are operating in the country.
. My proposed project is useful and beneficial for Bahawalpur city. Food products industries like
fish, dairy, packaged food, restaurants are linked to this industry. Mainly it produces for the
“Cold Storage” purpose. So we generate the idea to set up an ice plant according to the
requirements of the people of this city as this city has a great demand. Depending on the facts
this area of opportunity has not been exploited properly. We primarily focused on developing an
idea to set up a ice manufacturing plant for business purpose or to be known as
“ICE 2 ICE, ICE PLANT”.
This project is related to setting up an ice plant of 50-tons capacity per day to cater to the needs
of the associations such as fish sellers, hotels, restaurants, dairy, etc. The proposed project will
manufacture ice blocks varying from 130 kg to 150 kg in weight.
The History of Ice Makers
Only within the past 200 years or so have people been able to make ice in their homes. If you
had lived in a warm climate before then, you might never see ice in your lifetime. Until the
advent of refrigeration and freezing technology, ice was cut from lakes and rivers during the
winter and stored in insulated places for use during warmer months. Ice also was imported from
cold to warm climates. The quality and quantity of the ice, however, was unpredictable at best.
Ice Maker Inventors
o In 1850, Dr. John Gorrie, a physician, scientist, inventor and humanitarian,
demonstrated an ice maker and was granted a patent for the design in 1851,
though he never brought it into commercial production. Gorrie is considered the
father of refrigeration, inventing, among other things, an air-cooling system for a
Florida hospital. He was not the only one working in the field, however.
Alexander Twining received a patent in 1853 for an ice maker, and James
Harrison of Australia received a patent in 1855 for an ice maker as well. In 1866,
Thaddeus Lowe invented the first commercially produced ice machine, with the
first commercially produced ice being sold in Dallas that same year.
Home Refrigeration
10. o Refrigeration was invented in the mid-1800s then continuously developed by
different people in different countries. Home refrigerators began to replace the
old-fashioned ice box, but the early models did not have freezer compartments.
By the 1920s refrigerators in the home became widespread in the West. Freezer
compartments and ice cube trays were gradually added to new refrigerator models
so that people could make ice cubes at home.
First Ice Maker in a Refrigerator
o In 1953 the Servelcompany first introduced a refrigerator with a built-in ice
maker. The technology gradually evolved from people having to fill the water
manually to water hook-ups that allowed the house's tap water line to be
connected to the ice maker. By the 1960s, refrigerators with built-in ice makers
were widespread.
First Ice Maker in the Door of a Refrigerator
o In 1965, Frigidaire introduced the first refrigerator with the ice maker in the door,
along with a water dispenser, so that ice and water could be dispensed without
having to open the appliance. By 1985, ice cube maker storage had improved so
that up to 12 pounds of ice could be kept on hand.
Ice plant requirements
Space
11. Modern icemakers are compact in comparison with block ice equipment, but it is not always
possible to compare directly the space occupied by different types; for example they may not be
available in the same unit sizes. However some guidance on the space requirements for
icemakers with a nominal capacity of 50 tons a day
Space required for an icemaker producing 50tons/day
Type of ice Floor area m2 Height m
Block 190 (5000 sqftapprox) 5.0
Power
Average power and peak power requirements may be different, and both have to be considered at
the planning stage. The average power relates to the energy consumed in making a ton of ice,
and this is important in calculating operating cost. Peak power is important to the designer since
it will determine what electrical supply is required, and may also affect operating cost if a peak
demand factor is applicable.
The energy required to make a tons of ice is not constant. It varies widely depending on a
number of factors, the most important of which are
Type of ice units
Operating temperature
Make-up water temperature
Cooling water temperature
Air temperature
Size of plant
Utilization of plant
Method of refrigeration
Energy consumption figures quoted by manufacturers for unspecified operating conditions
should be used only as a general guide.
Other Equipment
Other Equipment Details Quantity
12. Generator 100 KVA (Engine Bus) 1
Transformer 100 KVA 1
Water Bore Diameter 3” – 4” 1
Total Equipment Cost
Furniture & Fixture
Description Qty Cost/Unit Total Cost
Tables 3 5,000 15,000
Chairs 12 1,500 18,000
Fans 4 1,800 7,200
Lights 12 350 4,200
Computer 1 20,000 20,000
Telephone 1 2,500 2,500
Total Furniture & Fixtures 66,900
Office Vehicle
Description Qty Cost/Unit Total Cost
14. Input Requirement:
The basic raw material required for producing ice blocks is water, common salt. These raw
materials are readily available in the local market. Replenishments needed during maintenance
are ammonia gas and compressor oil.
Raw Material
Description 2,010 2,011 2,012 2,013
Ammonia consumption @ Rs. 21,840 24,960 28,080 31,200
Nacl consumption @ Rs. 5,950 6,800 7,650 8,500
Compressor oil for Rs. 19,600 22,400 25,200 28,000
TOTAL 47,390 54,160 60,930 67,700
Factory overhead:
a) FIXED COSTS
-Power KW 600 10 72,000
- Machinery @ 2.34% installed cost 70,241
- Building @ 1% construction cost 16,720
- Vehicles @ 5% of cost 28,100
Total Fixed cost 219,618
15.
16. Water and Gas:
Equipment detail unit
Water Bore Diameter 3” – 4” 1
GAS 6
Electricity:
2012 2013 2014 2015
Electricity Expense 72,000 79,200 87,120 95,832
Technology involved:
Technology/Process Options
The machinery used for the ice plant is local. It includes compressor, condenser, water tank
suitable for 350-700 ice cans, brine agitator, accumulator for parallel supply of ammonia,
craneand trolley, oil separator, ice cans of size 11” x 22” x 48”, electric motor
Merits & demerits of a particular technology
The local machinery is readily available in the market at a very reasonable price. One of the
benefits of using locally manufactured machinery is availability of spare parts and it’s easier to
find operators to operate these machines.
17. Machine Maintenance
The maintenance process starts after mid of July. Normally, it takes one month for the
overhauling of plant, during which the plant is closed for one month.
18. Energy required to manufacture ice kWh/ton of ice made
Type of ice Temperate area
Block 40-50
The values in Table are for icemaker machinery only.
Water
In addition to water for making ice, water may be required for cooling, as in a refrigeration plant
condenser, or for heating, as in a warm water defrosting system.
The amount of water required for making ice is roughly equal to the amount of ice being
produced plus some allowance for wastage and for prevention of buildup of solids in the water
circulating system.
Fresh water for making ice for use with fish must satisfy the requirements for drinking water. In
addition, the chemical composition of water for making ice must meet the equipment
manufacturers' requirements; hard water containing excessive amounts of solids may foul the
icemaker and may also yield a soft wet ice. On the other hand pure water may cause problems,
particularly in flake ice plants, because the ice sticks hard to the drum; the remedy is to fit a
dosing device that puts 200-500 g salt into each tons of water to improve release of the ice
without making the ice detectably salty when used on fish.
It is inadvisable to use shell and tube condensers in a refrigeration system where cooling water is
run to waste, unless a plentiful supply of cheap water is available, independent of the domestic
drinking water supply; otherwise water costs may be prohibitive, since 15 tons of cooling water
at 10°C or 60 tons at 25°C are required for each tons of ice produced. Other factors can affect
cooling water consumption, and manufacturers' precise figures should be used at the detailed
planning stage.
Air cooled condensers can be used on small plants, but for most commercial installations
evaporative condensers, or shell and tube condensers with a cooling tower, are more likely to be
supplied. Evaporative condensers and cooling tower cooling systems normally use less than 1/2
tons of water for each tons of ice, plus some small additional allowance if an overspill is
necessary to prevent buildup of solids in the recirculated water.
19. Block ice
Tapered rectangular metal cans filled with water are immersed in a tank containing refrigerated
sodium chloride brine. The dimensions of the can and the temperature of the brine are usually
selected to give a 24 hour production time, and batches of cans are emptied and refilled in
sequence during that period. Ice block weight can range from 12 to 150 kg depending on
requirements; 150 kg is regarded as the largest size of block one man can conveniently handle. A
block ice plant requires continuous attention and is labour intensive. The icemaker and the store
require a good deal of floor space and impose heavy loads on the building structure. For these
reasons block ice plants are going out of use, and more modern automatic plants are replacing
them.
Location:
We would set up our ice plant 10-15 minutes walking distance from Bahawalpur. As ice is
not easily available in this area and people of this area bears a lot of transportation expenses to
get ice, so we are selecting this area to set up our ice plant.
Product’s Range and Plant Capacity:
We will be producing block ice only. The proposed project has a capacity of producing 50 ice
blocks on the basis of 2 shifts of 12 hours. The maximum capacity of plant is 5000 tons per
annum. Estimated capacity during:
Market Entry Timing:
20. The ice plant should be started up when the season begins in mid Sep and closed when it end up
in mid June. The peak season is of four months i.e. from March to mid June. The rest of the
period is moderate season. The best time to enter into this business is in the month of March.
Raw Material Requirement:
The basic raw material required for producing ice blocks is water, common salt. These raw
materials are readily available in the local market. Replenishments needed during maintenance
are ammonia gas and compressor oil.
Machinery Requirements:
The main equipment required for running the ice plant is compressor, capacitor, condenser, and
electric motors, power etc
.
Name of civil contractors:
XXXXXXXXXXXXXXXX
Machinery Suppliers:
XXXXXXXXXXXXXX
21. Project Engineering:
The machinery of the proposed project will be purchased from any experienced engineer or a
specialized ice making machine manufacturer.
Implementation Stage:
Total time period for the starting of project is estimated to be 2 month year from the date of
approval of finance.
Cost of the Project:
The total cost of the project is estimated to be Rs.3 millionThe fixed cost of the project is Rs. 4.50
millionwhich arefinanced locally. The amount of initial permanent net working capital required is Rs. 5
lakh.
Means of Finance:
Forty Percent (40%) of the estimated cost of the proposed project will be obtained through loan
and the remaining 60%will be contributed by the Owner.
Financial Plan:
The total cost of the project is estimated to be Rs(3000000).Forty percent Rs (2.40 million)of the
estimated cost of the proposedproject will be obtained through loan from Habib Bank Ltd and the
remaining 60% Rs (2.60 million) will be contributed by the owner.
Implementation Schedule:
S.NO ACTI V I T IES MONTH YEAR
1 Order for Local Machinery may 2012
22. 2 Arrival of Local Machinery at site June 2012
Construction of Building and Civil
3 Works: Start June 2012
Complete JULY 2012
4 Erection &Installation of Machinery Start MAY 2012
Complete MAY 2012
5 Order for Raw Materials APRIL 2012
6 Start of Commercial Production JULY 2012
Market Analysis
Target Customers:
The target customers for ice plant can be divided into two categories:
Domestic users, such as ice cream sellers.
Second category is institutional buyers, who buy in bulk, hotels, restaurants, fish sellers,
dairy plants etc.
Description of Market:
Institutional buyers buy the bulk of the block ice production, in institutions related to food
industry. Business sectors, which utilize ice in the country, include the following:For the
protection of fish, Meat and also for Dairy Plants.
Other potential institutional buyers of ice are bakeries, confectioners, hotels which buy ice
blocks in bulk
23. Present Demand:
In market our production’s demand is more than200 ice blocks per day. Which is already served
by our competitors, but we are having location advantage and we can take over the market.
Demand Supply Gap:
Our production of ice blocks is 50 ice blocks per day and there is demand of 200 ice blocks per
day. So there is demand supply gap of 150 blocks.
Ex-factory price:
Our whole sale price is Rs. 280 per ice block
Retail price:
Our retail price is Rs. 320per ice block.
Distribution Channel:
Ice blocks are supplied to supplier through trucks, bullock cart etc.
Technical Analysis:
Block ice is the most popular type of ice sold for a variety of reasons. It melts more slowly than
other types of ice and thus lasts longer. It can be placed in open truck with only a tarpaulin to
protect it from the elements and shipped to a location of four hours away.
Its rectangular shape makes it easy to stack of up to 15 meters and store large amounts. Block ice
has merits of easy to transport and separate as well. Other types of ice have the tendency to
freeze into a solid mass, making it difficult to work with.
24. Manufacturing Process:
Production Process Flow
Cleaning of Sheet
Steel Ice Containers
Placing of Containers
in Water Tank
containing Nacl
Filling of Sheet Steel
Ice Containers with
water while vertically Temp Reduced to –17°C to –20°C
Movement Nacl Tank by
floating in of Ice Blocks
hooks
Delivery of Ice Blocks
Extracting of Ice Blocks
from Sheet Steel
Containers
Movement of Ice Blocks by
hooks
Delivery of Ice Blocks
25. Flow Chart
Ice cans are placed in can grids and moved to beneath the filling tank which automatically fills
each can with proper level of pre-cooled water and then stop. Filtered water must be used to
make ice intended for human consumption.
The cans are then hoisted and carried to the brine tank and immersed inside. The brine, which is
a calcium chloride solution kept at a temperature of -10degree, is constantly circulated by
agitator in order to keep the temperature consistent throughout the tank.
Air is blown into the center of the can to induce a swirling motion. This causes any impurities
and air bubbles in the water to be collected in the center of cans. Prior to finish freezing, this core
is removed by a suction pump and replaced with fresh pre-cooled water.
The time required for the water to be frozen varies according to the size of cans being used,
150lbs. block requires 24 hours, 300 lbs. Takes 48 hours.
When the ice has completely formed, the grids are lifted up from the brine tank and moved to
place in the thawing tank. Using the warm water,which heats the can until the ice allowed to be
slid out. The block ice is then removed from the can by a can dumper.
The empty cans are returned to filling tank for next ice making cycle. The ice is moved to ice
storage and stacked by an ice stacker, or it can be delivered to customer right away upon
requested.
26. List of Machinery:
Description
Ammonia Compressor (8x8) , Driven Wheel
Ammonia Condensor Atmosphere type with 2" pipe
Electric Motor 100 H.P.1450 RPM
Brine Tank for 720 Ice cans, 4mm local made
Cooling Coil V-type 4" pipe & 1800 ft
Brine Agitator 18" Fan Metal
Accumulator for parallel supply of ammonia
Crane & Trolley with Railing Channel & Girder
Ammonia Valves for Complete Plant
Ammonia Pipes for Complete Plant
Oil Separator Buffer Type
4 gauge Suction, Discharge, Oil Pressure
Wood work for Ice Cans, Tank Cover
'Ice Cans of 1.5 mm
Water Fitting Complete
Electric Motor 7.5"
Centrifugal Pump 2.5"x3"
27. Cooling coil Gas transfer pipe
Receiver Cool water pump
Condenser
28. Other Equipment
Other Equipment Details Quantity
Generator 100 KVA (Engine Bus) 1
Transformer 100 KVA 1
Water Bore Diameter 3” – 4” 1
Total Equipment Cost
Furniture & Fixture
Description Qty
Tables 3
Chairs 12
Fans 4
Lights 12
Computer 1
Telephone 1
Total Furniture & Fixtures
Office Vehicle
Description Qty
Suzuki Pick-up 1
Motorcycle (Honda 70) 1
Bicycle (Chinese) 1
Total Vehicle Cost
29. Input Requirement:
The basic raw material required for producing ice blocks is water, common salt. These raw
materials are readily available in the local market. Replenishments needed during maintenance
are ammonia gas and compressor oil.
Raw Material
Description 2,010 2,011 2,012 2,013
Ammonia consumption @ Rs. 21,840 24,960 28,080 31,200
Nacl consumption @ Rs. 5,950 6,800 7,650 8,500
Compressor oil for Rs. 19,600 22,400 25,200 28,000
TOTAL 47,390 54,160 60,930 67,700
Factory overhead:
a) FIXED COSTS
-Power KW 600 10 72,000
- Machinery @ 2.34% installed cost 70,241
- Building @ 1% construction cost 16,720
- Vehicles @ 5% of cost 28,100
Total Fixed cost 219,618
30. Water and Gas:
Equipment detail unit Cost/unit Total cost
Water Bore Diameter 3” – 4” 1 200,000 200,000
GAS 6 40000 240,000
Electricity:
10% PER ANNUM.
2010 2011 2012 2013
Electricity Expense 72,000 79,200 87,120 95,832
Technology involved:
Technology/Process Options
The machinery used for the ice plant is local. It includes compressor, condenser, water tank
suitable for 350-700 ice cans, brine agitator, accumulator for parallel supply of ammonia, crane
and trolley, oil separator, ice cans of size 11” x 22” x 48”, electric motor.
Merits & demerits of a particular technology
The local machinery is readily available in the market at a very reasonable price. One of the
benefits of using locally manufactured machinery is availability of spare parts and it’s easier to
find operators to operate these machines.
Machine Maintenance
The maintenance process starts after mid of July. Normally, it takes one month for the
overhauling of plant, during which the plant is closed for one month.
31. Personnel analysis
Factory staff:
S.NO Type of Staff Number Basic salary Total salaries
required per Person, per year
per month
1 Tank man 6 5,000 180000
2 Machine 1 6000 36,000
Operator
ADMINISTRATION AND GENERAL STAFF
Description Qty Salary Monthly Annual
Salary Cost
Accounts Officer 1 7,000 7,000 42,000
Security Guard 1 6,000 6,000 36,000
Driver 2 5,000 10,000 60,000
Office Boy 1 3,000 3,000 18,000
Total
Administrative
Expenses 156,000
32. SWOT Analysis
Strengths:
The labor to manufacture ice is easily available we can reach easily to low cost labor. Moreover
the location advantage for our project is very much attractive. We can avail maximum advantage
from this market.
Weaknesses:
Our weakness is that we are not producing ice up to the present demand of the consumer.
Because we have one unit to produced ice if we increase the plant in to 2 then we increase the
production.
Opportunities:
Duration of summer doesn’t matter because the packaged food exporting business keeps on
going for almost whole year and the fishing activities keeps going on for almost 7-8 months a
year. Due to which demand for ice is high for more than 7 months a year. Growing market for
ice plants are industries linked to food products i.e. fish, dairy, bakeries, restaurants etc. With
this growing demand a large number of ice plants are operating in the country.
There are approximately 1,300 ice plants operating in the Punjab, catering to the needs of
different institutional and domestic buyers. The total installed capacity of ice plants in Punjab is
approximately 432,669-tons of ice blocks per day2. The need of ice blocks is increasing due to
economic growth, as major buyers are institutional buyers (dairy, bakery, hotel, etc.), who buy in
bulk.
33. Threats:
Competitive Structure of the market
The market of the ice plant is highly competitive; therefore if the entrepreneur is not well
responsive and fulfilling the demand of the consumer he/she may not be able to capitalize the
opportunity properly.
Selection of the wrong venue
Selection of the wrong venue can be a major hurdle in achieving the desired business objectives.
The clientele taste should be properly tracked.
34. Conclusion & Recommendation:
The location plays an important role, as finished ice blocks should be easily accessible to
dealers .
It is important that solid ice blocks are produced through proper freezing time utilization
as solid ice blocks are much heavier, more transparent and provides higher price in the
market.
Weather factor plays an important role, due to seasonal nature of the business i.e. In
summers the demand for ice blocks increases, while after mid September the temperature
starts changing & demand starts to fall, which means the entrepreneur should reduce the
production according to the demand of ice.
One of the most important aspects for success of any business is minimizing the cost of
production, in case of ice plant this can be achieved by proper training of workers,
which would ensure reduction in raw material wastage and better maintenance of
machinery etc.
It is advisable to run the plant on natural gas, rather than electricity, as the major expense
in production of ice is electricity. The use of natural gas instead of electricity will reduce
the electricity expense approximately by half.
In order to sell the ice blocks, it is recommended to develop a chain of dealers who buy the ice
blocks on regular basis. The dealer deposits a guarantee in the shape of cash security, keeping in
view the number of blocks to be purchased on daily basis. In case the dealer is unable to pick the
agreed number of blocks on a particular day, the amount is deducted from his security.
35. G
OOD LUCK
We wish a very best of luck to ice
manufacturing plant. May it progress in
this field and achieve its desired goals.
(AMEEN)
