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INTRODUCTION

1.1 General

Vegetables are rich source of vitamins, carbohydrates, salts and proteins. With increased health awareness in the general public and changing dietary patterns, vegetables are now becoming an integral part of average households daily meals. In addition, high population growth rate has also given rise to high demand in basic dietary vegetables. Increased health awareness, high population growth rate, changing dietary patterns of increasingly affluent middle class and availability of packaged vegetables, has therefore generated a year round high demand for vegetables in the country in general and in major city centers in particular. However, our farmers have yet not been able to cash this opportunity and still follow traditional sowing and picking patterns. This results in highly volatile vegetable supply market wherein the market is flooded with seasonal vegetables irrespective of demand presence on one hand and very high priced vegetables in off-season on the other. Lack of developed vegetable processing and storage facility robs our farmers from their due share of profit margins. In natural season local vegetables flood the markets substantially bringing down the prices. In the absence of storage infrastructure and vegetable processing industry in the country, off-season vegetables farming is the only viable option that can add value to the farmer produce. The term plastic culture is used to describe the broad and general use of plastics in agriculture. Plastic culture can extend the growing season and improve crop health and growth. 1.4 Advantages

Benefits from year-round production include year-round income, retention of old customers, gain in new customers, and higher prices at times of the year when other local growers (who have only unprotected field crops) do not have produce. Other potential benefits of season extension technologies are higher yields and better quality. In summers for off season vegetables cultivation high quality indeterminate seed is easily available in markets. This indeterminate seed grows upwards with provided support similar to Pumpkin instead of spreading on ground Therefore Tunnel farming has increased the production of plants in even smaller areas, which is turned out to be profitable. Small farmers with small cultivating area can get benefits from plastic tunnel farming and can increase their income. In plastic tunnel farming, problems due to less supply of water are alleviating by using drip system irrigation. In addition, with year-round production you can provide extended or year-round employment for skilled employees whom you might otherwise lose to other jobs at the end of the outdoor growing season. Disadvantages include no break in the yearly work schedule, increased management demands, higher production costs, and plastic disposal

problems. 1.5 Farm Size

The proposed project is based on a land holding of 7.5 acres; however the distance of the farm from the market will determine the feasible size of the project. Near large markets like Lahore, projects with smaller land holdings can be a viable option, but large land holdings are recommended for projects that are planned away from large markets. 1.7 Process Flow Chart

Figure 1-2: Production flow of off- season vegetables

NURSERY/ SAPLING

FIELD BED PREPARATION

SOIL FERTILIZING

NURSERY TRANSPLANTATION

HARVESTING

TOP DRESS FERTILIZING

PLANT PROTECTION

MOISTURE CONDITIONING

GRADING

POST HARVESTING ASPECTS

SHIPMENT/ DESPATCH

1.8

Production Flow of off-season vegetables

The production flow varies slightly for different vegetables. The following production flow is based on the production of tomatoes: i. Sowing of seeds in a separate plot of land for nursery. ii. Preparation of seed beds in the field for cultivation of vegetables. iii. Using fertilizer in the soil to maintain its fertility. iv. Transplantation of nursery in the soil or sowing of seeds directly in the soil. v. Maintaining level of moisture in the soil. vi. Protection from the pests, diseases and other wild growths by using pesticides/sprays of chemicals, and trimming. vii. Using fertilizer of different varieties for the smooth growth of plantation. viii. Picking/harvesting at various times as per nature/requirement of the plantation. ix. Grading of crop on the basis of quality and other standards. x. Application of post harvesting technology for picking/plucking, packing and storing the vegetables in order to fetch the maximum price. xi. Transportation to the sale points in local or export markets.

CURRENT INDUSTRY STRUCTURE


Vegetables Can Be Sown Growing under plastic is more competitive in todays vegetable market, it gives superior yields and early spring production. Following crops are high value vegetables and has shown significant increase in earliness. Melons Squashes Tomato Water melon Brinjal Pepper Cucumber Bitter Gourds

TECHNICAL ANALYSIS
3.1 Plantation & Growth Essentials There are 15 essential requirements for healthy growth of a plant. The requirement and their respective sources are provided in the following table: Figure 3-1: Plantation growth essentials SOURCE Air & Water Land Carbon, Hydrogen, Oxygen, Nitrogen, Phosphorus and Potash Molybdenum, Manganese and Chlorine REQUIREMENT

3.2

Fertilizers on Production

Using fertilizers containing Nitrogen, Phosphorus and Potash the yield of the crop can be maximized. Appropriate quality and quantity of fertilizer plays a great role in the production and quality of vegetables. 3.3 Sowing & Picking period of off-season vegetables

Following are sowing and picking periods of selected off-season vegetables in their respective normal growing seasons:

Table 3-1 sowing and Picking period for the selected off-season vegetables Vegetables Tomato Brinjal Sowing Period October (Nursery) November (transplantation) October (Nursery) Picking Period February-May February-May

Squashes Cucumber

Sweet pepper/ Hot pepper

November (transplantation) End of October to 1st week of November (direct seeding) End of October to end of December (direct seeding) Mid of September to 1st week of October. End of Oct. to November (Transplantation) to 1st week

End of December to April Mid January to May End of January to September

3.4

Off-season cultivation methods

There are number of ways and methods to cultivate vegetables in off-seasons. Some of the methods are explained as under: 3.4.1 Artificial Methods Vegetables can be grown in off-season through artificial methods; the details of these methods are given below: Growing Beneath the Sarkanda This is an old method and is usually adopted near the big cities. The main vegetables grown under this method are tomato, chili, cucumber, and bottle gourd. The nursery of these vegetables is planted in October/November and a wall of Sarkanda is affixed in the direction of North South, which protect plant from cold winds and mist. This method of cultivation is not beneficial because the growth of the plant tends to be slow, as the plant does not receive required sunshine and desired humidity. Building of Green Houses Through building green houses, the sunshine intensity is controlled. The vegetables under this method are grown mostly in the winter season. Here the temperature, humidity, carbon dioxide, ventilation of air and irrigation etc. is controlled. Green houses can be built of plain glass or of fiberglass material. The main drawback in the usage of this method is heavy capital cost. Plastic Tunnel Cultivation by this method is gaining popularity because of low cost and easy usage. Plastic tunnels are transparent which provides required sunshine to the plants, and the plastic also plays a barrier against the cool air in winter. 3.5 Structures Various types of structures are available to lengthen the growing season for the crop and improve overall crop health and quality. The following are just a few of the structures available, such as high tunnels, low tunnels, walk-in tunnels, and greenhouses. Structures that are used for winter production must be able to withstand heavy rainfall, snow, and wind. Structures that are used for summer production must have good ventilation. Many structures may not be suitable for year-round production. In the construction of tunnel the major materials involved are mild steel bars and plastic sheets. Plastic sheets are used for roof covering of the tunnel shaped construction, which is built with steel bars. Bamboo lengths can also be used in some proportion with the mild steel bars. Plastic sheet is to be spread in such a manner that it enables the stoppage of cold air from outside. The tunnel construction offers maximum crop yield, better maintenance of the fertility of land, controlled temperature and humidity, protection from wild animals and insects and better water conservation. There are three types of tunnels, known as high, low and walk-in tunnels. 1. Low Tunnel

It is cheaper than high tunnel but creates difficulty for soil preparation, spraying and picking. The tunnels are suitable for cucumber sown flat bed, melons, watermelons, bitter gourds, squashes, and snake gourds etc. The crop yield in this type of tunnel is however low compared to high tunnels. Figure 3-2: Low Plastic Tunnels
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2. Walk-in Tunnels Walk-in tunnels are lower than the high tunnels but they are gaining popularity as they provide high yield compared to low tunnels. The tunnel is suitable for growing tomatoes, cucumbers, sweet pepper and hot pepper. Figure 3-3: Walk-in Tunnel

3. High Tunnel

High tunnel facilitates easy access for soil preparation, picking and spraying due to its width and height. Crops yield maximum in this type of tunnel. The tunnel is suitable for growing tomatoes, cucumbers and sweet peppers. Figure 3-4: Picture of High Tunnel

3.6

Recommended Tunnel

In this pre-feasibility study, cultivation is recommended with the use of low tunnels on the basis of its low construction cost. All the calculations are done on the basis of low tunnel technology. The specification of low tunnel is given in the following table: Table 3-2: Specifications of Low Tunnel Material Specification Pipe material Steel Mild steel, painted with red oxide paint Diameter 6 mm Length 10 ft Plastic 0.05 mm thick and 10 ft wide Height 2.5 ft, Shapes U alphabet and V alphabet Width 5 ft Length 190 ft No. of tunnels 30 per acre

Tunnel Specification

Support Structure Each tunnel will be 190 feet long, 2.5 feet high and 5 feet wide. The tunnel is built by 6-mm diameter steel bar of 10 feet length, in half moon shape. The steel bars are put at

regular intervals of approximately 10 feet. Each tunnel structure will then be covered by 0.05-mm thick and 10 feet wide plastic sheet. Approximately 30 tunnels can be constructed on an acre of land. Figure 3-5: Support structure in low tunnels

Seed and its Importance For tunnel cultivation, F1 hybrid seed bred for tunnel is used, because they have the ability to resist multiple diseases. These hybrid seeds cost more than the ordinary seeds. The productivity and quality of the crop is ensured from quality of these seeds. Hybrid seeds have above 90% germination capacity as compared to that of ordinary one. The ordinary seed is produced from the crop itself whereas hybrid seed is produced through a special process. For every crop, new hybrid seed needs to be purchased / sown. The crop yield achieved from hybrid seeds is 3 to 4 times more than to the ordinary seeds and is also less prone to diseases. Useful Tips for off-season vegetable farming Any person who is planning to adopt this technology should have some practical knowledge about farming. Land that is being utilized for off-season vegetable farming should be tested which will help in determining the quality of land for agriculture purposes. Farmer should ensure that the plant they are planning to grow must have the ability to self-pollinate under the plastic sheet. Selection of the seed is most important factor because this determines the productivity of the crop. Vegetables, which are in demand, should be cultivated; this will help in earning higher profit margins. Timing of cultivation of vegetables has to be done accurately. The farmer should have knowledge about the benefit that the early crop will offer and should gather data about the prices of these early crops.

4 LAND UTILIZATION
Table 4-1: Total Land utilization per Vegetable Vegetables Tomato ( Determinate) Capsicum Cucumber (Perth.) 4.1 A Soil Preparation and Sowing Laser leveling or with any precise method soil should be properly leveled Deep ploughing and harrowing. Apply well decomposed FYM 6 ton per acre or green managing is recommended at least 60 days before sowing. Apply basal dose chemical fertilizer one month before sowing followed by irrigation.

(Acres) 2.5 2.5 2.5

4.2 Mode of Land Acquisition

Prepare soil, complete beds & mulching one week before sowing. Irrigation field after seeding in such a way that moisture should reach the seed place. After few days light irrigation should be repeated to assure the proper moistures at seed place.

Agricultural land can be taken on lease or purchased for the implementation of the proposed project. 4.3 Material Availability Tunnel material i.e. mild steel bar, Plastic Sheet, Iron Wire, Bamboo, is available locally from different suppliers. Syngenta Pakistan ltd and hajji sons are the major suppliers of hybrid seeds. Fertilizers of all kinds are available locally. Pesticides of different natures are also available locally. For water we use electric tube-well is available.

4.4 Expected Production and Sale price

LOW TUNNEL (MADE BY BAMBOO STICKS) Sr. No. 1 2 3 4 5 6 CROP Seed Count 16000 17000 17000 16000 14000 17000 Actual Plants 12000 14000 14000 13000 12000 14000 Yield/Plant (Kg) 2 1.5 1.5 2.5 4 2 Total Yield (Kg) 24000 21000 21000 32500 48000 28000 Price per (Kg) 12 15 15 8 6 10 Total Sales 288000 315000 315000 260000 288000 280000

Tomato Cucumber Bitter Gourd Bottle Gourd Water Melon Melon

Equipments & Machinery: Following equipments and machinery is required for an off-season vegetable farm of 7.5 Acres: Description Tractor (deep ploughing etc) Spray Machine (Elect. Charging) Motor Bike (Used) Tube well Other Tools Total Amount Unit Cost (Rs.) 6000 8000 40000 60000 30000 Total Amount 45,000 8000 40000 60000 30,000 183,000 Type of Investment R F F F F

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6.1

HUMAN RESOURCE REQUIREMENT


Number of Staff Required

Table 6-1: Number of Staff & Officers required Description Number Monthly Salary Per Person(Rs.) Farm Manager Labor Labor
(Daily Wagers)

Annual Salary(Rs.) 180,000 192,000 336,000 708,000

1 2 4

15000 8000 42000

Total *Daily wagers are required for almost 8 months a year.

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7.1

INFRASTRUCTURE REQUIREMENT
Total Land and Building Covered Area

ANTICIPATED ESTIMATE OF INCOME FOR TUNNEL FARMING


LOW TUNNEL (One Acre)

S. No 1 2

ITEMS Land improvement Land improvement Land leveling and deep ploughing etc Bamboo or Mulberry Sticks for structure Plastic (White) Plastic (Black) Mulching Seed (Bitter gourd) Fertilizers Pesticides Ropes Water Miscellaneous TOTAL

SPECIFICATIONS By green manuring. Guara and Jantar. Organic matter. F.Y.M. / Poultry manure. 10 Trolleys Chisel plough + Rotavator + Leveler + Cultivator. Self by tractor 1400 pieces (10 ft long each) 90 kg (4 gauge) 25 kg (2 gauge) F-1 Hybrid special for Tunnels As per need and soil As per program, crop & need Tube well irrigation (Sarya and labor not added) 550 pieces of 2 (sootar) (10 feet long)

PRICE QUANTITY / UNIT 4000 1000 1 10

TOTAL Investment 4000 10000


F. F

Type of

6000

6000

4 5 6 7 8 9 10 12 13

8 190 205 1.5 30000 10000 2500 2000 5000

1400 90 25 16000 1 1 1 (3) months 1

11200 17100 5125 24000 30000 10000 2500 6000 5000 130925

F F R R R R F R R

4 a)

50800 80125 Note: The cost of project may greatly vary depending upon the choice of tunnel material, nutritional requirements and selection of seed.

If replaced by Iron (Sarya) If made by Sarya Fixed Costs Running Costs

140

350

49000 168725

Table 7-2: Expenses Assumptions Raw Material price growth rate Water cost per Irrigation per Acre (Rs.) Irrigation (No. of Months) No. of times land irrigated (per month) Fixed Electricity per Month Maintenance Cost of Tunnel Structure Machine Maintenance Growth Rate 5% 668 5 3 6,000 3,000 5%

8 PROJECT ECONOMICS
Table 8-1: Project Cost Description Land Equipments and Machinery Pre-operational Expenses Human Resource Maintenance Cost of Tunnel Structure Electricity Bill Total Cost Cost (in Rs.) 22,500,000 183,000 105,000 876,938 22,500
72,000

23,759,438

Table 8-2: Total Fixed Cost Description Tunnel Construction Pre-Operating Expense Equipments and Machinery Tube well Land Total Fixed Cost

Unit Cost (Rs.) 36800*7.5 14000*7.5

Total Amount 276,000 105,000 83,000 60,000 22,500,000 23,024,000

Table 8-3: Total Running Cost Description Tunnel Tractor Human Resource(Total) Maintenance Cost of Tunnel Structure Electricity Bill Total Running cost Table 8-4: Projects Return Project Internal Rate of Return (IRR Net Present Value (NPV) (in Rs) Payback Period (Years) 32.49% 636,750 3.357 6000*12 72,000 14,484,38 3000*7.5 Unit Cost (Rs.) 80125*7.5 6000*7.5 Total Amount 600,938 45,000 708,000 22,500

Table 13-2: Economy related Assumptions Electricity Growth Rate Water price growth rate Wage Growth Rate 10% 10% 5%

9 KEY SUCCESS FACTORS


9.1 The commercial viability of the project depends upon the regular and consistent supply of good quality hybrid seeds and fertilizers. The other important aspect is the need for strong linkages with the local market and progressive vegetable exporter. Guidelines for successful cultivation 1. Use of high quality hybrid seeds. 2. Having and maintaining fertility of land within the tunnel during the period of cultivation.

Following principles need to be pursued for the best productivity of vegetables:

3. Selection of profitable vegetables on the basis of best analysis of cost and revenues for a given season. Cost efficiency through better management. 4. Timely control of pests, diseases and exercise of preventive measures. 5. Maintenance & control of internal temperature & humidity in the tunnel. 6. Timely irrigation and fertilization. 7. Timely training and grading of plantation. 8. Expansion in customers market. 9. Fertilization should be done at the soil bed preparation stage. The second fertilization, after 3 weeks interval the third after 6 weeks and finally during the harvesting period. 10. Post harvest includes protection from direct sunlight and speedy transport to the market. 11. Proper soil analysis for determining soil nutritional level.

10 THREATS FOR THE BUSINESS


o Crop failure in any year. o Effect of change in the government regulations. o Absence of crop insurance.

11 OPPORTUNITIES FOR THE BUSINESS


Hybrid seeds that provide higher yield can lead to lower unit cost. Off-season cultivation of high value vegetables will fetch better price and provide continuous supply to the processing industries. Higher prices can be obtained by producing the right crops, at the right times and of better quality. They may also depend on negotiating skills and targeting high price buyers.

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FINANCIAL ANALYSIS
12.1 Projected Income Statement
Const Year Sales COST OF GOODS SOLD Raw Material Payroll (Production Staff) Machine Maintenance Direct Electricity Diesel Oil Direct Water Plastic Cost Total Gross Profit OPERATING EXPENSE Payroll (Admin) Payroll (Marketing and Sale) Fixed electricity Insurance Expense Administrative Overheads Amortization (Pre-operational Expenses) Transport Cost Packing Cost Depreciation Total Operating Profit Year-1 3,198,125 431,760 1,065,600 150,000 0 0 15,000 186,750 1,849,110 1,349,015 66,000 0 42,000 0 31,981 9,730 450,000 270,000 62,338 932,049 416,966 Year-2 3,358,031 453,348 945,000 157,500 0 0 16,500 149,400 1,721,748 1,636,283 69,300 0 46,200 0 33,580 9,730 472,500 283,500 62,338 977,148 659,135 Year-3 3,525,933 476,015 992,250 165,375 0 0 18,150 168,542 1,820,332 1,705,601 72,765 0 50,820 0 35,259 9,730 496,125 297,675 62,338 1,024,712 680,889 Year-4 3,702,229 499,816 1,041,863 173,644 0 0 19,965 174,051 1,909,338 1,792,891 76,403 0 55,902 0 37,022 9,730 520,931 312,559 62,338 1,074,885 718,006 Year-5 3,887,341 524,807 1,093,956 182,326 0 0 21,962 183,483 2,006,533 1,880,808 80,223 0 61,492 0 38,873 9,730 546,978 328,187 62,338 1,127,821 752,987 Year-6 4,081,708 551,047 1,148,653 191,442 0 0 24,158 192,475 2,107,775 1,973,933 84,235 0 67,641 0 40,817 9,730 574,327 344,596 62,338 1,183,683 790,249 Year-7 4,285,793 578,600 1,206,086 201,014 0 0 26,573 202,144 2,214,418 2,071,376 88,446 0 74,406 0 42,858 9,730 603,043 361,826 62,338 1,242,646 828,730 Year-8 4,500,083 607,530 1,266,390 211,065 0 0 29,231 212,240 2,326,456 2,173,627 92,869 0 81,846 0 45,001 9,730 633,195 379,917 62,338 1,304,895 868,732 Year-9 4,725,087 637,906 1,329,710 221,618 0 0 32,154 222,855 2,444,243 2,280,844 97,512 0 90,031 0 47,251 9,730 664,855 398,913 62,338 1,370,629 910,215 Year-10 4,961,342 669,801 1,396,195 232,699 0 0 35,369 233,997 2,568,062 2,393,279 102,388 0 99,034 0 49,613 9,730 698,098 418,859 62,338 1,440,059 953,221

NON-OPERATING EXPENSE Financial Charges on Long-term Loan Financial Charges on Running Finance Land Lease Building Rental Total PROFIT BEFORE TAX Tax PROFIT AFTER TAX Retained Earnings beginning of year Retained Earnings end of year

32,013 50,781 112,500 0 195,294 221,672 15,709 205,963 0 205,963

27,170 0 112,500 0 139,670 519,465 75,366 444,099 205,963 650,062

21,649 0 112,500 0 134,149 546,740 82,185 464,555 650,062 1,114,617

15,355 0 112,500 0 127,855 590,151 93,038 497,113 1,114,617 1,611,730

8,180 0 112,500 0 120,680 632,307 103,577 528,730 1,611,730 2,140,461

0 0 112,500 0 112,500 677,749 114,937 562,812 2,140,461 2,703,273

0 0 112,500 0 112,500 716,230 125,680 590,549 2,703,273 3,293,822

0 0 112,500 0 112,500 756,232 139,681 616,551 3,293,822 3,910,373

0 0 112,500 0 112,500 797,715 154,200 643,515 3,910,373 4,553,887

0 0 112,500 0 112,500 840,721 169,252 671,468 4,553,887 5,225,356

12.2 Projected Cash Flow Statement


Const Year Operating activities Net profit Amortization (Pre-operational Expenses) Depreciation Equipment Spare Parts Inventory Accounts payable Cash provided by operations Financing activities Long term debt principal repayment Lease Payment Lease Expense Addition to long term debt Running Finance Repayment Issuance of share Cash provided by/ (used for) financing activities Total Investing activities Capital expenditure Cash (used for)/ provided by investing activities Net Cash Cash balance brought forward Cash Balance Running Finance Cash carried forward Year-1 205,963 9,730 62,338 (625) 151,049 428,454 (34,593) (112,500) 112,500 (362,720) 591,385 707,550 695,050 (820,050) (820,050) (125,000) 0 (125,000) 362,720 237,720 (397,313) 31,141 0 0 31,141 237,720 268,861 0 268,861 Year-2 444,099 9,730 62,338 (656) (9,836) 505,675 (39,436) (112,500) 112,500 0 (39,436) 466,238 0 0 466,238 268,861 735,099 0 735,099 Year-3 464,555 9,730 62,338 (689) 7,061 542,994 (44,957) (112,500) 112,500 0 (44,957) 498,037 0 0 498,037 735,099 1,233,136 0 1,233,136 Year-4 497,113 9,730 62,338 (724) 7,414 575,871 (51,251) (112,500) 112,500 0 (51,251) 524,620 0 0 524,620 1,233,136 1,757,756 0 1,757,756 Year-5 528,730 9,730 62,338 (760) 7,784 607,822 (58,427) (112,500) 112,500 0 (58,427) 549,396 0 0 549,396 1,757,756 2,307,151 0 2,307,151 Year-6 562,812 9,730 62,338 (798) 8,174 642,255 0 (112,500) 112,500 0 0 642,255 0 0 642,255 2,307,151 2,949,407 0 2,949,407

(12,500) (12,500)

(112,500) 228,665

12.3

Projected Balance Sheet


Const Year Year-1 268,861 13,125 112,500 0 394,486 722,750 62,338 660,413 87,570 87,570 1,142,469 0 151,049 151,049 194,072 194,072 591,385 205,963 797,348 1,142,469 Year-2 735,099 13,781 112,500 0 861,381 722,750 124,675 598,075 77,840 77,840 1,537,296 0 141,213 141,213 154,635 154,635 591,385 650,062 1,241,447 1,537,296 Year-3 1,233,136 14,470 112,500 0 1,360,106 722,750 187,013 535,738 68,110 68,110 1,963,954 0 148,274 148,274 109,678 109,678 591,385 1,114,617 1,706,002 1,963,954 Year-4 1,757,756 15,194 112,500 0 1,885,449 722,750 249,350 473,400 58,380 58,380 2,417,229 0 155,687 155,687 58,427 58,427 591,385 1,611,730 2,203,115 2,417,229 Year-5 2,307,151 15,954 112,500 0 2,435,605 722,750 311,688 411,063 48,650 48,650 2,895,317 0 163,472 163,472 0 0 591,385 2,140,461 2,731,846 2,895,317 Year-6 2,949,407 16,751 112,500 0 3,078,658 722,750 374,025 348,725 38,920 38,920 3,466,303 0 171,645 171,645 0 0 591,385 2,703,273 3,294,658 3,466,303

Current Assets Cash Equipment Spare Parts Inventory Pre-paid land lease Pre-paid building rent Total Fixed Assets Less: Accumulated depreciation Net Fixed Assets Intangible Assets Pre-operational Expenses Total Total Assets Current Liabilities Running Finance Accounts payable Total Long-term liabilities Long-term Loan Total Equity Paid-up Capital Retained Earnings Total Total Liabilities And Equity

237,720 12,500 112,500 0 362,720 722,750 0 722,750 97,300 97,300 1,182,770 362,720 362,720 228,665 228,665 591,385 0 591,385 1,182,770

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