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Project presentation 311013

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Leon Verdes

Project Balaji proposes establishing a second manufacturing facility in Kuppam, Andhra Pradesh to meet growing demand for cheese and other dairy products. Key points: - The new plant would produce cheddar and mozzarella cheese for customers like Britannia and pizza chains, as well as milk powder. With strategic partner Danone, it would also produce infant formula and follow-on products. - Initial estimates indicate a total investment of $54 million without Danone involvement or $86 million with Danone, generating annual returns of 13-25% respectively within the first full year of operation. - Sufficient milk supply and land have been secured near Kuppam, while utilities and manpower

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PROJECT BALAJI A CASE FOR SECOND MANUFACTURING FACILITY IN INDIA
Indian Dairy – An Overview  World’s largest and fastest growing markets for milk & milk products. India accounts for 17 % of Global Milk production  India Milk production :  131 Mn Tons annualized (2012)  180 Mn Tons annualized by 2020 – (Source : National Dairy Plan)  Average annual growth rate : 3 - 4%  Milk distribution  43% of the milk is for self consumption  37% goes to small unorganized sector  10% goes to Co-ops and Government  10% private sector like SDDL Source: NDDB (National Dairy Development Board) 2
Processed Cheese - Customer Wise Volume FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 14,000 12,000 10,000 8,000 6,000 4,000 2,000 Installed Capacity Cheddar 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 Total Projected Volume 4,537 5,026 5,746 6,344 6,947 7,550 8,205 8,918 9,693 10,535 11,450 Britannia 3,600 4,000 4,600 5,100 5,600 6,100 6,645 7,238 7,884 8,588 9,355 Others 937 1,026 1,146 1,244 1,347 1,450 1,561 1,680 1,808 1,947 2,095 3 0 Volume in MT
Mozzarella Cheese - Customer Wise Volume FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 30,000 25,000 20,000 15,000 10,000 5,000 Installed Capacity Mozz 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 Total Projected Volume 4,723 5,596 6,762 8,213 9,959 11,705 13,820 16,387 19,508 23,310 27,948 Dominos 2,034 2,712 3,666 4,885 6,376 7,867 9,707 11,977 14,777 18,233 22,496 Pizza Hut 1,445 1,590 1,749 1,924 2,116 2,308 2,517 2,746 2,995 3,267 3,563 Others 1,244 1,294 1,347 1,404 1,467 1,530 1,596 1,664 1,736 1,810 1,888 4 0 Volumes in MT
Schreiber Dynamix Dairies, Ltd. Baramati Plant 5
Status of Baramati Plant 6 • 1 Mn Liters per Day : Present Milk Handling Capacity • Aug 2014 : Target of Commercial Production From New Dryer • 1.6 Mn Liters per Day : Post Expansion Milk Handling Capacity • 435 Mn Lbs per Annum : Manufacturing Capacity • Upto 1,480 Partners : Currently Deployed including 740 contractual partners • 110 Customers : Currently Being Served
Challenges in Baramati  Milk : Demand exceeds supply  Space for Expansion : 9,693 Sq. Mtr Ground space available (Against permitted limit of 50 % Ground Coverage, 40 % already covered) 7
Challenges in Baramati  Utilities  Water Availability - A major constraint, highly dependent on Monsoon  Maximum utilization of Utilities already achieved  Manpower  50 % Manpower comprises of Contract Labor - upto 740 partners per day  Availability of contractual partners - A major challenge  To manage a plant with more than 1,000 partners during some periods is almost impossible. Social risk is jeopardizing the future of Schreiber Dynamix 8
Data : Jan 2012 till Aug 2013 (Avg. daily milk processing) 0.27 0.25 0.09 As Is Capacity Actual Utilization % Utilization SMP Produced in both Dryers to meet market demand 0.03 0.05 0.02 0.08 0.20 0.20 0.09 0.02 0.05 0.02 0.02 75% 81% 104% 85% 97% 92% 22% 120% 100% 80% 60% 40% 20% 0% 0.30 0.25 0.20 0.15 0.10 0.05 - Milk Reception Pre-process SMP Dairy Whitener Cheese UHT Casein Utilizaiton (%) Raw Milk (M Gal) Sections 9 Challenges in Baramati – Optimum Capacity Utilization All Product lines fully utilized except Casein
Opportunity offered by decentralization - Plant in South India  Customer demands are increasing – Unable to cater growing demands of Cheese (Cheddar & Mozz)  Set up strategic alliance with SDDL – Nutricia (Danone) for a Greenfield project  Customers like Britannia, Pizza Hut, Dominos and many more want us to decentralize operation to meet any contingency & Optimize logistic costs 10
Opportunity offered by decentralization - Plant in South India • Consistent availability of Milk. Milk availability within radius of 150 kms – 3.1 Mio liters per day  Andhra Pradesh : 1.10 Mio liters per day  Tamil Nadu : 0.94 Mio liters per day  Karnataka : 1.10 Mio liters per day  36 acres land acquired & Legal clearance obtained for Industrial construction 11
Opportunity offered by decentralization - Plant in South India  Water availability  Water source - Ground Water  Water Survey Conducted  Good potential zone for ground water availability  Manpower  Available  Needs to train on Technical Skills & GMP  Other Utilities  Built as per need 12
Schreiber Dynamix: Project Balaji 13
Plant Location Delhi Existing Plant Baramati, State Maharashtra Proposed Plant Kuppam, State Andhra Pradesh Population : 7 Mio in 100 KM radius 14
Plant Location TELANGANA STATE Newly Separated Out From Andhra Pradesh KUPPAM Andhra Pradesh 15
Proposal  Establish Second Manufacturing Facility in Kuppam in Andhra Pradesh – Growth Opportunity for Schreiber Dynamix  Products proposed :  Cheddar & Mozzarella for Britannia, Dominos & Pizza Hut  Infant Formulation (IF) & Follow On (FO) for Nutricia (Danone)  Milk Powder 16
Assumptions  Milk Cost will be  At actual with Danone and Cheddar cheese.  Fix for Skim Milk powder and Mozz Cheese  Local Manpower will be trained to improve skills  Required quantity of Biomass Briquettes will be available  Separate AR will be made for Bulk Coolers 17
Daily Raw Milk Requirement (Without Danone) 0.45 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 Year 18 FY17 FY18 FY19 FY20 FY21 FY22 FY23 Cheese - Cheddar + Mozzarella 0.20 0.23 0.25 0.29 0.39 0.39 0.39 0.00 Mio Ltrs
Year Wise Production – Cheese (Without Danone) 18000 16000 14000 12000 10000 8000 6000 4000 2000 Year 19 FY17 FY18 FY19 FY20 FY21 FY22 FY23 0 Cheese - Cheddar + Mozzarella 6210 6986 7652 9096 11984 11984 11984 MT /Year YOY Growth 9.5% 18.9% 31.7% 31.7% 31.7%
Tentative Cost Estimates (Without Danone) Exchange Rate : 1USD = INR 60 20 Sr. Description Mio INR Mio USD 1 Land development & Civil Cost 655 11.10 2 Processing Equipment 1,296 21.97 3 Utilities 925 15.68 4 Laboratory Equipment 48 0.81 5 Finished Goods + Engineering Stores 114 1.93 6 Engineering charges & Statutory approvals 25 0.42 7 Startup Expenses 15 0.25 8 Contingencies 62 1.04 9 Travelling & Administrative expenses 46 0.78 Total Tentative Expenditure 3,186 54.00
Saving Calculations ( Without Danone) FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 Total Volume (Mio lbs /year) - - - 23.54 26.39 29.31 34.35 43.63 43.63 43.63 Average VI (USD /year) - - - 0.31 0.31 0.31 0.31 0.31 0.31 0.31 Net Savings (Mio USD / Year) - - - 7.21 8.09 8.95 10.54 13.58 13.58 13.58 Estimated Investment (Mio USD) - - - 54.00 54.00 54.00 54.00 54.00 54.00 54.00 ROI % - - - 13% 15% 17% 20% 25% 25% 25% Spending Plan (Mio USD) 4.00 30.00 20.00 - - - - - - - 21
Daily Raw Milk Requirement (With Danone) 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 Year 22 FY17 FY18 FY19 FY20 FY21 FY22 FY23 Mn Ltrs Total Milk 0.20 0.23 0.54 0.55 0.55 0.58 0.63 Danone IF,FO, Others & SMP 0.11 0.14 0.17 0.20 0.24 (Including Proteinex base) SMP 0.17 0.12 0.00 0.00 0.00 Cheese - Cheddar + Mozz. 0.20 0.23 0.25 0.29 0.39 0.39 0.39
Year Wise Production – Cheese, Danone & SMP 25000 20000 15000 10000 5000 0 Year 23 SMP production stop due to increase in production for Danone FY17 FY18 FY19 FY20 FY21 FY22 FY23 MT / Year Danone IF,FO, Others & SMP (Including Proteinex base) 9,233 11,105 13,357 16,067 19,327 SMP 4,792 3,195 - - - Cheese - Cheddar + Mozz. 6,210 6,986 7,652 9,096 11,984 11,984 11,984
Additional Tentative Cost Estimates (for Danone) Exchange Rate : 1USD = INR 60 Sr. Description Mn INR Mn USD 1 Land development & Civil Cost 144 2.16 2 Processing Equipment 1,421 23.24 3 Utilities 275 4.21 4 Laboratory Equipment 15 0.24 5 Finished Goods Stores 59 0.96 6 Engineering charges & Statutory approvals 13 0.21 7 Startup Expenses 15 0.25 8 Travelling & Administrative expenses 7 0.12 9 Contingencies 46 0.77 Total Tentative Expenditure 1,995 32.16 * * Will be adjusted after meeting with Danone 24
Saving Calculations (With Danone) FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 Total Volume (Mio lbs /year) - - - 23.54 26.39 63.17 67.62 71.82 78.93 87.48 Average VI (USD /year) - - - 0.31 0.31 0.34 0.35 0.38 0.38 0.38 Net Savings (Mio USD / Year) - - - 7.21 8.09 21.52 23.84 27.13 29.93 33.29 Estimated Investment (Mio USD) - - - 54.00 54.00 86.16 86.16 86.16 86.16 86.16 ROI % - - - 13% 15% 25% 28% 31% 35% 39% Spending plan (Mio 4.00 30.00 20.00 20.00 12.00 - - - - - USD) 25
Product wise VI and ROI Calculation (Without Danone) Sr. Product Production lbs /day VI (INR /lbs) VI (USD /lbs) Total VI / day (Mio USD) 1 Cheddar Cheese 19,841 22.68 0.378 0.0075 2 Mozzarella Cheese 19,841 27.22 0.454 0.0090 3 Non Hygroscopic Whey Powder 19,841 11.34 0.189 0.0038 4 FAT 8,708 4.54 0.076 0.0007 Total VI per day 0.0209 Total days of operation per year 345 Total VI per annum 7.21 Total investment in Mio INR 54 ROI 13% 26 First Full Year Of Saving - FY17
Product wise VI and ROI Calculation (With Danone) Sr. Product Production lbs /day VI (INR /lbs) VI (USD /lbs) Total VI / day (Mio USD) 1 Cheddar Cheese 24,449 22.68 0.378 0.0092 2 Mozzarella Cheese 24,449 27.22 0.454 0.0111 3 Demineralized Whey Protein (DWP 28%) 7,275 25.40 0.423 0.0031 4 FAT 39,021 4.54 0.076 0.0030 5 Danone IF, FO and OTHERS 58,995 27.22 0.454 0.0268 6 SMP 30,622 18.14 0.302 0.0093 Total VI per day 0.0624 Total days of operation per year 345 Total VI per annum 21.52 Total investment in Mio INR 86 ROI 25% First Full Year Of Saving - FY19 27
Project Highlights – Without Danone  Establish 2nd Manufacturing Facility in Kuppam, Andhra Pradesh  Total Investments : USD 54 Mio  Estimated VI per annum : USD 7.21 Mio  ROI (*) : 13.36 %  Products proposed : Cheddar & Mozz Cheese SMP & Whey Powder (*) First Full Year Of Saving - FY17
Project Highlights – With Danone  Augment Infrastructure to cater for Nutricia (Danone)  Additional Investments : USD 32.16 Mio  Total Investments : USD 86.16 Mio (USD 54 Mio + USD 32.16 Mio)  Estimated VI per annum : USD 21.52 Mio  ROI (*) : 25 %  Products proposed : Infant Formulation (IF) & Follow On (FO) for Nutricia (Danone) (*) First Full Year Of Saving - FY19
Water Recovery Projects 31 Oct 13
Project in Brief  Availability of water for plant operations has become challenge.  SDDL present water requirement is 3,058 M³/day.  During 2013 Summer, we had average shortfall of 757 M³/day.  Additional water of 1,500 M³/day needed post Nestle dryer in operation.  This may lead to average shortfall of 2,257 M³/day if similar drought situation repeats.  We can treat COW water coming out from new Evaporator of Nestle Dryer project & can purify COW water about 450 M³/day.  There is a separate AR for water recycling proposing to generate 900 M³/day of water from existing evaporators, CIP flushing and WTP backwash.  Still there will be shortfall of 907 M³/day.
Cow Water Treatment Plant New Evaporator
COW Water Treatment Project Summary Installation of Cow Water Treatment Plant with following parameters: 1) Installation of Filtration unit to process 24.4 KLPH evaporator Condensate (COW) Water from new evaporator. 2) Treatment plant output 21.9KLPH at 90% recovery rate. 3) The plant will be designed to operate for 20hrs/day. 4) The treated permeate will be used to replace Raw/soft water in process CIP and secondary applications. • Estimated Investment – USD 735,356 • Expected Savings – USD 99,522 • Expected ROI – 13.5%
COW Water Treatment Project Investment Sr. Description Amount (USD) 1. RO Polishing Unit, Skid Mounted with MCC and Control Unit, Feed Rate 24.4KLPH, RO Permeate Rate 21.9KLPH, Recovery Rate 90% 414,206 2. Buffer Tank (20KL), Pump, PHE, UV System with 2 lamps (Hitech), Activated Carbon Filter (Ion Exchange), etc. 184,909 3. Utility Piping, Valves upto Battery Limits 20,600 4. Electrical cables and switchgears for Power Supply and Lighting 10,800 5. Fabrication of platforms, supporting structures and monorails 10,800 6. Chemical storage and dosing system 10,800 7. Maintenance Spares for 1 year 50,000 8. Civil construction with metal sheet roof including drainage 22,941 9. Civil foundations for equipment installation 10,300 Total Investment for COW Water AR 735,356
COW Water Treatment Project Savings Calculations Sr. Description Unit Treated COW Water Quantity Average Tanker Water Charges Total Savings M³/day M³/Year USD/M³ USD/Year 1 Reduction in Tanker Water with COW Water Treatment M³/ year 438.98 151,448 1.27 192,603 2 Less Plant Operating Cost USD/ Year 438.98 151,448 (82,608) 3 Less Plant Operations Manpower Cost USD/ Year 4 Partners / day (10,473) Total Water Reduction M³/year 151,448 Net Savings --> 99,522 Estimated ROI: 13.5%
Water Recycling Project (COW water – Existing Evaporator, CIP Rinse/Flushing and WTP Back Wash)
Water Recycling Project Summary Install Water Treatment/Purification Plant with following parameters: 1) Installation of water purification plant for existing evaporator COW water, CIP final rinse/flushing & WTP back wash water. 2) Approx. 1,150 m3/day water will be treated and output capacity would be 900 m3/day with recovery rate 78.3%. 3) The plant will be designed to operate for 19hrs/day. 4) The treated permeate water quality will be as potable BIS standard 10500 and this will blend in reservoir tank • Estimated Investment – USD 936,960 • Expected Savings – USD 217,466 • Expected ROI – 23.2%
Water Recycling Project Investment Sr. Description Amount (USD) 1. Water treatment Plant 60m3/hr 465,747 2. RZ-163-12- Inline Hydro Optic Disinfection 76,235 3. CIP Kit & Accessories 6,072 4. Flow Meter 4" Size or Flow Switch 10,794 5. Aseptic Sampling Valve 2,699 6. Ballast Thermo Control Cabinet 8,096 7. Utility Piping, Valves upto Battery Limits 147,273 8. Electrical cables, switchgears for Power Supply & Lighting 19,636 9. Fabrication of platforms, supporting structures and monorails 39,273 10. Chemical storage and dosing system 29,455 11. Spare 1KW UV Lamp 1,598 12. Start-up & Training 10,300 13. Civil construction and foundations for equipment installation 49,091 14. Equilization Tank 300 KL 70,691 Total Investment for Water Recycling AR 936,960
Water Recycling Project Savings Calculations Sr. Description Unit Quantity of Treated Water Average Raw water cost (MIDC+Tanker) Total Savings M³/Year USD/M³ USD/Year 1 Water avialable for reuse M³/ year 273,600 1.08 294,178 2 Less:- Plant Operating Manpower Cost USD/ Year - 3 Less:- Plant Operating Cost (Utilities/Chemical/Maint) USD/ Year 273,600 0.40 (109,440) 4 Benefit:- WWTP treatment cost reduction. Considering stoppage of 1 stream of 500M³/day, times 300 days/year USD/ Year 150,000 0.22 32,727 Total Water Reduction M³/ year 273,600 Net Savings --> 217,466
Dryer Revamping for Baby Food Products 31 Oct 13
SCOPE STATEMENT SDDL DANONE Civil work for Wet Blending set up & its CIP station. Wet Blending Set up all Equipment. Utility lines from battery limit for wet blending set up. CIP station for Wet blending equipment. Pipe lines for Product / Milk transfer to & fro from wet blending set up. Electrical panel, PLC Control for wet blending set up. Puf paneling for Isolation of Mineral Dryer from other facilities. Provision for Interfacing of the New PLC with existing PLC. Dryer Concentrate Vat replacement with Hygienic design & CIP system for the same. Veg Oil unloading facility. Fluidized bed flex plate replacement. Fines Recovery system modification. Crack Test to be carried out for Dryer. Ventilation system for all floors at Dryer. Filtration level - G4, F7, H10 HVAC for Powder packing. Humidity control will be provided. Filtration - G4, F7, H10 Sealing machine for sealing two liners & Nitrogen flushing provision. (New machine).
SCOPE STATEMENT SDDL DANONE Balance tank replacement at Evaporator with Hygienic design. Main Air Supply fan Filtration system modification to take atmospheric air only. Filtration G4, F7, H10 Epoxy coating for floor at Dryer. Vendor suggested Brit Proofings. Separate entry for Lactose Dryer. Wet Cleaning Automation. Cold Fluid bed Dehumidifier replacement and relocation. Provision of Dehumidifier for Root Blower. Relocation of dehumidifier on terrace. Gravity feed Metal Detector before packing. Sensitivity : SS 1.2 mm Relocation of Filtration system of Fluid bed blowers. Isolation of Wet area (HPP & Concentrate vats) in Dryer with separate entry. (GA in slide no.9)
Tentative Execution Schedule Activity Period Week 1 Week 2 Week 3 Week 4 Week 5 Construct walls with PIR sandwich panels 4 Weeks Epoxy coating of Floors & Structure 1 Week Fines Return & Fluid bed revamping 2 Weeks Dryer Wet section Revamping 2 Weeks Ventilation system for Dryer & Packing 3 Weeks Balance Tank replacement at Evaporator 2 weeks Air Intake Filtration system modification 2 weeks Wet Cleaning Automation 4 Weeks • Wet Blending set up installation is Offline activity & not considered here. • Activities those require total Dryer shutdown are only considered. • Crack Test will be done separately & thus not considered.
Cost Estimate Activity Estimated Investment (INR) Estimated Investment (USD) Isolation of Dryer from other production area. 16,443,482 274,058 Crack Test of Dryer 1,444,065 24,068 Air Supply Fan modifications and Provision of Hepa filteration for all Fans / Blowers 12,734,630 212,244 Evaporator Balance tank replacement with Hygenic Design 405,875 6,765 Cyclone Modification 29,499,893 491,665 Vacuum cleaners 1,500,000 25,000 Gravity Feed Metal Detector & auto sampler for powder packing 5,561,620 92,694 Laboratory Equipments * 4,100,000 68,333 Air Ventilation System for Dryer and Powder Packing 14,390,229 239,837 Wet Cleaning Automation 16,961,866 282,698 Civil Building & utilities provision for Wet Blending set up 23,080,158 384,669 Engineering & Project Management 1,500,000 25,000 Nitrogen Plant Capacity Upgrade 4,000,000 66,667 Repairs after Crack test 5,000,000 83,333 Electrical cable rerouting at Dryer due to civil modification 2,000,000 33,333 Crane Charges and Labor Charges 2,500,000 41,667 Insurance 100,000 1,667 Contingencies (10%) 13,614,682 226,911 Estimated Investment 154,836,500 2,580,608 Danone Investment for Wet Blending set up 46,922,500 782,042 Estimated Investment (with Danone) 201,759,000 3,362,650 Euro 1 = INR 85, USD 1 = INR 60
EQ Audit Compliance EQ Audit Compliance SDDL Recommendation Activity Estimated Investment (INR) Estimated Investment (USD) Euro 1 = INR 85, USD 1 = INR 60 Estimated Investment (INR) Estimated Investment (USD) Roof Replacement (2,900 Square meter) 2,651,228 44,187 1,325,614 22,094 CIP Kitchen for Dryer and Independent CIP arragement for Fluidized bed 20,000,000 333,333 20,000,000 333,333 Removable Thermal Insulation Panels 15,107,149 251,786 - - New Filler 31,058,438 517,641 - - Flexible connections to replace 4,209,132 70,152 4,209,132 70,152 boots and flanged connections Contingencies (10%) 7,302,595 121,710 2,553,475 42,558 Estimated Investment 80,328,542 1,338,809 28,088,221 468,137
Cheese Expansion at Baramati 31 Oct 13
Project in Brief  Existing Cheese capacity - 630 MT / Month. (Mozzarella 460 MT & Cheddar 170 MT).  Proposed Cheese capacity - 950 MT / Month. (Mozzarella 650 MT & Cheddar 300 MT).  Existing Cheese manufacturing set up will be used for Cheddar production.  New set up will be installed on adjacent terrace and will be used for Mozzarella production.  Old Cheese manufacturing Equipments will be purchased from Tine Dairy, Norway without EPCG benefit.
Volume Projections FY 13 FY 14 FY 15 FY 16 FY 17 MT/ year Mozzarella 4,720 5,600 6,760 8,210 9,960 Cheddar 2,950 3,270 3,730 4,120 4,520 Total 7,670 8,860 10,500 12,340 14,470 Current Plant Capacity 7,560 7,560 7,560 7,560 7,560 Proposed Plant Additional Capacity 3,840 3,840 3,840 Proposed Capacity After expansion 11,400 11,400 11,400 Additional Volume 2,940 3,840 3,840 SMP Production with additional Milk capacity generated due to on line milk standardization (Kg / month) 73,000 73,000 73,000 SMP VI USD / Kg 0.33 0.33 0.33 Cheese VI USD / Kg 0.37 0.37 0.37 Additional Differential VI Generated per year for Cheese (USD) 1,078,000 1,408,000 1,408,000 Additional VI Generated per year for SMP (USD) 292,000 292,000 292,000 ROI 35.2% 43.6% 43.6% USD 1 = INR 60, Euro 1 = INR 85
Commercials  Estimated Investment : USD 3.89 Mio  Estimated Savings : USD 1.37 Mio  Estimated ROI : 35.15%
Questions ?

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Project presentation 311013

  • 1. PROJECT BALAJI A CASE FOR SECOND MANUFACTURING FACILITY IN INDIA
  • 2. Indian Dairy – An Overview  World’s largest and fastest growing markets for milk & milk products. India accounts for 17 % of Global Milk production  India Milk production :  131 Mn Tons annualized (2012)  180 Mn Tons annualized by 2020 – (Source : National Dairy Plan)  Average annual growth rate : 3 - 4%  Milk distribution  43% of the milk is for self consumption  37% goes to small unorganized sector  10% goes to Co-ops and Government  10% private sector like SDDL Source: NDDB (National Dairy Development Board) 2
  • 3. Processed Cheese - Customer Wise Volume FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 14,000 12,000 10,000 8,000 6,000 4,000 2,000 Installed Capacity Cheddar 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 Total Projected Volume 4,537 5,026 5,746 6,344 6,947 7,550 8,205 8,918 9,693 10,535 11,450 Britannia 3,600 4,000 4,600 5,100 5,600 6,100 6,645 7,238 7,884 8,588 9,355 Others 937 1,026 1,146 1,244 1,347 1,450 1,561 1,680 1,808 1,947 2,095 3 0 Volume in MT
  • 4. Mozzarella Cheese - Customer Wise Volume FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 30,000 25,000 20,000 15,000 10,000 5,000 Installed Capacity Mozz 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 3,837 Total Projected Volume 4,723 5,596 6,762 8,213 9,959 11,705 13,820 16,387 19,508 23,310 27,948 Dominos 2,034 2,712 3,666 4,885 6,376 7,867 9,707 11,977 14,777 18,233 22,496 Pizza Hut 1,445 1,590 1,749 1,924 2,116 2,308 2,517 2,746 2,995 3,267 3,563 Others 1,244 1,294 1,347 1,404 1,467 1,530 1,596 1,664 1,736 1,810 1,888 4 0 Volumes in MT
  • 5. Schreiber Dynamix Dairies, Ltd. Baramati Plant 5
  • 6. Status of Baramati Plant 6 • 1 Mn Liters per Day : Present Milk Handling Capacity • Aug 2014 : Target of Commercial Production From New Dryer • 1.6 Mn Liters per Day : Post Expansion Milk Handling Capacity • 435 Mn Lbs per Annum : Manufacturing Capacity • Upto 1,480 Partners : Currently Deployed including 740 contractual partners • 110 Customers : Currently Being Served
  • 7. Challenges in Baramati  Milk : Demand exceeds supply  Space for Expansion : 9,693 Sq. Mtr Ground space available (Against permitted limit of 50 % Ground Coverage, 40 % already covered) 7
  • 8. Challenges in Baramati  Utilities  Water Availability - A major constraint, highly dependent on Monsoon  Maximum utilization of Utilities already achieved  Manpower  50 % Manpower comprises of Contract Labor - upto 740 partners per day  Availability of contractual partners - A major challenge  To manage a plant with more than 1,000 partners during some periods is almost impossible. Social risk is jeopardizing the future of Schreiber Dynamix 8
  • 9. Data : Jan 2012 till Aug 2013 (Avg. daily milk processing) 0.27 0.25 0.09 As Is Capacity Actual Utilization % Utilization SMP Produced in both Dryers to meet market demand 0.03 0.05 0.02 0.08 0.20 0.20 0.09 0.02 0.05 0.02 0.02 75% 81% 104% 85% 97% 92% 22% 120% 100% 80% 60% 40% 20% 0% 0.30 0.25 0.20 0.15 0.10 0.05 - Milk Reception Pre-process SMP Dairy Whitener Cheese UHT Casein Utilizaiton (%) Raw Milk (M Gal) Sections 9 Challenges in Baramati – Optimum Capacity Utilization All Product lines fully utilized except Casein
  • 10. Opportunity offered by decentralization - Plant in South India  Customer demands are increasing – Unable to cater growing demands of Cheese (Cheddar & Mozz)  Set up strategic alliance with SDDL – Nutricia (Danone) for a Greenfield project  Customers like Britannia, Pizza Hut, Dominos and many more want us to decentralize operation to meet any contingency & Optimize logistic costs 10
  • 11. Opportunity offered by decentralization - Plant in South India • Consistent availability of Milk. Milk availability within radius of 150 kms – 3.1 Mio liters per day  Andhra Pradesh : 1.10 Mio liters per day  Tamil Nadu : 0.94 Mio liters per day  Karnataka : 1.10 Mio liters per day  36 acres land acquired & Legal clearance obtained for Industrial construction 11
  • 12. Opportunity offered by decentralization - Plant in South India  Water availability  Water source - Ground Water  Water Survey Conducted  Good potential zone for ground water availability  Manpower  Available  Needs to train on Technical Skills & GMP  Other Utilities  Built as per need 12
  • 14. Plant Location Delhi Existing Plant Baramati, State Maharashtra Proposed Plant Kuppam, State Andhra Pradesh Population : 7 Mio in 100 KM radius 14
  • 15. Plant Location TELANGANA STATE Newly Separated Out From Andhra Pradesh KUPPAM Andhra Pradesh 15
  • 16. Proposal  Establish Second Manufacturing Facility in Kuppam in Andhra Pradesh – Growth Opportunity for Schreiber Dynamix  Products proposed :  Cheddar & Mozzarella for Britannia, Dominos & Pizza Hut  Infant Formulation (IF) & Follow On (FO) for Nutricia (Danone)  Milk Powder 16
  • 17. Assumptions  Milk Cost will be  At actual with Danone and Cheddar cheese.  Fix for Skim Milk powder and Mozz Cheese  Local Manpower will be trained to improve skills  Required quantity of Biomass Briquettes will be available  Separate AR will be made for Bulk Coolers 17
  • 18. Daily Raw Milk Requirement (Without Danone) 0.45 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 Year 18 FY17 FY18 FY19 FY20 FY21 FY22 FY23 Cheese - Cheddar + Mozzarella 0.20 0.23 0.25 0.29 0.39 0.39 0.39 0.00 Mio Ltrs
  • 19. Year Wise Production – Cheese (Without Danone) 18000 16000 14000 12000 10000 8000 6000 4000 2000 Year 19 FY17 FY18 FY19 FY20 FY21 FY22 FY23 0 Cheese - Cheddar + Mozzarella 6210 6986 7652 9096 11984 11984 11984 MT /Year YOY Growth 9.5% 18.9% 31.7% 31.7% 31.7%
  • 20. Tentative Cost Estimates (Without Danone) Exchange Rate : 1USD = INR 60 20 Sr. Description Mio INR Mio USD 1 Land development & Civil Cost 655 11.10 2 Processing Equipment 1,296 21.97 3 Utilities 925 15.68 4 Laboratory Equipment 48 0.81 5 Finished Goods + Engineering Stores 114 1.93 6 Engineering charges & Statutory approvals 25 0.42 7 Startup Expenses 15 0.25 8 Contingencies 62 1.04 9 Travelling & Administrative expenses 46 0.78 Total Tentative Expenditure 3,186 54.00
  • 21. Saving Calculations ( Without Danone) FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 Total Volume (Mio lbs /year) - - - 23.54 26.39 29.31 34.35 43.63 43.63 43.63 Average VI (USD /year) - - - 0.31 0.31 0.31 0.31 0.31 0.31 0.31 Net Savings (Mio USD / Year) - - - 7.21 8.09 8.95 10.54 13.58 13.58 13.58 Estimated Investment (Mio USD) - - - 54.00 54.00 54.00 54.00 54.00 54.00 54.00 ROI % - - - 13% 15% 17% 20% 25% 25% 25% Spending Plan (Mio USD) 4.00 30.00 20.00 - - - - - - - 21
  • 22. Daily Raw Milk Requirement (With Danone) 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 Year 22 FY17 FY18 FY19 FY20 FY21 FY22 FY23 Mn Ltrs Total Milk 0.20 0.23 0.54 0.55 0.55 0.58 0.63 Danone IF,FO, Others & SMP 0.11 0.14 0.17 0.20 0.24 (Including Proteinex base) SMP 0.17 0.12 0.00 0.00 0.00 Cheese - Cheddar + Mozz. 0.20 0.23 0.25 0.29 0.39 0.39 0.39
  • 23. Year Wise Production – Cheese, Danone & SMP 25000 20000 15000 10000 5000 0 Year 23 SMP production stop due to increase in production for Danone FY17 FY18 FY19 FY20 FY21 FY22 FY23 MT / Year Danone IF,FO, Others & SMP (Including Proteinex base) 9,233 11,105 13,357 16,067 19,327 SMP 4,792 3,195 - - - Cheese - Cheddar + Mozz. 6,210 6,986 7,652 9,096 11,984 11,984 11,984
  • 24. Additional Tentative Cost Estimates (for Danone) Exchange Rate : 1USD = INR 60 Sr. Description Mn INR Mn USD 1 Land development & Civil Cost 144 2.16 2 Processing Equipment 1,421 23.24 3 Utilities 275 4.21 4 Laboratory Equipment 15 0.24 5 Finished Goods Stores 59 0.96 6 Engineering charges & Statutory approvals 13 0.21 7 Startup Expenses 15 0.25 8 Travelling & Administrative expenses 7 0.12 9 Contingencies 46 0.77 Total Tentative Expenditure 1,995 32.16 * * Will be adjusted after meeting with Danone 24
  • 25. Saving Calculations (With Danone) FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 Total Volume (Mio lbs /year) - - - 23.54 26.39 63.17 67.62 71.82 78.93 87.48 Average VI (USD /year) - - - 0.31 0.31 0.34 0.35 0.38 0.38 0.38 Net Savings (Mio USD / Year) - - - 7.21 8.09 21.52 23.84 27.13 29.93 33.29 Estimated Investment (Mio USD) - - - 54.00 54.00 86.16 86.16 86.16 86.16 86.16 ROI % - - - 13% 15% 25% 28% 31% 35% 39% Spending plan (Mio 4.00 30.00 20.00 20.00 12.00 - - - - - USD) 25
  • 26. Product wise VI and ROI Calculation (Without Danone) Sr. Product Production lbs /day VI (INR /lbs) VI (USD /lbs) Total VI / day (Mio USD) 1 Cheddar Cheese 19,841 22.68 0.378 0.0075 2 Mozzarella Cheese 19,841 27.22 0.454 0.0090 3 Non Hygroscopic Whey Powder 19,841 11.34 0.189 0.0038 4 FAT 8,708 4.54 0.076 0.0007 Total VI per day 0.0209 Total days of operation per year 345 Total VI per annum 7.21 Total investment in Mio INR 54 ROI 13% 26 First Full Year Of Saving - FY17
  • 27. Product wise VI and ROI Calculation (With Danone) Sr. Product Production lbs /day VI (INR /lbs) VI (USD /lbs) Total VI / day (Mio USD) 1 Cheddar Cheese 24,449 22.68 0.378 0.0092 2 Mozzarella Cheese 24,449 27.22 0.454 0.0111 3 Demineralized Whey Protein (DWP 28%) 7,275 25.40 0.423 0.0031 4 FAT 39,021 4.54 0.076 0.0030 5 Danone IF, FO and OTHERS 58,995 27.22 0.454 0.0268 6 SMP 30,622 18.14 0.302 0.0093 Total VI per day 0.0624 Total days of operation per year 345 Total VI per annum 21.52 Total investment in Mio INR 86 ROI 25% First Full Year Of Saving - FY19 27
  • 28. Project Highlights – Without Danone  Establish 2nd Manufacturing Facility in Kuppam, Andhra Pradesh  Total Investments : USD 54 Mio  Estimated VI per annum : USD 7.21 Mio  ROI (*) : 13.36 %  Products proposed : Cheddar & Mozz Cheese SMP & Whey Powder (*) First Full Year Of Saving - FY17
  • 29. Project Highlights – With Danone  Augment Infrastructure to cater for Nutricia (Danone)  Additional Investments : USD 32.16 Mio  Total Investments : USD 86.16 Mio (USD 54 Mio + USD 32.16 Mio)  Estimated VI per annum : USD 21.52 Mio  ROI (*) : 25 %  Products proposed : Infant Formulation (IF) & Follow On (FO) for Nutricia (Danone) (*) First Full Year Of Saving - FY19
  • 31. Project in Brief  Availability of water for plant operations has become challenge.  SDDL present water requirement is 3,058 M³/day.  During 2013 Summer, we had average shortfall of 757 M³/day.  Additional water of 1,500 M³/day needed post Nestle dryer in operation.  This may lead to average shortfall of 2,257 M³/day if similar drought situation repeats.  We can treat COW water coming out from new Evaporator of Nestle Dryer project & can purify COW water about 450 M³/day.  There is a separate AR for water recycling proposing to generate 900 M³/day of water from existing evaporators, CIP flushing and WTP backwash.  Still there will be shortfall of 907 M³/day.
  • 32. Cow Water Treatment Plant New Evaporator
  • 33. COW Water Treatment Project Summary Installation of Cow Water Treatment Plant with following parameters: 1) Installation of Filtration unit to process 24.4 KLPH evaporator Condensate (COW) Water from new evaporator. 2) Treatment plant output 21.9KLPH at 90% recovery rate. 3) The plant will be designed to operate for 20hrs/day. 4) The treated permeate will be used to replace Raw/soft water in process CIP and secondary applications. • Estimated Investment – USD 735,356 • Expected Savings – USD 99,522 • Expected ROI – 13.5%
  • 34. COW Water Treatment Project Investment Sr. Description Amount (USD) 1. RO Polishing Unit, Skid Mounted with MCC and Control Unit, Feed Rate 24.4KLPH, RO Permeate Rate 21.9KLPH, Recovery Rate 90% 414,206 2. Buffer Tank (20KL), Pump, PHE, UV System with 2 lamps (Hitech), Activated Carbon Filter (Ion Exchange), etc. 184,909 3. Utility Piping, Valves upto Battery Limits 20,600 4. Electrical cables and switchgears for Power Supply and Lighting 10,800 5. Fabrication of platforms, supporting structures and monorails 10,800 6. Chemical storage and dosing system 10,800 7. Maintenance Spares for 1 year 50,000 8. Civil construction with metal sheet roof including drainage 22,941 9. Civil foundations for equipment installation 10,300 Total Investment for COW Water AR 735,356
  • 35. COW Water Treatment Project Savings Calculations Sr. Description Unit Treated COW Water Quantity Average Tanker Water Charges Total Savings M³/day M³/Year USD/M³ USD/Year 1 Reduction in Tanker Water with COW Water Treatment M³/ year 438.98 151,448 1.27 192,603 2 Less Plant Operating Cost USD/ Year 438.98 151,448 (82,608) 3 Less Plant Operations Manpower Cost USD/ Year 4 Partners / day (10,473) Total Water Reduction M³/year 151,448 Net Savings --> 99,522 Estimated ROI: 13.5%
  • 36. Water Recycling Project (COW water – Existing Evaporator, CIP Rinse/Flushing and WTP Back Wash)
  • 37. Water Recycling Project Summary Install Water Treatment/Purification Plant with following parameters: 1) Installation of water purification plant for existing evaporator COW water, CIP final rinse/flushing & WTP back wash water. 2) Approx. 1,150 m3/day water will be treated and output capacity would be 900 m3/day with recovery rate 78.3%. 3) The plant will be designed to operate for 19hrs/day. 4) The treated permeate water quality will be as potable BIS standard 10500 and this will blend in reservoir tank • Estimated Investment – USD 936,960 • Expected Savings – USD 217,466 • Expected ROI – 23.2%
  • 38. Water Recycling Project Investment Sr. Description Amount (USD) 1. Water treatment Plant 60m3/hr 465,747 2. RZ-163-12- Inline Hydro Optic Disinfection 76,235 3. CIP Kit & Accessories 6,072 4. Flow Meter 4" Size or Flow Switch 10,794 5. Aseptic Sampling Valve 2,699 6. Ballast Thermo Control Cabinet 8,096 7. Utility Piping, Valves upto Battery Limits 147,273 8. Electrical cables, switchgears for Power Supply & Lighting 19,636 9. Fabrication of platforms, supporting structures and monorails 39,273 10. Chemical storage and dosing system 29,455 11. Spare 1KW UV Lamp 1,598 12. Start-up & Training 10,300 13. Civil construction and foundations for equipment installation 49,091 14. Equilization Tank 300 KL 70,691 Total Investment for Water Recycling AR 936,960
  • 39. Water Recycling Project Savings Calculations Sr. Description Unit Quantity of Treated Water Average Raw water cost (MIDC+Tanker) Total Savings M³/Year USD/M³ USD/Year 1 Water avialable for reuse M³/ year 273,600 1.08 294,178 2 Less:- Plant Operating Manpower Cost USD/ Year - 3 Less:- Plant Operating Cost (Utilities/Chemical/Maint) USD/ Year 273,600 0.40 (109,440) 4 Benefit:- WWTP treatment cost reduction. Considering stoppage of 1 stream of 500M³/day, times 300 days/year USD/ Year 150,000 0.22 32,727 Total Water Reduction M³/ year 273,600 Net Savings --> 217,466
  • 40. Dryer Revamping for Baby Food Products 31 Oct 13
  • 41. SCOPE STATEMENT SDDL DANONE Civil work for Wet Blending set up & its CIP station. Wet Blending Set up all Equipment. Utility lines from battery limit for wet blending set up. CIP station for Wet blending equipment. Pipe lines for Product / Milk transfer to & fro from wet blending set up. Electrical panel, PLC Control for wet blending set up. Puf paneling for Isolation of Mineral Dryer from other facilities. Provision for Interfacing of the New PLC with existing PLC. Dryer Concentrate Vat replacement with Hygienic design & CIP system for the same. Veg Oil unloading facility. Fluidized bed flex plate replacement. Fines Recovery system modification. Crack Test to be carried out for Dryer. Ventilation system for all floors at Dryer. Filtration level - G4, F7, H10 HVAC for Powder packing. Humidity control will be provided. Filtration - G4, F7, H10 Sealing machine for sealing two liners & Nitrogen flushing provision. (New machine).
  • 42. SCOPE STATEMENT SDDL DANONE Balance tank replacement at Evaporator with Hygienic design. Main Air Supply fan Filtration system modification to take atmospheric air only. Filtration G4, F7, H10 Epoxy coating for floor at Dryer. Vendor suggested Brit Proofings. Separate entry for Lactose Dryer. Wet Cleaning Automation. Cold Fluid bed Dehumidifier replacement and relocation. Provision of Dehumidifier for Root Blower. Relocation of dehumidifier on terrace. Gravity feed Metal Detector before packing. Sensitivity : SS 1.2 mm Relocation of Filtration system of Fluid bed blowers. Isolation of Wet area (HPP & Concentrate vats) in Dryer with separate entry. (GA in slide no.9)
  • 43. Tentative Execution Schedule Activity Period Week 1 Week 2 Week 3 Week 4 Week 5 Construct walls with PIR sandwich panels 4 Weeks Epoxy coating of Floors & Structure 1 Week Fines Return & Fluid bed revamping 2 Weeks Dryer Wet section Revamping 2 Weeks Ventilation system for Dryer & Packing 3 Weeks Balance Tank replacement at Evaporator 2 weeks Air Intake Filtration system modification 2 weeks Wet Cleaning Automation 4 Weeks • Wet Blending set up installation is Offline activity & not considered here. • Activities those require total Dryer shutdown are only considered. • Crack Test will be done separately & thus not considered.
  • 44. Cost Estimate Activity Estimated Investment (INR) Estimated Investment (USD) Isolation of Dryer from other production area. 16,443,482 274,058 Crack Test of Dryer 1,444,065 24,068 Air Supply Fan modifications and Provision of Hepa filteration for all Fans / Blowers 12,734,630 212,244 Evaporator Balance tank replacement with Hygenic Design 405,875 6,765 Cyclone Modification 29,499,893 491,665 Vacuum cleaners 1,500,000 25,000 Gravity Feed Metal Detector & auto sampler for powder packing 5,561,620 92,694 Laboratory Equipments * 4,100,000 68,333 Air Ventilation System for Dryer and Powder Packing 14,390,229 239,837 Wet Cleaning Automation 16,961,866 282,698 Civil Building & utilities provision for Wet Blending set up 23,080,158 384,669 Engineering & Project Management 1,500,000 25,000 Nitrogen Plant Capacity Upgrade 4,000,000 66,667 Repairs after Crack test 5,000,000 83,333 Electrical cable rerouting at Dryer due to civil modification 2,000,000 33,333 Crane Charges and Labor Charges 2,500,000 41,667 Insurance 100,000 1,667 Contingencies (10%) 13,614,682 226,911 Estimated Investment 154,836,500 2,580,608 Danone Investment for Wet Blending set up 46,922,500 782,042 Estimated Investment (with Danone) 201,759,000 3,362,650 Euro 1 = INR 85, USD 1 = INR 60
  • 45. EQ Audit Compliance EQ Audit Compliance SDDL Recommendation Activity Estimated Investment (INR) Estimated Investment (USD) Euro 1 = INR 85, USD 1 = INR 60 Estimated Investment (INR) Estimated Investment (USD) Roof Replacement (2,900 Square meter) 2,651,228 44,187 1,325,614 22,094 CIP Kitchen for Dryer and Independent CIP arragement for Fluidized bed 20,000,000 333,333 20,000,000 333,333 Removable Thermal Insulation Panels 15,107,149 251,786 - - New Filler 31,058,438 517,641 - - Flexible connections to replace 4,209,132 70,152 4,209,132 70,152 boots and flanged connections Contingencies (10%) 7,302,595 121,710 2,553,475 42,558 Estimated Investment 80,328,542 1,338,809 28,088,221 468,137
  • 46. Cheese Expansion at Baramati 31 Oct 13
  • 47. Project in Brief  Existing Cheese capacity - 630 MT / Month. (Mozzarella 460 MT & Cheddar 170 MT).  Proposed Cheese capacity - 950 MT / Month. (Mozzarella 650 MT & Cheddar 300 MT).  Existing Cheese manufacturing set up will be used for Cheddar production.  New set up will be installed on adjacent terrace and will be used for Mozzarella production.  Old Cheese manufacturing Equipments will be purchased from Tine Dairy, Norway without EPCG benefit.
  • 48. Volume Projections FY 13 FY 14 FY 15 FY 16 FY 17 MT/ year Mozzarella 4,720 5,600 6,760 8,210 9,960 Cheddar 2,950 3,270 3,730 4,120 4,520 Total 7,670 8,860 10,500 12,340 14,470 Current Plant Capacity 7,560 7,560 7,560 7,560 7,560 Proposed Plant Additional Capacity 3,840 3,840 3,840 Proposed Capacity After expansion 11,400 11,400 11,400 Additional Volume 2,940 3,840 3,840 SMP Production with additional Milk capacity generated due to on line milk standardization (Kg / month) 73,000 73,000 73,000 SMP VI USD / Kg 0.33 0.33 0.33 Cheese VI USD / Kg 0.37 0.37 0.37 Additional Differential VI Generated per year for Cheese (USD) 1,078,000 1,408,000 1,408,000 Additional VI Generated per year for SMP (USD) 292,000 292,000 292,000 ROI 35.2% 43.6% 43.6% USD 1 = INR 60, Euro 1 = INR 85
  • 49. Commercials  Estimated Investment : USD 3.89 Mio  Estimated Savings : USD 1.37 Mio  Estimated ROI : 35.15%

Editor's Notes

  • #8: Not Clear. Don’t be too detailed. Just state we can’t get more milk and demand is growing.
  • #9: Water availablilty, just make a bullet point somewhere. Not half a slide. Manpower – add a line stating “Having to manage a plant with more than 1,000 partners during some periods is almost impossible). Social risk is jeopardizing the future of Dynamix.
  • #12: Opportunity offered by Decentralization instead of Need Major point is we have customers in the South, not overcoming constraints in Baramati – specifically mention large customers (Brittania, Danone, Danone Nutrition)
  • #13: Water availablilty, just make a bullet point somewhere. Not half a slide. Manpower – add a line stating “Having to manage a plant with more than 1,000 partners during some periods is almost impossible). Social risk is jeopardizing the future of Dynamix.
  • #17: Add yogurt for Danone and maybe Britannia????