Green Food Packaging As Breakthrough To Replace Styrofoam

Green Food Packaging As Breakthrough

To Replace Styrofoam

A Paper For

Chemical Product Design Competition 2014

Proposed by:

Fahima

Honesty Indria Nisa

Meyda Astria

Radhianisa Igatama

Viky Muruatut

UNIVERSITAS INDONESIA

ii Universitas Indonesia

COCOFOAM:

Green Food Packaging As Breakthrough

To Replace Styrofoam

A Paper For

Chemical Product Design Competition 2014

Proposed by:

Fahima

Honesty Indria Nisa

Meyda Astria

Radhianisa Igatama

Viky Muruatut

UNIVERSITAS INDONESIA

iii Universitas Indonesia

SUMMARY

In this dynamic era, people tend to have interest in something practical since time

is considered as the precious one. This fact also reflects in food consumption.

They want to carry on their food in the package that is normally made of

styrofoam. It is one kind of polystyrene with the following thermal properties:

high thermal, light, and easy to be manufactured. Nevertheless, it has negative

impact either for environment or the consumer. Styrene is raw material for

styrofoam which is carcinogenic agent for human being, can’t be biodegraded,

and unrenewable petroleum derived compound. Therefore, Styrofoam has to be

replaced by the material that is eco-friendly and safe for human. We propose a

breakthrough as the solution to solve this problem: Cocofoam. It uses coconut

fiber as raw material because of the high availability of coconut in Indonesia.

According to Asia Pacific Coconut Community, Indonesia has big potential as it

has big area of coconut planting,on 2010 it has 3.8 million ha as the coconut

planting area. Further, based on Badan Pusat Statistik, Indonesia has 3.29 million

coconut trees available to be produced. Coconut fiber can produce strong, durable,

and thermostable food package. The manufacturing process is initiated by

washing the fiber to remove wax. Then it is immersed in NaOH solution 20% for

1 hour to remove lignin and hemicellulose. Next step is performing chemical

treatment using acetic anhydride for 3 hours to strengthen bond between the fiber

and its matrix. After that, the fiber is manufactured as composite using acrylic

thermoplastic resin as the matrix. Last step is composite moulding using

aluminium mould by heating process. This product will be distributed to food

industry in Java and Bali areas.

Keyword : Coconut fiber, Styrofoam, Food Packaging

iv Universitas Indonesia

TABLE OF CONTENT

COVER ............................................................................................................................... i

SUMMARY ...................................................................................................................... iii

TABLE OF CONTENT ................................................................................................... iv

LIST OF FIGURE .......................................................................................................... vii

LIST OF TABLE ........................................................................................................... viii

CHAPTER I INTRODUCTION ..................................................................................... 1

1.1 Background ............................................................................................................... 1

1.1.1 Problem Identification..................................................................................... 1

1.1.2 Problem Boundaries ........................................................................................ 2

1.2 Needs Identification ................................................................................................. 2

1.2.1 List of Needs ................................................................................................... 2

1.2.2 Benchmarking ................................................................................................. 3

1.3 Concept Selection .................................................................................................... 4

CHAPTER II LITERATURE REVIEW ........................................................................ 6

2.1 Overview of Food Industry and Food Packaging ..................................................... 6

2.2 Type of Food Packaging ........................................................................................... 7

2.3 Styrofoam (Polystyrene) ........................................................................................... 7

2.3.1 Definition of Styfrofoam .................................................................................... 7

2.3.2 Bad Impact of Styrofoam (Polystyrene) ............................................................ 8

2.4 Coconut Fiber Availability and Potency ................................................................... 9

2.5 Overview of Coconut Fibers ................................................................................... 11

2.5.1 Coconut Fibers content .................................................................................... 11

2.5.2 Advantages of Coconut Fibers ......................................................................... 11

2.5.3 Properties of coconut fibers that can be used as food packaging ..................... 11

2.6 Composite ............................................................................................................... 12

CHAPTER III PROTOTYPE........................................................................................ 14

3.1 Product Description ............................................................................................... 14

3.1.1 Characteristic and Spesification of the Product .............................................. 14

3.1.2 Product Positioning ........................................................................................ 15

CHAPTER IV PRODUCT MANUFACTURING AND SUPPLY CHAIN ............... 18

4.1 Market Segmentation ............................................................................................. 18

4.2 Production Capacity ............................................................................................... 19

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4.3 Manufacturing Process ........................................................................................... 20

4.3.1 Block Flow Diagram ....................................................................................... 20

4.3.2 Detailed Process Explanation .......................................................................... 22

4.3.3 Equipment Profile ........................................................................................... 22

4.3.4 Scheduling ....................................................................................................... 23

4.4 Mass and Energy Balance ...................................................................................... 24

4.4.1 Mass Balance .................................................................................................. 24

4.4.2 Energy Balance ............................................................................................... 24

4.5 Plant Location and Layout ..................................................................................... 25

4.5.1 Plant Location ................................................................................................. 25

4.5.2 Plant Layout .................................................................................................... 26

4.6 Raw Materials Supply ............................................................................................ 28

PT.ZeltsAishwaryaMulia, Jakarta ............................................................................. 28

4.7 Product Distribution ............................................................................................... 29

4.7.1 Location of Product Distribution Based On Plant Location ........................... 29

4.7.2 Product Distribution Chain ............................................................................. 30

4.7.3 Distribution Route ........................................................................................... 30

CHAPTER V PRODUCT ECONOMICS .................................................................... 32

5.1 Capital Expenditure .............................................................................................. 32

5.1.1 Equipment Cost and Installation Cost ............................................................. 32

5.1.2 Market Research Cost .................................................................................... 34

5.1.3 Site Development and Building Cost ............................................................. 35

5.1.4 Installation Cost ............................................................................................. 35

5.1.5 Total Capital Investment ................................................................................ 36

5.2 Operational Expenditure ........................................................................................ 36

5.2.1 Raw Material Cost ......................................................................................... 36

5.2.2 Utility Cost ..................................................................................................... 37

5.2.3 Maintenance Cost ........................................................................................... 37

5.2.4 Labor Cost ..................................................................................................... 37

5.2.5 Patent Cost .................................................................................................... 38

5.2.6 Distribution Cost ........................................................................................... 38

5.2.7 Marketing Cost ............................................................................................... 39

5.2.8 General Expenses .......................................................................................... 39

5.2.9 Insurance and Factory Over Head (FOH) ..................................................... 40

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5.2.10 Total Operational Cost .................................................................................. 40

5.3 Economic Analysis ................................................................................................ 41

5.3.1 Product Pricing ................................................................................................ 41

5.3.2 Investment ....................................................................................................... 41

5.3.3 Cash Flow ....................................................................................................... 42

5.3.4 Cost Breakdown .............................................................................................. 43

5.4 Profitability Analysis ............................................................................................. 43

5.4.1 Internal Rate of Return (IRR) ......................................................................... 43

5.4.2 Payback Period ................................................................................................ 44

5.4.3 Break Even Point (BEP) ................................................................................. 44

5.4.4 Net Present Value (NPV) ................................................................................ 45

5.5 Sensitivity Analysis ............................................................................................... 45

5.5.1 Influence of Raw Material Cost .................................................................... 46

5.5.2 Influence of Product Price ............................................................................. 46

CHAPTER VI CONCLUSION AND SUGGESTION................................................. 49

REFERENCE .................................................................................................................. 50

Appendix .......................................................................................................................... 52

Appendix A.1 ................................................................................................................ 52

Appendix A.2 ................................................................................................................ 54

Appendix A.3 ................................................................................................................ 57

Appendix A.4 ................................................................................................................ 58

Appendix A.5 ................................................................................................................ 63

vii Universitas Indonesia

LIST OF FIGURE

Figure 2.1 Coconut Planting Areas in Asia-Pacific Country (APCC, 2003) ................... 10

Figure 3.1 Product Positioning ......................................................................................... 15

Figure 3.2 Cocofoam’s Logo and Tagline ....................................................................... 16

Figure 3.3 Cocofoam’s Medium Size Blueprint .............................................................. 17

Figure 4.1 Block Flow Diagram of Cocofoam Production .............................................. 21

Figure 4.2 Satelite View of Factory Location .................................................................. 26

Figure 4.3 Map View of Factory Location ....................................................................... 26

Figure 4.4 Plant Layout .................................................................................................... 27

Figure 4.5 Product Distribution Chain ............................................................................. 30

Figure 4.6 Alternative Routes of Product Distribution .................................................... 30

Figure 4.7 Distribution Route .......................................................................................... 31

Figure 4.8 Distribution Process Through Land Route ..................................................... 31

Figure 4.9 Grinder ............................................................................................................ 58

Figure 4.10 Oven Drier .................................................................................................... 58

Figure 4.11 Hot Press Machine ........................................................................................ 59

Figure 4.12 Moulding Machine........................................................................................ 59

Figure 4.13 Mass balance Diagram of Cocofoam Production ......................................... 60

Figure 4.14 Energy balance Diagram of Cocofoam Production ...................................... 61

Figure 5.1After Tax Cashflow and Before Tax Cashflow ............................................... 42

Figure 5.2 Cumulative Cashflow ..................................................................................... 42

Figure 5.3 Cost Breakdown ............................................................................................. 43

Figure 5.4 Payback Period ............................................................................................... 44

Figure 5.5 Sensitivity Analysis Curve-IRR ..................................................................... 47

Figure 5.6 Sensitivity Analysis Curve-NPV .................................................................... 48

Figure 5.7 Sensitivity Analysis Curve-PBP ..................................................................... 48

viii Universitas Indonesia

LIST OF TABLE

Table 1.1 List of Needs and Rankings ............................................................................... 3

Table 1.2 List of Spesification ........................................................................................... 4

Table 1.3 Criteria in Food Packaging ................................................................................. 4

Table 1.4 Concept Screening ............................................................................................. 5

Table 1.5 Concept Scoring ................................................................................................. 5

Table 1.6 List of Needs and Rankings Based on Several Categories ............................... 52

Table 1.7 List of Metrics .................................................................................................. 52

Table 1.8 Benchmarking .................................................................................................. 53

Table 1.9 Concept Combination ....................................................................................... 53

Table 1.10 List of Concept ............................................................................................... 54

Table 2.1 Type of Some Food Packagings ....................................................................... 54

Table 3.1 Perceptual Mapping Detail Computation ......................................................... 57

Table 3.2 Dimension of Cocofoam’s Size ........................................................................ 57

Table 4.1 Calculation of Cocofoam Production Capacity ................................................ 20

Table 4.2 Production Time of Cocofoam Production ...................................................... 23

Table 4.3 Production Time of Cocofoam Production ...................................................... 24

Table 4.4 Scheduling of Cocofoam Production ............................................................... 24

Table 4.5 Mass balance of Cocofoam production ............................................................ 24

Table 4.6 Energy Balance balance of Cocofoam production ........................................... 25

Table 4.7 Alternatives of Raw Material Supplier ............................................................. 28

Table 4.8 Raw Material Supplier ..................................................................................... 28

Table 4.9 Region and Percentage of Distribution ............................................................ 29

Table 4.10 Retailer in Jabodetabek Region ...................................................................... 62

Table 4.11 Retailer in Java Region .................................................................................. 62

Table 4.12 Retailer in Bali Region ................................................................................... 63

Table 5.1 Main Equipment Cost....................................................................................... 33

Table 5.2 Market Research Cost ...................................................................................... 35

Table 5.3 Site Development and Building Cost ............................................................... 35

Table 5.4 Installation Cost ............................................................................................... 35

Table 5.5 Total Capital Investment .................................................................................. 36

Table 5.6 Raw Material Cost ............................................................................................ 36

Table 5.7 Utility Cost ....................................................................................................... 37

Table 5.8 Total Maintenance Cost ................................................................................... 37

Table 5.9 Total Patent Fee ................................................................................................ 38

Table 5.10 Total Distribution Cost ................................................................................... 39

Table 5.11 Total Marketing Cost ..................................................................................... 39

Table 5.12 General Expenses ........................................................................................... 40

Table 5.13 Insurance Cost ................................................................................................ 40

Table 5.14 Factory Over Head (FOH) Cost ..................................................................... 40

Table 5.15 Total Operational Cost ................................................................................... 41

Table 5.16 Break Even Point ............................................................................................ 45

Table 5.17 Influence of Raw Material Cost Towards IRR, NPV, and Payback Period ... 46

Table 5.18 Influence of Product Price Towards IRR, NPV, and Payback Period ............ 47

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Table 5.19 Main Equipment Cost..................................................................................... 63

Table 5.20 Detail of Equipment Electricity Cost ............................................................. 64

Table 5.21 Maintenance Cost of Main Equipment ........................................................... 64

Table 5.22 Maintenance Cost of Supporting Equipment ................................................. 64

Table 5.23 Maintenance Cost of Buliding ........................................................................ 65

Table 5.24 Direct Labor Cost ........................................................................................... 66

Table 5.25 Indirect Labor Cost......................................................................................... 66

Table 5.26 Patent Fee ....................................................................................................... 67

Table 5.27 Copyright Fee ................................................................................................. 67

Table 5.28 Industry Design Fee ....................................................................................... 67

Table 5.29 Brand Fee ....................................................................................................... 68

Table 5.30 Distribution Cost From Factory to Distribution Center ................................. 68

Table 5.31 Distribution Cost From Distribution Center to Retailer (Jabodetabek Area) . 68

Table 5.32 Distribution Cost From Distribution Center to Retailer (Java Area) ............. 69

Table 5.33 Distribution Cost From Distribution Center to Retailer (Bali Area) .............. 69

Table 5.34 Marketing Cost in Printed Media ................................................................... 69

Table 5.35 Marketing Cost in Online Media .................................................................... 69

Table 5.36 Marketing Cost in Radio ................................................................................ 70

Table 5.37 Creating an Developing Website Cost ........................................................... 70

Table 5.38 Detail of Employee Insurance Cost ................................................................ 70

Table 5.39 Product Pricing ............................................................................................... 70

Table 5.40 Loan From Bank ............................................................................................ 71

Table 5.41 Loan From Investor ........................................................................................ 71

Table 5.42 Depreciation of Main Equipment ................................................................... 72

Table 5.43 Depreciation of Supporting Equipment .......................................................... 73

Table 5.44 Cashflow Calculation ..................................................................................... 77

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CHAPTER I

INTRODUCTION

1.1 Background

In this dynamic era, people tend to have interest in something practical since

time is considered as the precious one. This fact also reflects in food consumption.

They want to carry on their food in the package that is normally made of

styrofoam. Styrofoam is one kind of polystyrene with the following thermal

properties: high thermal stability, light, and rather easy to be manufactured.

Nevertheless, it has negative impact either for environment or the consumers.

Styrene is raw material for styrofoam which is carcinogenic agent for human

being, can only be degradaded after hundred of years, and unrenewable petroleum

derived compound. Therefore, Styrofoam has to be replaced by the material that is

eco-friendly and safe for human.

Our team is designing a product that can replace styrofoam that is named

Cocofoam. The name is derived from two words namely Coconut which is the raw

material for these products, which can replace the styrofoam. Cocofoam uses a

composite principle by using resin to make coconut fibers can be molded into a

food packing form. It uses coconut fiber as raw material because of the high

availability of coconut fiber in Indonesia. According to Asia Pacific Coconut

Community, Indonesia has big potential as it has big area of coconut planting, on

2010 it has 3.8 million hectare as the coconut planting area. Based on Badan

Pusat Statistik, Indonesia has 3.29 million coconut trees available to be produced.

Coconut fiber can produce strong, durable, and thermostable food package.

1.1.1 Problem Identification

Identifications of problems from Cocofoam packaging are as follows:

1. Indonesia is a country which has many fast food consumers and therefore

uses a lot of food packaging.

2. The existing food packaging which is commonly used is made from

petroleum-based compound.

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3. Most of existing food packaging when having contact with a high temperature

food is releasing carcinogenic compound which is very harmful to human body.

4. Some of existing food packaging has bad impact for environment because it

takes a very long time to be degradaded by the environment.

5. The existing packaging has many weakness such easy to spills over, easy to leak

and not practical.

1.1.2 Problem Boundaries

1. Cocofoam packaging can be used for the food with a temperature range of 0oC to

93oC.

2. Our company is small scale companies, with simple technology and utilization of

production capacity that is not too large.

3. Our consumers is small and medium scale of food industry's in Java and Bali

areas.

1.2 Needs Identification

For determining needs, first we spread questionnaire and form of interview to

people in which are potential users of food packaging. The most important thing to

determine needs is asking them about their complains of current food packaging they

used.

1.2.1 List of Needs

After we got the list of data from correspondents, we change the list of results

into needs of consumers. Then, we give rank of those needs based on their

importance as follow:

1 : Undesirable 4 : Highly Desirable

2 : Not Important 5 : Essensial

3 : Nice to have

The result of list of needs and the ranks is shown in Table 1.1

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Table 1.1 List of Needs and Rankings

Needs

Number Needs Rank

Essential

6 Not dangerous for human body 5

Highly Desirable

7 Degrade Easily 4

2 Water Proof 4

4 Thermostable 4

Nice to Have

3 Affordable Price 3

1 Practical 3

Not Important

5 Has no odor 2

Undesireable

8 Attractive Form 1

9 Attractive Color 1

After we make list of needs and give rankings, the next step is arranging the

needs into several categories, as shown in Table 1.2

1.2.2 Benchmarking

To determine the spesification of our product, we need to make list of metrics

and then comparing our product with existing food packaging as our competitors. List

of metrics of our product is shown in Table 1.3

After making list of metrics, the next step is comparing our product with

existing product. Existing food packaging that we choose as our competitors are

styrofoam, plastic, paper, and paper box. We choose these product as our competitors

because these product this far is the most commonly used food packaging in

Indonesia. The benchmarking is shown in Table 1.4

After we do the bechmarking with existing food packaging, we make list of

list of spesification which contain spesification of our product and also marginal

value and ideal value of the metric unit. List of spesification is shown in Table 1.5

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Table 1.2 List of Spesification

Needs

No

Spesification Rank Metric Unit Marginal Value Ideal Value

Price of Food Packaging

3 Price of Product 3 Rp Rp

1.000

Rp 100 - 1.000

Performance of Food Packaging

1 Ergonomic 3 Subjective ●●●●● ●●●●●

2 Time to Patch Water

Before Leak

4 Hours 10 24

4 Thermal Stability 4 oC (0) - (+93) (-50) - (+95)

5 Odor 2 Subjective No Odor No Odor

Health Aspect

6 Toxicity 5 Subjective Non Toxic Non Toxic

Environmental Aspect

7 Time to Degrade 4 Years 0,019 - 0,038 0,019 - 0,038

Physical Appearance of Food Packaging

8 Ergonomic 1 Subjective ●● -

9 Ergonomic 1 Subjective ●● -

1.3 Concept Selection

Before creating and selecting concept of our product, first we need to make

combination of several concepts. These concept is combination between new concept

and existing concept based on form of food packaging, how to open food packaging,

base material of food packaging, and resin of the composite material. After that, we

make list of concept based the combination that we make previously. The concept

combination and list of concept is shown in Table 1.6 and Table 1.7. After making

list of concept, the next step is concept screening. The aim of the concept screening is

to score the criteria. The product screening has 3 criterias to score the concept.

Product with higher score wil be continue to the product testing. Those criterias are

as follow:

Table 1.3 Criteria in Food Packaging

No Criteria

1 Easy to Manufacture

2 Affordable Production

Cost

3 Easy to be Formed

5


In concept screening, we give rate of each concept. The rate is explained as

follow:

Score minus (-) indicate that the new product has lower quality than

reference product

Score zero (0) indicate that the new product has same quality than

reference product

Score plus (+) show that the new product has better quality than reference

product

Then, the concept screening is shown in Table 1.9

Table 1.4 Concept Screening

Concept Number

Criteria 1 2 3 4 5 6 7 8 9 10 11 12

Easy to Manufacture - - + 0 0 0 + + + 0 + 0

Affordable Production

Cost

- - + 0 0 0 + - - 0 - -

Easy to be Formed - - - - - - 0 0 0 0 + 0

Total -3 -3 1 -1 -1 -1 2 0 0 0 1 -1

Result No No Yes No No No Yes No No Reference Yes No

The result of concept screening shows that concept number 3, 7, and 11 can

continue to the next step which is concept screening. In concept scoring, each of

selection criteria will be given a weight factor based on priority of the criteria. The

concept that will be chosen in this concept scoring is the concept that has the highest

score. Concept scoring is shown in Table 1.10

Table 1.5 Concept Scoring

Criteria Weight Concept Number

3 7 11

Easy to Manufacture 25% 3 0,75 3 0,75 3 0,75

Affordable Production

Cost

40% 4 1,6 4 1,6 4 1,6

Easy to be Formed 25% 2 0,5 5 1,25 3 0,75

Practical 10% 2 0,2 3 0,3 3 0,3

Total 100% 3,05 3,9 3,4

Result Not Chosen Chosen Not Chosen

So based on concept scoring, the selected concept for our product is concept

number 7. So based on this, the concept of food packaging that we make is in form of

cubic which is clamshell type, made from coconut husk as base material and resin

used is Ethyl Vinyl Acetate (EVA).


CHAPTER II

LITERATURE REVIEW

2.1 Overview of Food Industry and Food Packaging

Packaging is a means of providing the correct environmental conditions for food

during the length of time it is stored and/or distributed to the consumer. A good

package has to perform the following functions:

1. It must keep the product clean and provide a barrier against dirt and other

contaminants.

2. It should prevent losses. Its design should provide protection and convenience in

handling, during transport, distribution and marketing. In particular, the size,

shape and weight of the packages must be considered.

3. It must provide protection to the food against physical and chemical damage (eg

water and water vapour, oxidation, light) and insects and rodents.

4. It must provide identification and instruction so that the food is used correctly

and have sales appeal.

In Indonesia, food industry is one of the most important industries which need

packaging to protect and serve their food to their customer. It has the expenditure

50.66% compared with non-food industry. We can divide to two types of food

industries; there are fast food industry and processed food. Five biggest fast food

restaurants are McDonald’s with 142 outlets, KFC (Kentucky Fried Chicken) with

457 outlets, Dunkin Donut with more than 200 outlets, Pizza Hut with more than 200

outlets, and Hoka Hoka Bento with 141 outlets. They use various types of packaging

such as paper, wood fiber, and plastic. As example is McDonald’s, it uses plastic

material called Clarified Polypropylene (CPP) for McCafe beverage cups, and wood

fibre for sandwich. Meanwhile for KFC is using paper for its packaging. In 2012,

Greenpeace organization accused KFC using paper packaging made using wood from

Indonesian rainforests which it said was endangering the habitat of the Sumatran

Tiger. Greenpeace said that it has examined for paper packaging KFC by testing

glass, cardboard, french fries package and tissue.

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For processed food, the main player is UKM (Unit Kecil Menengah) and

they use styrofoam as their packaging. It is because by using the material like

wood fiber is too expensive for them. However styrofoam is dangerous for human

body because it contains styrene that is processed by using benzene. Benzene can

generate problem in thyroid gland, disturb the neuron system that can cause

fatigue, accelerated heartbeat, insomnia, tremble body, and become easily

agitated. In Indonesia, the utilization of styrofoamis 884 million per day. So it is

an important issue to make a packaging with the low cost and also not give a bad

impact to the health.

2.2 Type of Food Packaging

Generally, the packaging material may either be rigid or flexible. Rigid

containers include glass and plastic bottles and jars, cans, pottery, wood boxes,

drums, tins, plastic pots and tubes. They give physical protection to the food

inside that is not provided by flexible packaging. Flexible packaging is a major

group of materials that includes plastic films, papers, foil, some types of vegetable

fibers and cloths that can be used to make wrappings, sacks and sealed or

unsealed bags. Food industries have to decide which packaging material will be

more appropriate for their food product taking note of the advantages and

disadvantages of their choice or perhaps what other attributes can be incorporated

in the packaging material based on the end use properties of the food product.

Type of some food packaging is shown in Table 2.1

2.3 Styrofoam (Polystyrene)

2.3.1 Definition of Styfrofoam

Styrofoam is actually a brand name for the material, polystyrene (PS).

The single-molecule form of polystyrene is known as styrene. PS foam, the type

used in food packaging for products like take-away containers, supermarket meat

trays, etc., is created by injecting the plastic polymer, polystyrene, with a gas-such

as HCFC 22, CFC 11, or CFC 12 (all ozone destroying chlorofluorocarbons), or

pentane-to expand it into that puffy material. Toxic and hazardous chemicals,

including styrene, benzene and ethylene, are used to make PS foam and are a

byproduct of PS foam production.

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We use Styrofoam on a daily basis, in particular, the disposable food

packaging used for take-aways. It is so commonly used that people assume it

should be safe, especially since there are hardly any news in the media relating to

the harms of Styrofoam. However, no news does not always mean good news.

Studies have been done worldwide and countless reports have been published on

the negative impacts of this material, both on the environment and on health. Most

Singaporeans are not fully aware of this issue and do not know the seriousness of

it. We feel it is about time to create some awareness and for the people to make

their own informed choice. Or better yet, to completely ban this silent killer.

2.3.2 Bad Impact of Styrofoam (Polystyrene)

The main impact of styrofoam are from Benzene and Polystyrene, the big

effect of thestyrofoam are human health and enviroment. It will be explained

below about the bad impact of styrofoam;

a. Human Health Impacts of Polystyrene

There are potential health impacts from polystyrene foam food packaging

associatied with its production, and with the leaching of some of its chemical

components into food and drink. The general public is not typically warned of

these public hazards. Styrene, a component of polystyrene, is a known

hazardous subtance that mediacal evidence and the US Food and Drug

Administration suggests leaches from polystyrene containers into food and

drink. Polystyrene food containers leach styrene when they come into contact

with warm food or drink, and acidic foods causing human contamination and

posing a direct health risk to people. It is for the reasons that is not

recomemended that plastic take – out containers ever be heated in a

microwave. Styrene is a suspected carcinogen and neurotoxin which

potentially threatens human health. Several adverse health effect have been

attributted to styrene. Some studies have concluded that at expose levels

above 100 parts per million, human experience acute mucous membrane

irritation with the eyes, nose, and throat particularly affected. Increased levels

of styrene concentration may cause fatique, irritation, and decrease in

concentration ability. Styrene has been linked to increased levels of

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chromosomal damage, abnormal pulmonary function and cancer in workers at

polystyrene and styrene plants.

Another known toxin, Benzene, is a chemical component of polystyrene

foam. It is a known carcinogen and enters the human body either though the

skin or respiratory sistem.

b. Environmental Impacts of Polystyrene

Polystyrene foam is designed for a useful life of minutes or hours, but it

continues to exist in our enviroment for hundreds or thousands of year. Non-

biodegradable food service ware, especially polystyrene foam, constitutes a

large portion of litter in Hong Kong, and the cost of managing this litter is

high and rising. Like any another disposable product or packing material, the

proliferated used of polystyrene foam containers will add to the burden on

disposal and the landfills.

Polystyrene foam present unique management issues because of its

lightweight nature, floatability, and prevalence to be be blown from disposal

sites even when disposed of properly. The lightweight and buoyant

polystyrene travels easily through gutters and storm drains, eventually

reaching the ocean. Pollution of waterways and waterfront negatively affects

to tourism and quality of life. When polystyrene travel down waterways and

storm drains into the ocean, it breaks down into smaller, non-biodegradable

pieces that are ingested marine life and other wildlife thus harming or killing

them.

Although polystyrene manufactures claim that their products are “ozone-

friendly” or free of CFC’s, this is only partially true. Most polystyrene is now

manufactured with HCFC-22, which, though less sestructive than its chemical

cousins, CFC-11 and CFC-12, is still a greenhouse gas and harmful to ozone

layer.

2.4 Coconut Fiber Availability and Potency

Indonesia has the widest planting area of coconut compared by other country

(APCC, 2005). However, coconut production per year is still low. The production

of coconut in Indonesia reaches about 15.5 billion per year while the total of by-

product is accumulated by 3.75 million tons coconut water, 0.75 million tons shell

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charcoal, 1.8 billion tons coconut fiber, and 3.3 million tons coir dust (Mahmud,

Zainal and Yulius Ferry, DepartemenPertanian, 2005). Normally, some industries

still focus on coconut meat to be processed whereas the by-products only become

waste. Actually, there are a lot of business opportunities that can be developed by

processing the by-products.

One of by-product being potential is coconut fiber. The fiber is produced

about 35% from one coconut. Fiber is normally utilized as raw material for car

seat, bed, pillow, hardboard, and car dashboard, and any composite material.

Besides, it is also processed to obtain coco peat as planting media for horticultural

plant and is used as heavy metal pollutant adsorbent. The properties of fiber that is

thermostable, strong, and able to neutralize soil acidity make it suitable to be

processed to obtain the product mentioned earlier. Nevertheless, Indonesia only

export 191 tons of coconut husk containing fiber on 2003. This amount is really

low since we actually can augment the production regarding to wide planting area

in this country.

Inspired by that facts above, we propose a new innovation about utilizing

coconut fiber to be eco-friendly polymer for food packaging. We are strongly sure

to choose coconut fiber since its availability is high and coconut fiber utilizing is

only a few. In addition, enormous amount of non-degradable packaging waste

which has become serious problem encourage us to invent high feasibility eco-

friendly packaging. Figure 2.1 shows coconut planting areas in Asia-Pacific

Country.

Figure 2.1 Coconut Planting Areas in Asia-Pacific Country (APCC, 2003)

11


2.5 Overview of Coconut Fibers

2.5.1 Coconut Fibers content

Coconut palm are mainly cultivated in the tropical regions such as

Indonesia and the product from the palm is applied in food and non-food products.

The coconut palms comprise of a white meat which has a total percent by weight

of 28 surrounded by a protective shell and husk which has a total percent by

weight of 12 and 34. The husk from the coconut palm comprises of 30% weight of

fiber and 70% weight of pith material.

Coconut fibers was obtained from the fibrous (mesocarp) of the coconut

from the coconut palm. Coconut fiber has high lignin content and low cellulose

content, so as resulted of resilient, strong, and highly durable materials

characteristics. The remarkable lightness of the fibers was due the cavities arising

from the dried out sieve cells.

2.5.2 Advantages of Coconut Fibers

The advantages of coconut fibers are:

a. It is a renewable resource

b. The fibers is abundant, non-toxic in nature, biodegradable, low density and

very cheap.

c. The coconut fiber has a high degree of retaining water and also rich in

micronutrients

d. The fibers instead of going to waste are explored for new uses, which in turn

provide gainful employment to improve the standard living condition.

2.5.3 Properties of coconut fibers that can be used as food packaging

The fibers structure and property in a coconut fibers is determined by the

quantity of cellulose and non-cellulosic constituents and this influences the

crystalline and moisture regain. Fibers that have high cellulose content, with

degree of polymerization that is high and low microfibrillar angle gives better

mechanical properties while those with higher content of lignin.

The main constituents of coconut fibers than can be used as food

packaging is coconut fiber has the highest percentage by volume of lignin, which

makes the coconut fibers very tough and stiffer when compared to other natural

12


fiber. This can be attributed to the fact that the lignin helps provide plant tissue

and the individual cells with compressive strength and also stiffens the cell wall of

the fiber where it protect the carbohydrate from chemical and physical damage.

The lignin of the coconut fibers is practically multicellular naturally and

its diameter and length range from different dimensions and its usually very thick

at the middle of the fiber length. Furthermore, the lignin content also influences

the structure such as properties, flexibility, hydrolysis rate and with high lignin

content it appear to be finer and also more flexible. From the above explanation, it

can conclude that coconut fibers can be used as food packaging.

2.6 Composite

Composite is a blend of two or more materials with different phase into a new

material that has a physical or mechanical properties which are better than both

(Zulfia, 2010). Composites consist of reinforcment and filler (matrix). Generally

reinforcement is the form of fiber, metal, or fiber. The reinforcement has less

elastic properties but harder and more powerful. Meanwhile, the filler has the

function of binding fibers into one unified structure, protects the fiber from

damage and environmental effects and affect the appearance of a composite

material. Usually the material that used as a filler is metal, ceramics, and

polymers. If the resin is used it will less hard

From fiber and resin will be generated composite materials with the physical

and mechanical properties that are different from their constituent. Composite

materials have many advantages, including lighter weight, strength and higher

strength, corrosion resistant and has a lower assembly costs due to the reduced

number of components and connecting bolts.

Now, in general,man-made composites can be divided into three main groups:

1. Polymer Matrix Composites (Polymer Matrix Composites - PMC)

This material is a composite material that is often used , called, as (FRP -

Fibre Reinforced Polymers or Plastics) - these materials use a polymer-based

resin as the matrice, and some types of fiber such as glass, carbon and aramid

(Kevlar) as the reinforcement.

2. Metal Matrix Composites (Metal Matrix Composites - MMC)

13


MMC evolves in automotive industry, these materials use a metal such as

aluminum as matrices and reinforcements with fibers such as silicon carbide.

3. Ceramic Matrix Composites (Ceramic Matrix Composites - CMC)

CMC is used in very high temperature environments, these materials use a

ceramic as the matrix and reinforced with short fibers, or fibers (whiskers)

which are made of silicon carbide or boron nitride

Currently, various types of natural fibers has been investigated for use in

composites, such as straw, wood, coconut husk, rice husk, wheat fiber, sugar,

bamboo, grass, sisal, raffia, banana fiber, pineapple leaf fiber, papyrus, corn, etc. .

Some herbs have properties such as thermoplastic that can be used as a substitute

for thermoplastics. Natural fibers are a renewable source, has a lower price, it is

not harmful to health, and is the solution of the problem of environmental

pollution because it can be produced from the recycled waste material.


CHAPTER III

PROTOTYPE

3.1 Product Description

3.1.1 Characteristic and Spesification of the Product

Our product has added value as it is biodegradable since it comes from

natural raw material and experiences manufacturing process turning it into

unhazardous material. We consider “biodegradable” as our main parameter in

facing world problem related to environment. Therefore, our product has to

represent our ideas as a solution to one of the problem.

The product will be a package which is a container box that will be used as

food packaging. In order to make it easy to open and close, there is hasp to keep

the box close, this type of food packaging usually called clamshell. Besides, it is

also waterproof and practical that it will be really portable one. The materials

contained in every single box are mixture of coconut husk and resin ethyl vinyl

acetate (EVA)

The manufacturing process itself contributes to properties of our product.

Mostly made from coconut husk, our product has added value that make it capable

to compete in the market. It is thermostable as it is really important since we live

in the world that force us to be practical and in hurry. Moreover, it is easy to be

degraded thus we believe our product will reduce the problem of waste and it will

be first step that we especially environmental department do not need to think

about the enormous amount of waste that exists every single time.

The color of our product is brown. We prefer to keep the original color of

coconut husk in order to show the people the originality of our product. Therefore,

the customers will believe that our product comes from nature, synergize with the

nature, and will be back to the nature. The shape itself is a box which is preferred

by our respondent filling our questionnaire and it is considered as the suitable

shape since rectangle makes us easier in organizing some items of food in the

container.

15


3.1.2 Product Positioning

Figure 3.1 Product Positioning

We use perceptual mapping to know the advantages of our product

compared to others. As we know, in Indonesia, the similar products that usually

used in the market are styrofoam, plastic, paper box, and paper. As the

comparison, there are five product functions which we have gotten by identifying

the main customers need, those are; ease of degradation, price, practical, water

proof, thermostable, and level of danger.

The perceptual mapping shows that our product has the excellence in the

case of water proof, thermostable, practical, level of danger, and ease of

degradation. Meanwhile in terms of price, our product has the lowest score

compare to others, but consumers nowadays are smart when choosing product.

They don’t mind with the price of the product as long as the quality is appropriate.

Based on that, we believe that the consumer will buy our product because it is

practical and concern of healthy and environment. Table 3.1 shows detail

computation of perceptual mapping.

00.20.40.60.8

11.21.4

Price

Practical

Water Proof

Thermostable

Level of

Danger

Ease of

degradation Cocofoam

Styrofoam

Plastic

Paper

Paper Box

16


3.2 Product’s Brand, Logo, and Motto

Our society tends to be interested and eager to try new product when a

new type of product is launched. One parameter that gives significant impact is

brand. Brand has a role as icon to attract customers along market competition. A

product with an attractive selling namehas a great opportunity to get the attention

of costumers and compete in the market.Brand which has a unique side, different

from others, but exclusive, will be easily remembered by customers and will build

the image of the product. Figure 3.2 shows Cocofoam’s logo and tagline

Figure 3.2 Cocofoam’s Logo and Tagline

We create brand called “cocofoam” in order to emphasize that our product

comes from part of coconut. In addition, “cocofoam” is a name that simply

represent the product and direct the customer into an imagination that coconut is

our raw material. The use of English was done to anticipate when these products

are marketed abroad or exported. In addition, Indonesian people are more

interested in a foreign language because it seems more interesting and qualified.

We choose green as dominant color in the logo to show that this product is

biodegradable. We believe that the logo perfectly demonstrates the synergy

between our product and environment. The recycle replacing “o” letter illustrated

are the way we show and later prove that our product is recyclable. It is important

since our main goal is to make the better condition on the earth by generating

ideas and turning it into the product as the “representative” of our ideas.

Our tagline represents our action to love the earth by creating eco-friendly

product and proposing an action to love the body by using unhazardous raw

material that is save for our healthy. Besides, the tagline is really simple that it

will be memorized easily. We think that this tagline will make the product more

attractive since the point that people concern is that what happens through their

body. It will make the customers wonder about what this product can do related to

our healthy. Through this product, we will prove the world that we can utilize one

17


of asset that is highly available in Indonesia to make a change for environment in

order to give contribution for better earth.

3.3 Product’s Blueprint

As we have mentioned in advance, Cocofoam is container box that will fit

for the food. This shape is chosen since it is preferred by our respondents filling

the questionnaire. Besides, this shape is considered as the suitable one related to

its easiness in organizing food. We vary the size of Cocofoam to suit it towards

the portion of the food served hence the customers can choose the size which fits

with the food that they want to serve.

Cocofoam will be wrapped by plastic in order to organize them in carton

box. One carton box consists of six packs. One pack comprises of twenty pieces

of Cocofoam. All of them will be distributed to some regions with the logo

attached in each carton box. Table 3.2 shows dimension of three size types of

Cocofoam. Figure 3.3 below shows Cocofoam’s blueprint which is in medium

size

Figure 3.3 Cocofoam’s Medium Size Blueprint


CHAPTER IV

PRODUCT MANUFACTURING AND SUPPLY CHAIN

4.1 Market Segmentation

The market segmentation is marketing strategy that involves dividing a broad

target market into subsets of consumer who have common need, grouping market

in segments potential consumer with same characteristic, designing and

implementing strategies to target their needs and desires using media channel and

best allow to reach them. The criteria for segmentation are :

1. It is possible to measure

2. It must be large enough to earn profit

3. It must be stable

The main important from the segmentation market our fabric is more focused

to sources allocation and it is basis to determine strategy all of component statistic

and value. The segmentation have market target to give basic for positioning and

market segmentation is the key factor for survive with other products.

We classify our consumers in terms of geographic, demographic,

psychographic, and behavior. Those fundamental elements are considered to give

the significant impact for our product.

a. Geographic segmentation

In geographic segmentation, consumer market is divided based on the

location, address, or in this case is the city. Our product will first be sold in

some of big cities in Bali and Java. The location selection is based on the

percentage of population, sum of population in Bali and Java is 50% of

Indonesian population. Furthermore, in MP3EI (Masterplan Percepatandan

Perluasan Pembangunan Ekonomi Indonesia) Java Island has the role of the

drivers of national industry and service and one of the main activities is in the

19


food industry. Beside, Bali is located near Java so that the distribution cost can

be minimized. After that, we will distribute our product to the other island in

Indonesia.

b. Demographic segmentation

In this segmentation we divide the market as end costumer and non-end

customer. We will use mass production in our production system so that our

focus is in the non-end consumer that involved a company level until retailer

level, from traditional market into the multinational company.

c. Psychographic segmentation

Market segmentation in terms of psychographic classifies the market based on

the costumer characteristic. Our product is classified as the product that aware

in the environmental issue. Many companies and retailers recently concern

about the health and environment of their product so that we believe it will

help to increase our selling.

d. Behavior segmentation

This segmentation classifies the costumer based on the knowledge and the

reaction of the product. The segmentation that based on the knowledge hopes

that the user can understand clearly the function of our product so that their

attitude and reaction to the product will be better. Moreover, in Indonesia

itself, many companies and retailers give a positive reaction for green product.

4.2 Production Capacity

The objective of our product is to replace Styrofoam, so to determine the

production capacity of Cocofoam we only use data of styrofoam usage in

Indonesia per day. In one day, Indonesian people use 29.5 million Styrofoam

(kompas.com). Based on our market target, Cocofoam will be distributed to only

in Java and Bali region. The population in Java and Bali region is 57% of total

Indonesia population. So based on this data, the styrofoam usage in Java and Bali

region would be 14.7 million per day.

After getting data of styrofoam usage, we can determine the production

capacity of Cocofoam. Based on styrofoam usage, production capacity of

Cocofoam which want to be created in 2015 is only 0,5% from total usage of

styrofoam. We decided to do so because Cocofoam is a new product that has to

20


compete with existing product (styrofoam) and also we want to see consumer’s

response towards Cocofoam. The calculation of Cocofoam production capacity is

shown in Table 4.1 below:

Table 4.1 Calculation of Cocofoam Production Capacity

Styrofoam usage 14.700.000 packages per day

4.851.000.000 packages per year

Working Time 330 days per year

11 hours per day

Production Capacity

(0,5 % of styrofoam usage)

242.550.000 packages per year

Production Capacity per day 735.000 packages per day

4.3 Manufacturing Process

The main production process to make Cocofoam includes seven main stages

which are drying of coconut husk, extraction of coconut husk, washing of coconut

husk, chemical treatment, blending with matrix, molding, and packaging.

4.3.1 Block Flow Diagram

The block flow diagram of Cocofoam production is shown in Figure 4.1

21


Grinding WashingCoconut

Fiber

Water

Distilled Water

Chemical

Treatment

NaOH 5%

NaOH 5%

Blending with

Matrix

Resin

Drying

Water

MoldingPackaging

Coconut

Husk

Figure 4.1 Block Flow Diagram of Cocofoam Production

22


4.3.2 Detailed Process Explanation

The first step in making Cocofoam is to grind the coconut husk. Coconut

husk is part of coconut fruit which contain fiber. Coconut husk is grinded to

obtain coconut fiber. After being grinded, coconut fiber will become softer and

fiber-like appearance. The next step is soaking coconut fiber in water for 1 day.

For 1 kg of coconut fiber, it needs 5 L of water. This steps aims to remove outer

most wax layer of the coconut fibre, to ensure the proper interaction between fibre

and matrix material.

The next step is chemical treatment of coconut fiber. This step aims to

remove lignin, hemicellulose, silica and pith from the fibre to have better

impregnation between fibre and matrix and also to improve fibre surface

roughness. This step is done by soaking coconut fibre in 5 % aqueous solution of

NaOH for 2 days. For 1 kg of coconut fiber, it needs 2 L of NaOH.

After soaked in NaoH solution, coconut fiber is mixed with matrix or

binder. This step matrix is done to make the sheet of coconut fibre which is ready

to be mold in the next step. The first step is preparing the resin. Resin which used

is Ethylene Vinyl-Acetate (EVA). The composites composed of the coconut fibres

and resin were mixed for 30 minutes and being dried for 30 minutes using oven

with temperature 70 ºC before the sampled were prepared with a hot press. The

mixture of cocout fibre with resin is done by weight ratio 80:20.

The next step to make Cocofoam is molding of coconut fiber sheet. The

coconut fibre sheet is placed between two moulds then the sheet is pressed and

heated. This process takes 3 minutes. After that, Cocofoam can be taken out of the

mould. The last step is packaging of Cocofoam before distributed to consumers.

For 1 kg of coconut fibre can produced 12 cocofoam.

4.3.3 Equipment Profile

a. Grinder

Grinder or extraction machine is used to separate coconut husk and make

it into coconut fiber. There is 1 grinder used in Cocofoam plant.

23


b. Oven Drier

Oven drier is used to dry coconut fiber sheet before mold in molding.

There are 7 units of oven drier used in Cocofoam plant.

c. Hot Press Machine

Hot pressed is used to make coconut fibre into sheets, before molded in

moulding. There is 1 unit of hot press machine used in Cocofoam plant.

d. Moulding Machine

Moulding is used to mold coconut fiber sheet into clamshell form (like

common stryrofoam form). There is 1 unit of molding machine used in

Cocofoam plant.

4.3.4 Scheduling

The determination of production time and production scheduling is very

important which will affect production capacity and also profit of this Cocofoam

plant. Cocofoam plant will operate starting from 7 a.m. until 6 p.m., 7 days a

week and 330 days a year. Table 4.2, Table 4.3 and Table 4.4 shows production

time and scheduling. Since the first two steps to make Cocofoam (washing and

chemical treatment) are process which needs more than one days in process, so

the production time and scheduling is made in different table with the rest of the

process (resin mixing, oven drying, and molding).

Table 4.2 Production Time of Cocofoam Production

Process Step

Number Minutes

Total

Minutes Number

of

Operators 30 60 90 120

Grinding 1

30 1

Resin Mixing 4

30 2

Oven Drying 5

30 2

Molding 6

30 2

24


Table 4.3 Production Time of Cocofoam Production

Process Step

Number Days

Total

Days Number

of

Operators 1 2 3

Washing 2

1 2

Chemical treatment 3

2 2

Table 4.4 Scheduling of Cocofoam Production

Process Work Hours Total

Work

Hours 7 8 9 10 11 12 1 2 3 4 5 6

Start-up

Equipment

3

Loading Raw

Material

3

Process Batch

6

Equipment

Washing

3

4.4 Mass and Energy Balance

4.4.1 Mass Balance

Mass balance of Cocofoam production is shown in Table 4.5 and Figure 4.6

Table 4.5 Mass balance of Cocofoam production

Process Input Output

Component Mass Component Mass

Grinding Coconut Husk (kg) 49001,6 Coconut Husk (kg) 49001,6

Washing Coconut Fiber (kg) 49001,6 Coconut Fiber (kg) 49001,6

Water (L) 245008 Water (L) 245008

Chemical Treatment Coconut Fiber (kg) 49001,6 Coconut Fiber (kg) 49001,6

NaOH (kg) 98003,2 NaOH (kg) 98003,2

Blending with Resin Coconut Fiber (kg) 49001,6 Coconut Fiber (kg) 61252

Resin (kg) 12250,4 Resin (kg) 0

Drying in Oven Coconut Fiber (kg) 61252 Coconut Fiber (kg) 61250

Water (L) 2

Molding Coconut Fiber (kg) 61250 Cocofoam (pieces) 735000

4.4.2 Energy Balance

Energy balance of Cocofoam production is shown in Table 4.6 and Figure 4.7

25


Table 4.6 Energy Balance balance of Cocofoam production

Process Equipment Equipment

Capacity

Production

per Day

(kg)

Number of

Equipment

Power per

Equipment

(kW)

Total

Power

(kW)

Grinding Grinder 15

tonne/hour

49001,6 1 45 45

Washing Storage Tank -

Chemical

Treatment

Storage Tank -

Blending with

Resin

Storage Tank -

Drying in Oven Oven Drier 800 kg/hour 61252 7 10 70

Hot Press Hot Press

Machine

12 sheets/kg 61252 1 20 20

Molding Molding

Machine

20000

pieces/hour

735000

pieces

4 20,2 80,8

As can be seen in Table above, washing process, chemical treatment

process, and blending with resin process do not use any energy, since these

process is done without using any elctricity. But for washing process, the needs of

water will be calculated in economic analysis.

4.5 Plant Location and Layout

4.5.1 Plant Location

We choose the location of Cocofoam factory is in Jabodetabek region. The

exact place of the factory is at Karangsari, East Cikarang, West Java, Indonesia.

The location is considered to become our factory place based on some reasons,

which are:

a. The selected location is still in Jabodetabek region, and it becomes the main

consideration. It becomes easy to sell our product in Jabodetabek market if we

put factory location also in Jabodetabek region. In Cikarang itself, there are

many target distributors of our food packingproduct, such as: traditional

market, modern market, and food packing retail .

b. Karangsari, East Cikarang is near of tol. It is reachable by using

any kind of road transportation, including freight car or truck. Not only close

to distributors, this factory location is also close to the raw material supplier.

26


These are the view of factory location based on satellite view (Figure 4.8) or

based on map view (Figure 4.9).

Figure 4.2 Satelite View of Factory Location

Figure 4.3 Map View of Factory Location

4.5.2 Plant Layout

Plant layout of Cocofoam plant is shown in Figure 4.10

27


Equipment Warehouse

Raw Material Warehouse

Chemical Warehouse

CanteenDrying process

Office

Toilet

Mo

squ

e

Product Warehouse

Molding Process

Blending Process With Resin

Chemical Treatment

Washing Process Grinding Process

Security

Parking Lot

Green Area

Ben

gkel

Per

alat

an

Gate

Gate

Figure 4.4 Plant Layout

28


4.6 Raw Materials Supply

The distribution process of raw material is one of important factor in

determining factory location.. The distribution of raw material is important thing

to do to keep the raw material flow going smoothly. If the raw material flow going

smoothly, the product flow to consumers will also going smoothly.

Table 4.7 Alternatives of Raw Material Supplier

N

o

Raw

Materia

ls

Feed

Stock

Per Day

1st Supplier 2

nd Supplier 3

rd Supplier

Company

Name Price

Company

Name Price Company Name Price

1. Coconut

Fiber

61250

kg/day

CV.

Alindo,

Bandung,

Jawa

Barat

Rp

2.500/

kg

CV.

MuaraSubu

r,

Surabaya,

JawaTimur

Rp

3.500

/kg

MansaputraGemilang,

Surabaya, JawaTimur

Rp

2.500,00 -

3.000,00

/kg

2. NaOH

5%

122500

Liter/day

PT.Anugr

ah Putra

Kencana,

Bekasi

Rp

65.000

/Liter

PT.

CiptaBang

un, Bogor

Rp.

64.50

0/Lite

r

CV. Harum Kimia,

Jakarta Pusat

Rp

67.000/Lit

er

3 Resin

Ethylen

e Vinyl

Acetate

15312.5

kg/day

CV. Yes

Karya,

Bekasi

Rp10.

500.00

0/

metric

ton

CV.

Libratama,

Semarang

Rp.

10.19

0.000

/metri

c ton

PT.ZeltsAishwarya

Mulia, Jakarta

Rp.

11.700.00

0/ metric

ton

Table 4.8 Raw Material Supplier

Raw Materials Feed

Stock

per Day

1st Alternative of

Supplier (Factory

Location is at

Cikarang)

Order

Frequency

(in a

week)

Price Units

Coconut Fiber 61250

kg/day

CV. Alindo, Bandung,

Jawa Barat

once Rp 2.500,00 Kg

NaOH 5% 122500

Liter/day

PT.Anugrah Putra

Kencana, Bekasi

once Rp 65.000,00 Liter

Water 306250

Liter/day

PDAM Cikarang once Rp. 8.517,00 m3

Resin Ethylene

Vinyl Acetate

15312.5

kg/day

CV. Yes Karya, Bekasi once Rp10.500.000,00 ton

29


4.7 Product Distribution

The next process after the product had been made and packaged is the

distribution of the product to consumer. “Cocofoam” which have been packed in

packaging box will be processed to the stage of distribution to consumers. We use

box truck to distribute food packing product. Besides that, the location of our

product is in Java and Bali. So we decide to distribute our product to distribution

center first and then pay some service to distribute our product to market or

retailer.

4.7.1 Location of Product Distribution Based On Plant Location

Location of product distribution is determined based on the target area of

marketing. We decide that this food packing product will be distributed to some

big cities in Java and Bali such as Jabodetabek, Bandung, Yogyakarta, Semarang,

Solo, Surabaya. This decision is taken based on the fact that Java and Bali are the

island with the highest fast food industry in Indonesia. Beside that, Java and Bali

is quite near to each other compared to another island in Indonesia.Our

consumer’s targets are small and medium scale of food industry's in Java and Bali

areas. Consumer segmentation is more in urban areas or big cities in Indonesia.

Table 4.9 until Table 4.11 shows about retailer and its location:

Table 4.9 Region and Percentage of Distribution

Region Percentage

Jabodetabek and West Java 40%

Bali 25%

East Java 20%

Central Java 15%

Total 100%

30


Cikarang Bandung Yogyakarta Surakarta Semarang Surabaya

4.7.2 Product Distribution Chain

The product that had been made will be saved in storage for distribution to

consumer.

Figure 4.5 Product Distribution Chain

Figure 4.6 Alternative Routes of Product Distribution

4.7.3 Distribution Route

There are some distribution center that we choose, which are Jakarta,

Bandung, Depok, Tangerang, Bekasi, Solo, Yogyakarta, Semarang, Surabaya.

From these distribution center, products will be distributed to the retailer and

retailer. The distribution rute is shown below

Product Distribution

Plant Location Cikarang

Raw Material Supplier Local

Distribution Route Land Route

Transportation Truck

31


Figure 4.7 Distribution Route

Figure 4.8 Distribution Process Through Land Route

For the distribution using land route, we decide to use the truck because

the effectiveness and the flexibility to location target. By using truck, Shavol will

be sent to distribution center. After that, the product from distribution senter will

be distributed to retailer.

Storage Distribution

(Box Truck) Store

Storage

Retailer Consumer


CHAPTER V

PRODUCT ECONOMICS

The calculation of product economics in this chapter is based on

these following assumptions:

The construction of Cocofoam plant will start in the end of 2014. It

will take about a year to build the plant, hence it will be operated by

the end of 2015.

Some equipments will have the salvage value in the end of its year

period

Currency of 1 US$ is equal to Rp 12.090,00 based on the data on

January 19th 2014

In order to determine the product selling price, we use these following

assumptions:

- The plant will be operated for 10 years. It is excluded the

construction time.

- A year consists of 330 working days.

The Declining Balance method (DB 200%) is used to calculate the

depretiation value of each equipment (non-building). Meanwhile, to

calculate the depretiation value of building, the linear depretiation

method is used (based on UU PPH).

5.1 Capital Expenditure

5.1.1 Equipment Cost and Installation Cost

a. Main Equipment Cost

Bare-module cost is the total cost of main equipment that

required for production process. It is the whole cost that calculated

from the purchasing process of the equipment until it is installed on

the plant and ready to be used, therefore it consists of Free On

Board purchase cost, shipping cost, and installation cost.

33


The processes to calculate bare-module cost are:

The required data to calculate bare-module cost are the Free On

Board (FOB) purchase cost, material cost, labor cost, and

indirect module cost

The total material cost is added with the Free On Board

purchase cost will result on module cost

Labor cost is added with module cost will result on direct

module cost

Indirect module cost such as freight, tax, insurance,

engineering, and field expense is added with direct module cost

will result on bare-module cost

The calculation of bare-module cost is shown in the Table 5.1

Table 5.1 Main Equipment Cost

No Equipment Quantity FOB 2014

(US$)

FOB 2014

(Rp)

FOB 2015 (Rp) Shipping

Cost ($)

Shipping

Cost (Rp)

Total

Bare

Module

Cost

(Rp)

1 Grinder 1 $

3.000

Rp

36.270.000

Rp

37.081.154,94

$

70

Rp

848.718

Rp

37.929.8

73

2 Oven Drier 7 $

4.000

Rp

48.360.000

Rp

49.441.539,92

$

297

Rp

3.590.730

Rp

371.225.

889

3 Hot Press

Machine

1 $

1.500

Rp

18.135.000

Rp

18.540.577,47

$

297

Rp

3.590.730

Rp

22.131.3

07

4 Moulding

Machine

4 $

10.000

Rp

120.900.000

Rp

123.603.849,80

$

669

Rp

8.088.210

Rp

526.768.

239

Total Bare-

Module

Cost

Rp

958.055.

309

All of the purchased equipment have the life time value. In

cash flow calculation, when the equipment reach the end of its life

time value, it means that we should buy the new equipment since

that equipment are no longer can be used. Therefore, it is necessary

to know the data of equipment life time value and do the

34


depreciation calculation by using that data. The purpose of this

calculation is to know how much the amount of the equipment

value depreciation that occur in their life time value and to know

how much the amount of the salvage value that will be used in cash

flow calculation. We use the declining balance (DB 200%) method

on this calculation. The depreciation of equipment cost is shown in

the table in appendix.

b. Supporting Equipment Cost

Supporting equipment is the office equipment that also

required in supporting production process. The amount of

supporting equipment is estimated based on the total workers in

office. The example of supporting equipment are computer, fax,

printer, scanner, safety equipment such as safety shoes, fire

extinguisher, photocopy machine, table, chair, sofa, etc. The

calculation of supporting equipment cost is shown in the Table 5.2

From the table above, we can see that the total supporting

equipment cost required is Rp817,445,000. The depreciation

calculation for the supporting equipment is also required. The life

time value for the supporting equipment is different one to each

other. The depreciation calculation of supporting equipment will be

shown on the appendix.

5.1.2 Market Research Cost

As a new product, “Cocofoam” has to be very competitive in

market. However, it has to be known by consumer first before it can reach

through the next level which is to be the favorite packaging product. In

order to know the suitable marketing strategy for “Cocofoam”, we have to

do a market research. In doing market research, we hire consultant’s

service in order to get an accurate analysis.

Market research cost for this product is shown in the Table 5.3

35


Table 5.2 Market Research Cost

No Type of Cost Quantity Based Cost Cost (Rp)

1 Surveyor 2 Rp 2.800.000 Rp 5.600.000

2 Consultant 2 Rp 12.600.000 Rp 25.200.000

3 Survey Needs Rp 6.300.000 Rp 6.300.000

Total Market Research Cost Rp 37.100.000

5.1.3 Site Development and Building Cost

Site development and building cost is the cost required to build the

office and the plant. This cost consists of land cost, site development cost,

and building cost. The calculation of site development and building cost is

shown in Table 5.4

Table 5.3 Site Development and Building Cost

No Type of Cost Quantity Based Cost Cost (Rp)

1 Land (m2) 600 Rp 1.000.000 Rp 600.000.000

2 Site Development (Grass

Root Plant)

Rp -

3 Building (Office) (m2) 200 Rp 2.200.000 Rp 440.000.000

4 Building (Plant) (m2) 300 Rp 2.200.000 Rp 660.000.000

Total Site Development and

Building Cost

Rp 1.700.000.000

5.1.4 Installation Cost

Installation cost is the beginning cost for equipment, it consists of

water installation, electricity installation, hydrant installation, telephone

installation, and internet installation. The component of this cost is in the

Table 5.5.

Table 5.4 Installation Cost

No Type of Cost Cost

1 Water Installation Rp 55.000.000

2 Electricity Installation Rp 98.500.000

3 Hydrant Installation Rp 40.000.000

4 Telephone Installation Rp 30.000.000

5 Internet Installation Rp 10.000.000

Total Installation Rp 233.500.000

36


5.1.5 Total Capital Investment

According to Guthrie method, the formula to calculate TCI is:

) +

The purpose of TCI calculation is to know how much the cost

needed to start-up the plant construction and production process, analyze

the feasibility of the plant construction, and determine whether the product

price will result the acceptable profit margin or not.

Table 5.5 Total Capital Investment

Bare-Module Cost Rp 958.055.309

Supporting Equipment Cost Rp 817.445.000

Offsite Facilities Cost Rp 281.402.765,45

Site Development and Building Cost Rp 1.700.000.000

Market Research Cost Rp 37.100.000

Total Plant Investment Rp 5.789.003.075

Working Capital Rp 1.018.864.541

Total Capital Investment Rp 6.807.867.616

5.2 Operational Expenditure

5.2.1 Raw Material Cost

Raw material cost from Cocofoam is one of important cost in

economic analysis. Raw material costs are include the cost of purchased

the raw material that is Coconut fiber, NaOH 5%, and Resin EVA.

Table 5.6 Raw Material Cost

No Raw Material Requirement

per day

Unit Price (Rp) Total Price (Rp)

1 Coconut Fiber 49001,6 kg 2500 Rp122.504.000

2 NaOH 5% 46011,0 L 3000 Rp138.033.000

3 Resin EVA 12250,4 kg 10500 Rp128.629.200

Total Raw Material Cost Per Day Rp389.166.200

Total Raw Material Cost Per Year Rp128.424.846.000

37


5.2.2 Utility Cost

For this part we calculate the utility cost as the cost which is used

for the importance of production process or know as variable cost. The

following utilities are electricity and water to operate generator when there

is no supply of electricity from PLN. The electricity cost is shown in Table

5.8.

Table 5.7 Utility Cost

No. Utility Needs Unit Charge Charge

Unit

Cost (a day)

1 Water 245008 Liter/day 8,517 /L 2086733,136

2 Electricity at Waktu Beban

Puncak (WBP)

170,8 kW/day 1342 /kWh 229213,6

3 Electricity at Lewat Waktu

Beban Puncak (LWBP)

539,5 kW/day 760 /kWh 410020

Total Variable Cost in a day Rp2.725.966,74

Total Variable Cost in a year Rp899.569.022,88

5.2.3 Maintenance Cost

The continuous process which is done by each process equipment

can make the equipment did not work in intensive and optimum way. So,

we need to do maintenance. The maintenance is also done for factory

building and supporting tools for office needs. Total maintenance cost is

shown in Table 5.13

Table 5.8 Total Maintenance Cost

Maintenance Cost

Main equipment Rp17.530.500,00

Supporting equipment Rp 34.144.500,00

Building Rp96.048.162,34

Total Rp147.723.162,34

5.2.4 Labor Cost

We calculate the labor cost for direct labor and indirect labor

separately. Direct labor is all of the labors who are involved directly in a

production process at a factory. In this section, we will explain about the

cost in the direct labor. The decision about the salary of the labors is based

38


on UMR (Upah Minimum Regional), which is rule of Indonesia’s

government about minimum salary for employee or laborer based on

regional where the employee or laborer works.

Meanwhile, indirect labor consists of employees who do not affect

the amount of product produced or not directly related to production

activities of “Cocofoam” product. Indirect labor’s requirements are suited

to the organizational structure owned. The salary of each employee is

included employee benefits per year and insurance costs for employees

which are deducted each month for the cost of insurance. The details of

indirect labor can be seen in the Table 5.15

5.2.5 Patent Cost

Our product category is innovation product, so that we must

register it for patent, copy right, industry design, and brand. The

calculation of each fee can be seen in the Table 5.16 until 5.19

Table 5.9 Total Patent Fee

Fee Cost

Patent Fee Rp 62.425.000

Copyright Fee Rp 425.000

Industry Design Fee Rp 1.150.000

Brand Fee Rp 3.350.000

Total Fee Rp 67.350.000

5.2.6 Distribution Cost

To distribute our product from factory to distribution center we use

our own distribution car. The cost of this distribution consists of fuel cost,

driver fee, port fee, toll fee,etc. The detailing of distribution cost from

factory to distribution center is shown in Table 5.21until Table 5.24

For distribution of product from distribution centre to retailer we

use expedition service company. This company will send and distribute

our product from distribution centre to retailers. The fee for this expedition

company is based on weight of the product and the distance from

39


distribution centre to retailers. The distribution is done once a week, then

we calculate the distribution cost in a year.

Table 5.10 Total Distribution Cost

Distribution Cost

From factory to distribution center Rp348.000.000,00

From distribution center to traditional

market

Rp675.097.904,00

Total Distribution Cost per Year Rp1.023.097.904,00

5.2.7 Marketing Cost

The purpose of the marketing is to introduce, inform and

understand customer needs about suitability of the Cocofoam product with

consumer needs, so that our product will be sold quickly in accordance

with the economic analysis which we are designed. Marketing costs

include promotional activities planned; those are the cost of printed media,

online media, radio advertising, and websites. The total marketing cost is

shown in the Table 5.30

Table 5.11 Total Marketing Cost

No Type of Cost Cost per year

1 Grand Launching Product Cost Rp67.100.000

2 Advertising (Printed Media, Radio,

Online Advertising) Cost

Rp433.800.000

3 Creating and Developing Website

Cost

Rp2.200.000

Total Marketing Cost per year Rp503.100.000

5.2.8 General Expenses

General expenses are the expenses related to routine expenses of the

factory office to support the operational activity of the factory. The routine

expenses mainly come from administration expenses. The detail of general

expenses is shown in Table 5.31

40


Table 5.12 General Expenses

Expenses Total Cost per Year

Shipping and Correspondencies Rp 2.000.000

Phone Rp 5.000.000

Faximile Rp 2.500.000

Internet Rp 6.000.000

Operational Expenses Rp 10.000.000

Total General and Administrative Expenses

(Rp)

Rp 25.500.000

5.2.9 Insurance and Factory Over Head (FOH)

The insurances include insurance for accident, insurance for retired, and

insurance for health care.

Table 5.13 Insurance Cost

No. Insurance Type Amount Insurance Cost

1 Building and Equipments 2% from Total Plant Investment Rp115.780.061,49

2 Raw Materials 2% from Total Raw Materials Cost Rp2.568.496.920,00

3 Employees Total Insurance Rp166.327.080,00

Total Insurance Cost Rp2.850.604.061,49

Factory Over Head (FOH) includes indirect labor costs, office expenses,

insurance, and depreciation. FOH of company consists of fixed costs and

variable costs. The calculation of total FOH is shown at Table 5.34

Table 5.14 Factory Over Head (FOH) Cost

Fixed FOH Cost

Indirect Labour Rp 134.000.000

Fixed Utilitity Rp 899.569.023

Maintenance Rp 147.723.162

Depresiasi Rp 238.188.765

Asuransi Pabrik Rp 2.850.604.061

Total Fixed FOH Rp 4.270.085.011

5.2.10 Total Operational Cost

Operational cost is the expenses which are related to the operation of a

business, or to the operation of a device, component, piece of equipment

http://en.wikipedia.org/wiki/Expense

41


or facility. They are the cost of resources used by an organization just to

maintain its existence.

Table 5.15 Total Operational Cost

Operational Cost Fixed Cost (FC) (Rp) Variable Cost (VC) (Rp)

Direct Material Rp 128.424.846.000

Direct Labor Rp 898.200.000

Factory Over Head (FOH) Rp 4.270.085.011

Marketing Cost Rp 503.100.000

Distribution Cost Rp 1.023.097.904,00

Patent Rp 67.350.000,00

General Expenses Rp 25.500.000

Income tax Rp 43.841.696.455

TOTAL (Rp/Year) Rp 50.125.929.371 Rp 128.927.946.000

TOTAL (Rp/Year) Rp 179.053.875.371

5.3 Economic Analysis

5.3.1 Product Pricing

Price of product per unit can be determine by calculating direct material,

direct labor, factory overhead, marketing expenses, distribution expenses, general

and administration expenses, invest, and sales volume. Price of the product also

calculated based on forecasting for a high, moderate, and low production

capacity. The calculation is shown in Table 5.36. Based on calculation on Table

5.36, it is decided that sales price for Cocofoam after adding profit is Rp 850 per

package.

5.3.2 Investment

Interest rate is the amount of interest that must be pay for loan to Bank and

investors. In this case, our product loan the capital cost to one bank, Bank

Mandiri, as much as 40% of the Total Capital Investment and to investors with

60% of the Total Capital Investment.

For Bank loan, the interest rates is10,5%per year which will be paid in 5

years and the interest rate for investors is10% per year (higher than deposito rate

interest) which will also be paid in 5 years. Table 5.37 and Table 5.38 shows the

calculation of investment in Bank and investors.

42


5.3.3 Cash Flow

The cashflow consists of income and expense. The source of income are

revenue, before tax income, after tax income, and salvage value. Meanwhile, the

source of expenses are investment, operation cost, loan payment, and interest

payment. We assume that on the first and second year of production, our product

only sold about 50% and 70% of total production. This assumption is based on the

fact that our product is new, and it will take some time for consumer to receive

our product. For the rest of the year, the amount of our product that sold is equal

to total production. The cashflow calculations can be seen in appendix.

Figure 5.1After Tax Cashflow and Before Tax Cashflow

Figure 5.2 Cumulative Cashflow

Rp(80,000,000,000)

Rp(60,000,000,000)

Rp(40,000,000,000)

Rp(20,000,000,000)

Rp-

Rp20,000,000,000

Rp40,000,000,000

Rp60,000,000,000

1 2 3 4 5 6 7 8 9 10

ATCF dan BTCF

ATCF

BTCF

Rp(100,000,000,000)

Rp(50,000,000,000)

Rp-

Rp50,000,000,000

Rp100,000,000,000

Rp150,000,000,000

Rp200,000,000,000

Rp250,000,000,000

Rp300,000,000,000

After Tax

Cumulative Cashflow

Cumulative Cashflow

43


5.3.4 Cost Breakdown

Cost breakdown is used to see the percentage of each expense

spent by the factory. By making cost breakdown, we will know which

variable has the biggest percentage from operation cost.

Figure 5.3 Cost Breakdown

From Figure 5.3, it can be seen that direct material is the biggest

expenses at 95.03% from total operation cost, and general expenses is the

smallest expenses at 0.02%. Based on this, it is known that direct material

has the biggest influence to operational cost. Therefore, if there’s an

increase in direct material (such as raw material to produce Cocofoam), it

will also affect operational cost.

5.4 Profitability Analysis

The main reason for making a business is to get its profit. We use three

aspects to decide whether our business is feasible or not: IRR, Payback Period,

Break Even Point (BEP), and Net Present Value (NPV).

5.4.1 Internal Rate of Return (IRR)

Internal Rate of Return (IRR) is the measurement of maximum interest

that have to be paid for a project and still have a break event in the end of project

life. In other words, IRR is an interest while the value of NPV is 0, so that the

formula to calculate IRR is

Direct Material

(95,03%)Direct Labor (0,66%)

Factory Over Head

(FOH) (3,6%)Marketing Cost (0,37%)

Distribution Cost

(0,76%)General Expenses

(0,02%)

44


With the value of r is IRR. By using Microsoft Excel, we get that the value of IRR

for Cocofoam plant is 29%. This value is a quite high value for IRR, so that it will

attract the investor

5.4.2 Payback Period

Payback period is the time that needed for an investment to be paid back.

The formula to calculate payback period with effect of time-value money is

shown in equation below:

Payback period for Cocofoam plant is 3,92 year as shown in Figure 5.4

Figure 5.4 Payback Period

5.4.3 Break Even Point (BEP)

Break Even Pint (BEP) is an analysis to determine and find number of

products that have to be sold to the consumers in a certain price to cover the

operational cost and other cost, and also to gain profit. The equation to calculate

BEP is:

Rp(100)

Rp(50)

Rp-

Rp50

Rp100

Rp150

Rp200

Rp250

Rp300

0 2 4 6 8 10 12

Bil

lio

ns

Payback Period

45


Where total fixed cost is a cost which the value relative stable and variable

cost is a cost which the value is depend on number of production. The calculation

of BEP is shown in Table 5.39

Table 5.16 Break Even Point

Fixed Cost Rp 49.453.012.679

Variable Cost Rp 128.927.946.000

Price/unit Rp 850

BEP (unit) 133.867.104

BEP (Rp) Rp 113.787.038.445

From Table bla, number of Cocofam which have to be sold to cover the

production cost and gain profit is 135.867.104 unit.

5.4.4 Net Present Value (NPV)

Net Present Value (NPV) shows the net profit that received by a project in

the life time of the project with current interest rate. In other words, NPV is a

present value from the cashflow. A feasible project is a project that has the NPV

value more than 0, meanwhile the project with the NPV value less than 0 is not a

feasible project.

After change the profit in the future to net present value, all of the profit is

added with MARR 13.5%, so we get the value of NPV is Rp. 80.297.370.253.

Based on that value, this project is a feasible project to be done.

5.5 Sensitivity Analysis

Every factory is never always stable. There are some times that the factory

will have some changes in production, cost, profit, etc. These changes are caused

by some factors that affect the factory either directly or indirectly. These changes

also can cause the factory suffer financial loss or gain more profit. So, for these

reasons we need sensitivity analysis to see the influence of some changes to the

factory.

In this analysis, we will analyze some changes in raw materials cost and

selling price. These three are chosen because of this parameters are most likely

46


occur in our factory. The parameter to analyze these changes is Net Present Value

(NPV), Payback period, and IRR

5.5.1 Influence of Raw Material Cost

Raw materials influence the operation cost, so indirectly influence NPV

too. The deviation of raw materials price is making the NPV decrease along with

the increases of deviation because if the raw materials price increases, the

outcome of the factory is increase.

Besides that, the payback period also changes because of raw materials

deviation. The deviation of raw materials caused the payback period longer than

before along with the increase in raw materials price. These reason is caused by

the increase in raw material prices is influence the operation cost and if the other

cost and income is constant, the profit we have for payback period is decrease and

so the payback period is longer than before deviation.

Table 5.17 Influence of Raw Material Cost Towards IRR, NPV, and Payback Period

Deviation Total Raw Material

Cost IRR NPV PBP (Year)

-6% Rp120.719.355.240 43% Rp126.893.269.642 3,375015804

-4% Rp123.287.852.160 37% Rp111.361.303.179 3,584232358

-2% Rp125.856.349.080 31% Rp95.829.336.716 3,821101688

0% Rp128.424.846.000 25% Rp80.297.370.253 4,091494169

2% Rp130.993.342.920 19% Rp64.765.403.790 4,403068335

4% Rp133.561.839.840 13% Rp49.233.437.327 4,766007854

6% Rp136.130.336.760 9% Rp33.701.470.864 5,194155735

5.5.2 Influence of Product Price

Selling price is the only factor that not influenced directly with

operating cost or the other cost, but we cannot decide the selling price

randomly because if we decide the selling price randomly without consider

IRR, profit, etc the factory will not working or the investor will not invest

in our product.

47


Table 5.18 Influence of Product Price Towards IRR, NPV, and Payback Period

Deviation Product Price IRR NPV PBP

-6% Rp799 7% Rp25.069.898.839 5,419685169

-4% Rp816 15% Rp43.479.055.977 4,871974459

-2% Rp833 20% Rp61.888.213.115 4,44037137

0% Rp850 25% Rp80.297.370.253 4,091494169

2% Rp867 31% Rp98.706.527.391 3,803638637

4% Rp884 37% Rp117.115.684.529 3,562082468

6% Rp901 43% Rp135.524.841.667 3,35648678

If we assume the other value is constant, the increase in selling

price will increase the profit that will the factory get. Hence, the payback

period will decrease, NPV increase, and IRR increase.

Figure 5.5 Sensitivity Analysis Curve-IRR

0%

10%

20%

30%

40%

50%

-10% -5% 0% 5% 10%

IRR

Deviation

Sensitivity Analysis-IRR

Raw Material Cost

Product Price

Rp0

Rp50

Rp100

Rp150

-10% -5% 0% 5% 10%

NP

V Bil

lio

ns

Deviation

Sensitivity Analysis-Net Present

Value

Raw Material Cost

Product Price

48


Figure 5.6 Sensitivity Analysis Curve-NPV

Figure 5.7 Sensitivity Analysis Curve-PBP

0

1

2

3

4

5

6

-10% -5% 0% 5% 10%

Pa

yb

ack

Per

iod

Deviation

Sensitivity Analysis-Payback

Period

Raw Material Cost

Product Price

49


CHAPTER VI

CONCLUSION AND SUGGESTION

6.1 Conclusion

Based on explanation and review stated before, the conclusion for this paper are:

1. Based on questionnaire and interview result, consumers prefer food packaging with

these criteria: practical, do not harmful for human body, water proof, affordable,

and degrade easily.

2. Name of our product is Cocofoam with motto Love the Earth, Love Your Body

3. The factory is located in Karangsari, East Cikarang, West java, Indonesia.

4. The plant will be operated for 10 years

5. The capacity of production per day is 735000 packages.

6. Our market target located in Java and Bali region

7. Price of Cocofoam per piece is Rp. 850,-

8. Based on economic calculation, Cocofoam plant has IRR as much as 29%, NPV Rp.

87.766.760.161, and payback period 3,92 years.

6.2 Suggestion

The biggest obstacle in marketing Cocofoam is ensuring consumers to buy our product.

This is mainly because our competitor product such as styrofoam and plastic have been

widely used. To overcome this problem, informing consumers about the hazard of

styrofoam and plastic as food packaging is required. Further research and development is

needed in order to maximizing the quality of Cocofoam which is focusing in both

enviromentally friendly and healthy product. Also, deeper economic analysis is needed to

maximizing profit of this plant. We hope that in the future Cocofoam can be distributed in a

broader area in Indonesia and also foreign country.

50


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52


Appendix

Appendix A.1

Table 1.6 List of Needs and Rankings Based on Several Categories

Need

Number

Need Description Rank


3 Affordable Food Packaging 3


1 Practical 3

2 Water Proof 4

4 Thermostable 4

5 Has no odor 2

Health Aspect

6 Not dangerous for human body 5


7 Degrade Easily 4


8 Attractive Form 1

9 Attractive Color 1

Table 1.7 List of Metrics

Needs No Needs Spesification Metric Unit Rank


3 Affordable Food Packaging Price of Product Rp 3


1 Practical Ergonomic Subjective 3

2 Water Proof Time to Patch Water

Before Leak

Hours 4

4 Thermostable Thermal Stability oC 4

5 Has no odor Odor Subjective 2

Health Aspect

6 Not dangerous for human body Toxicity Subjective 5


7 Degrade Easily Time to Degrade Years 4


8 Attractive Form Ergonomic Subjective 1

9 Attractive Color Ergonomic Subjective 1

53


Table 1.8 Benchmarking

Number Needs Spesification Metric

Unit

Own

Product

Product A

(Styrofoam

)

Product

B

(Plastic)

Product

C (Paper)

Product D

(Paper

Box)

3 Affordable Food

Packaging

Price of

Product

Rp Rp

1.000

Rp

210

Rp 100 -

150

Rp

75

Rp 800 -

1000

1 Practical Ergonomic Subjective ●●●●● ●●●●● ●●●●● ●● ●●●●

2 Water Proof Time to Patch

Water Before

Leak

Hours 10 Infinite Infinite 0,08 -

0,16

0,08 - 0,16

4 Thermostable Thermal

Stability

oC (0) - (+93) (-50) -

(+95)

(-10) -

(+80)

(+ 25) -

(+35)

(+ 25) -

(+35)

5 Has no odor Odor Subjective No Odor No Odor No Odor No Odor No Odor

6 Not dangerous

for human body

Toxicity Subjective Non Toxic Very Toxic Very

Toxic

Non

Toxic

Non Toxic

7 Degrade Easily Time to

Degrade

Years 0,019 -

0,038

300-1000 100-1000 0,083 0,083

8 Attractive Form Ergonomic Subjective ●● ●● ●● ●● ●●

9 Attractive Color Ergonomic Subjective ●● ●● ●● ●● ●●

Table 1.9 Concept Combination

No Concept Based on

Form of Food

Packaging

Concept Based on How

to Open Food

Packaging

Concept Based on

Base Material of

Food Packaging

Concept Based on Resin

of Food Packaging

1 Round Clamshell Coconut Husk Ethyl Vinyl Acetate

(EVA)

2 Cubic With casing Bagasse Poly Propylene

Urea Formaldehyde

54


Table 1.10 List of Concept

Concept

Number

1 2 3 4 5 6 7 8 9 10

(Reference)

11 12

Form Round Round Round Round Round Round Cubic Cubic Cubic Cubic Cubic Cubic

How to

Open

With

casing

With

casing

With

casing

With

casing

With

casing

With

casing

Clamshell Clamshe

ll

Clamshe

ll

Clamshell Clamshell Clamshell

Base

Material

Coconut

Husk

Coconut

Husk

Coconut

Husk

Bagasse Bagass

e

Bagasse Coconut

Husk

Coconut

Husk

Coconut

Husk

Bagasse Bagasse Bagasse

Resin EVA Poly

Propylen

e

Urea

Formaldeh

yde

EVA Poly

Propyl

ene

Urea

Formaldeh

yde

EVA Poly

Propyle

ne

Urea

Formald

ehyde

EVA Poly

Propylene

Urea

Formaldehy

de

Appendix A.2

Table 2.1 Type of Some Food Packagings

Material Use Appearance Properties Temperature

Tolerance

Cost

Foamed Plystyrene Clamshells and other

hinged-lid containers,

tableware, meat trays.

Used for coffee and

other hot beverages.

Can be white, black,

vanilla, green, pink,

yellow or blue

Excellent heat

retention and cold

insulation.

Strong,

lightweight, won't

allow soak-

Moderate

temperature

resistance. Can hold

hot foods and is

microwaveable.

Certain hot food

Very economial.

A good choice

when

merchandising is

not needed.

55


through.

Polypropylene The most common

takeout packaging

material, used for

chicken roasters, bakery

and microwaveable

takeout containers.

Ussually made in

black or clear. Can

easily be made into

many shapes, sizes

and compartments

and molded with

design elements.

Very rigid, crack-

resistant, leak-

resistant. Can be

film sealed, if rim

is wide enough.

Preferred material

for microwave and

hot case. Can resist

temperatures up to

220 to 240.

Moderately

priced. Not as

expensive as

CPET.

Foamed Polypropylene Good for clamshells and

other hinged-lid

containers, tableware,

meat trays. This is a

relatively new product

and will become more

used various customers.

Usually white but can

be other colors

Excellent heat

retention and cold

insulation.

Strong,

lightweight, won't

allow soak-

through.

Can hold hot foods

and is

microwaveable

Moderately

priced. Not as

expensive as

CPET.

56


PVC Especially good for

merchandising cold,

foods, snack item and

bakery items.

Extremely high

clarity PETE can be

colored

Durable, tough,

clear.

Moderate

temperature

resistance..

PVC

Economically

priced

Pressed Paperboard Frozen applications or

fresh, film-sealed meals.

Terrific printed

graphic capability

Superior strength

when made with

a uni-body

construction.

One of the widest

temperature ranges

available.

Moderately

priced

57


Appendix A.3

Table 3.1 Perceptual Mapping Detail Computation

Criteria

Selection

Weight Own Product Product A

(Styrofoam)

Product B

(Plastic)

Product C

(Paper)

Product D

(Paper Box)

Score Total Score Total Score Total Score Total Score Total

Price

1: Very

Expensive

5: Very Cheap

15% 2 0,3 3 0,45 4 0,6 5 0,75 2 0,3

Practical

1: Very not

practical

5: Very

practical

15% 5 0,75 5 0,75 3 0,45 1 0,15 4 0,6

Water Proof

1: Not water

proof

5: Water proof

10% 5 0,5 5 0,5 5 0,5 1 0,1 2 0,2

Thermostable

1: Not

thermostable

5:

Thermostable

10% 5 0,5 5 0,5 3 0,3 1 0,1 1 0,1

Level of

danger to

human body

1: Harmful

5: Not harmful

25% 5 1,25 1 0,25 2 0,5 4 1 4 1

Ease of

degradation

1: Difficult to

be degradaded

5: Easy to be

degradaded

25% 5 1,25 1 0,25 2 0,5 3 0,75 3 0,75

Table 3.2 Dimension of Cocofoam’s Size

Specification Dimension (cm)

Large Size

Length:Width:Height 25:10:7

Medium Size


Small Size


58


Appendix A.4

Equipment Profile

Figure 4.9 Grinder

Price: US$ 3000/unit

Power: 45 kW

Capacity: 15 Tonne/hour

Number of Unit: 1

Figure 4.10 Oven Drier


Power: 10 kW

Handling Capacity: 800 kg/h

Number of Unit: 7

59


Figure 4.11 Hot Press Machine


Power: 20 kW

Number of Unit: 1

Capacity: 12 sheets/kg

Figure 4.12 Moulding Machine


Power: 20,2 kW

Number of Unit: 4

Capacity: 20000 pieces/hour

60



Fiber

Water

Distilled Water

Chemical

Treatment

NaOH 5%

NaOH 5%

Blending with

Matrix

Resin

Drying

Water

MoldingPackaging

Coconut

Husk49001,6 kg

49001,6 kg

245008 L

245008 L

Coconut

Fiber

49001,6 kg

98003,2 kg

98003,2 kg

Coconut

Fiber

49001,6 kg

12250,4 kg

2 L

Coconut

Fiber

61252 kg

Coconut

Fiber

61250 kgCocofoam

735000 pieces

Figure 4.13 Mass balance Diagram of Cocofoam Production

61



Fiber

Water

Water

Chemical

Treatment

NaOH 5%

NaOH 5%

Blending with

Matrix

Resin

Drying

Water

MoldingPackaging

Coconut

Husk45 kW

Coconut

Fiber

Coconut

Fiber

Coconut

Fiber

70 kW

Coconut

Fiber

100,8 kWCocofoam

Figure 4.14 Energy balance Diagram of Cocofoam Production

62


Table 4.10 Retailer in Jabodetabek Region

Location Traditional market

Jakarta Pasar RayaKramat Jati

Pasar Jatinegara

Pasar Pagi Mangga Dua

Pasar Cijantung

Pasar Grogol

Pasar Pramuka

Tanggerang Pasar Anyar, KecTanggerang

Pasar Bandeng, Kec Karawaci

Pasar Jatiwurung, Kec. Priuk

Pasar Malabar, Kec. Cibodas

Gasar Gerendeng, Kec. Karawaci

Bogor Pasar Kebon Kembang, Jl Dewi Sartika

Pasar Bogor, JL. Surya Kencana

Pasar Induk Cimanggu, Jl. Baru Kemang

Pasar Induk Jambu Dua, Jl. Pajajaran

Pasar Induk TU Kemang, Jl.Baru Kemang

Depok PasarMusi

Pasar KemirimukaKel.Kemirimuka, Kec. Beji

Pasar Cisalak Kel. Cisalak Pasar, kec. Cimanggis

Pasar Agung Kel. Depok Jaya, Kec. Pancoran Mas

Pasar CinereKel.Cinere, Kec. Limo

Bandung Pasar Puyuh, Kec Coblong

Pasar Wastukencana, Kec. Bandung Waten

Pasar Binong, Kec. Kiaracondong

Pasar Saerun, Kec. Batununggal

Pasar Taman Senang, Kec. Bojongloa Kaler

Table 4.11 Retailer in Java Region

Location Traditional Market

Solo Pasar Lengking

Pasar Tawangkuno

Yogyakarta Pasar Beringharjo

Pasar Giwangan

Semarang Pasar Johar

Pasar Prambean

Surabaya Pasar Kapasari

Pasar Aswatomo

63


Table 4.12 Retailer in Bali Region

Area Traditional Market

Bali Pasar Kumbasari

Pasar Ubud

Appendix A.5

Table 5.19 Main Equipment Cost

No Tools Quantity Prices per quantity

(Rp)

Shipping Cost (Rp) Total Price (Rp)

1 Computer 6 Rp 4.000.000 Rp

100.000

Rp

24.100.000

2 Fax 1 Rp 1.000.000 Rp

-

Rp

1.000.000

3 Photocopy Machine 1 Rp 10.000.000 Rp

-

Rp

10.000.000

4 Scanner 1 Rp 600.000 Rp

-

Rp

600.000

5 Printer 6 Rp 1.400.000 Rp

100.000

Rp

8.500.000

6 Projector 1 Rp 3.200.000 Rp

-

Rp

3.200.000

7 Chair 20 Rp 400.000 Rp

200.000

Rp

8.200.000

8 Table 20 Rp 500.000 Rp

300.000

Rp

10.300.000

9 Cabinet 3 Rp 1.500.000 Rp

300.000

Rp

4.800.000

10 Fan 3 Rp 550.000 Rp

-

Rp

1.650.000

11 Air Conditioner 1 Rp 2.500.000 Rp

-

Rp

2.500.000

12 Trash Can 5 Rp 25.000 Rp

-

Rp

125.000

13 Office Equipment 100 Rp 20.000 Rp

-

Rp

2.000.000

14 Alarm Bell 5 Rp 150.000 Rp

-

Rp

750.000

15 Fire Extuingisher 5 Rp 250.000 Rp

-

Rp

1.250.000

16 Masker 100 Rp 1.000 Rp

-

Rp

100.000

17 Helm 40 Rp 200.000 Rp

150.000

Rp

8.150.000

18 Gloves 40 Rp 2.500 Rp

-

Rp

100.000

19 Safety Shoes 40 Rp 200.000 Rp

100.000

Rp

8.100.000

20 Dispenser 3 Rp 1.000.000 Rp

100.000

Rp

3.100.000

21 Truck 4 Rp 144.250.000 Rp Rp

64


100.000 577.100.000

22 Operational Car 1 Rp 115.000.000 Rp

300.000

Rp

115.300.000

23 Motorcycle 1 Rp 12.000.000 Rp

200.000

Rp

12.200.000

24 Electrical Generator 1 Rp 7.000.000 Rp

100.000

Rp

7.100.000

25 Lamp 72 Rp 50.000 Rp

100.000

Rp

3.700.000

26 Room Air Freshener 8 Rp 90.000 Rp

-

Rp

720.000

27 CCTV 8 Rp 350.000 Rp

-

Rp

2.800.000

Total Supporting

Equipment Cost

Rp

817.445.000

Table 5.20 Detail of Equipment Electricity Cost

No. Equipment Amount Power (kW) Total Power

(kW)

Usage Time

(minute)

Usage Time

(hour)

kWh

1 Grinder 1 45 45 90 1,5 67,5

2 Oven Drier 7 10 70 90 1,5 105

3 Hot Press

Machine

1 20 20 90 1,5 30

4 Molding Machine 4 20,2 80,8 90 1,5 121,2

Total (in a day) 323,7

Table 5.21 Maintenance Cost of Main Equipment

Main Equipment Quantity Cost Total Cost Factor Maintenance Cost

Grinder 1 Rp36.270.000,00 Rp36.270.000,00

0,02

Rp725.400,00

Oven Drier 7 Rp48.360.000,00 Rp338.520.000,00

0,02

Rp6.770.400,00

Hot Press Machine 1 Rp18.135.000,00 Rp18.135.000,00

0,02

Rp362.700,00

Moulding Machine 4 Rp120.900.000,00 Rp483.600.000,00

0,02

Rp9.672.000,00

Total Rp17.530.500,00

Table 5.22 Maintenance Cost of Supporting Equipment

Supporting

Equipment

Quantity Price per Unit Shipping

Cost

Total Cost Factor Maintenance

Cost

Computer 6 Rp

4.000.000,00

Rp

100.000,00

Rp

24.100.000,00

0,1 Rp 2.410.000,00

Fax 1 Rp

1.000.000,00

Rp

-

Rp

1.000.000,00

0,1 Rp 100.000,00

Photocopy

Machine

1 Rp

10.000.000,00

Rp

-

Rp

10.000.000,00

0,1 Rp 1.000.000,00

Scanner 1 Rp

600.000,00

Rp

-

Rp

600.000,00

0,1 Rp 60.000,00

65


Printer 6 Rp

1.400.000,00

Rp

100.000,00

Rp

8.500.000,00

0,1 Rp 850.000,00

Projector 1 Rp

3.200.000,00

Rp

-

Rp

3.200.000,00

0,1 Rp 320.000,00

Chair 20 Rp

400.000,00

Rp

200.000,00

Rp

8.200.000,00

0,1 Rp 820.000,00

Table 20 Rp

500.000,00

Rp

300.000,00

Rp

10.300.000,00

0,1 Rp 1.030.000,00

Cabinet 3 Rp

1.500.000,00

Rp

300.000,00

Rp

4.800.000,00

0,1 Rp 480.000,00

Fan 3 Rp

550.000,00

Rp

-

Rp

1.650.000,00

0,1 Rp 165.000,00

Air

Conditioner

1 Rp

2.500.000,00

Rp

-

Rp

2.500.000,00

0,1 Rp 250.000,00

Trash Can 5 Rp

25.000,00

Rp

-

Rp

125.000,00

0,1 Rp 12.500,00

Office

Equipment

100 Rp

20.000,00

Rp

-

Rp

2.000.000,00

0,1 Rp 200.000,00

Alarm Bell 5 Rp

150.000,00

Rp

-

Rp

750.000,00

0,1 Rp 75.000,00

Fire

Extuingisher

5 Rp

250.000,00

Rp

-

Rp

1.250.000,00

0,1 Rp 125.000,00

Masker 100 Rp

1.000,00

Rp

-

Rp

100.000,00

0,1 Rp 10.000,00

Helm 40 Rp

200.000,00

Rp

150.000,00

Rp

8.150.000,00

0,1 Rp 815.000,00

Gloves 40 Rp

2.500,00

Rp

-

Rp

100.000,00

0,1 Rp 10.000,00

Safety Shoes 40 Rp

200.000,00

Rp

100.000,00

Rp

8.100.000,00

0,1 Rp 810.000,00

Dispenser 3 Rp

1.000.000,00

Rp

100.000,00

Rp

3.100.000,00

0,1 Rp 310.000,00

Truck 2 Rp

50.000.000,00

Rp

100.000,00

Rp

100.100.000,00

0,1 Rp10.010.000,00

Operational

Car

1 Rp

115.000.000,00

Rp

300.000,00

Rp

115.300.000,00

0,1 Rp11.530.000,00

Motorcycle 1 Rp

13.000.000,00

Rp

200.000,00

Rp

13.200.000,00

0,1 Rp 1.320.000,00

Electrical

Generator

1 Rp

7.000.000,00

Rp

100.000,00

Rp

7.100.000,00

0,1 Rp 710.000,00

Lamp 72 Rp

50.000,00

Rp

100.000,00

Rp

3.700.000,00

0,1 Rp 370.000,00

Room Air

Freshener

8 Rp

90.000,00

Rp

-

Rp

720.000,00

0,1 Rp 72.000,00

CCTV 8 Rp

350.000,00

Rp

-

Rp

2.800.000,00

0,1 Rp 280.000,00

Total Rp34.144.500,00

Table 5.23 Maintenance Cost of Buliding

TPI Rp960.481.623,45

Factor 0,1

Cost Rp96.048.162,34

66


Table 5.24 Direct Labor Cost

Direct Labour Number of

Employee

Salary per Month Penghasilan

tidak kena

pajak per

Year

PPH per Year Total Gross

Salary

Laborer

Factory laborer 10 Rp

2.050.000

Rp

15.840.000

Rp

1.314.000

Rp

246.000.000

Warehouseman 2 Rp

2.050.000

Rp

15.840.000

Rp

1.314.000

Rp

49.200.000

Operator 11 Rp

2.100.000

Rp

15.840.000

Rp

1.404.000

Rp

277.200.000

Security 1 Rp

2.050.000

Rp

15.840.000

Rp

1.314.000

Rp

24.600.000

Cleaning Service 2 Rp

2.050.000

Rp

15.840.000

Rp

1.314.000

Rp

49.200.000

Technician 2 Rp

2.500.000

Rp

15.840.000

Rp

2.124.000

Rp

60.000.000

Supervisor

Facility Supervisor 1 Rp

4.000.000

Rp

15.840.000

Rp

4.824.000

Rp

48.000.000

Product

Distribution

Control Supervisor

1 Rp

4.000.000

Rp

15.840.000

Rp

4.824.000

Rp

48.000.000

Safety Supervisor 1 Rp

4.000.000

Rp

15.840.000

Rp

4.824.000

Rp

48.000.000

Process Supervisor 1 Rp

4.000.000

Rp

15.840.000

Rp

4.824.000

Rp

48.000.000

Total 32 Total per Tahun (Rp) Rp

28.080.000

Rp

898.200.000

Table 5.25 Indirect Labor Cost

No. Position Salary per

Month

Number

of

Employee

Gross Salary Penghasilan

Tidak Kena

Pajak (Per Year)

PPH

1 Stakeholder

and

Financial

Department

Rp10.000.000,00 1 Rp10.000.000,00 Rp15.840.000,00 Rp15.624.000,00

2 Rp5.000.000,00 1 Rp5.000.000,00 Rp15.840.000,00 Rp6.624.000,00

3 Rp5.000.000,00 1 Rp5.000.000,00 Rp15.840.000,00 Rp6.624.000,00

4 General

Support and

Service

Department

Rp5.000.000,00 1 Rp5.000.000,00 Rp15.840.000,00 Rp6.624.000,00

5 HRD

Department

Rp3.000.000,00 1 Rp3.000.000,00 Rp15.840.000,00 Rp3.024.000,00

6 Rp3.000.000,00 1 Rp3.000.000,00 Rp15.840.000,00 Rp3.024.000,00

7 HSE and

Maintenance

Department

Rp5.000.000,00 1 Rp5.000.000,00 Rp15.840.000,00 Rp6.624.000,00

8 Rp5.000.000,00 1 Rp5.000.000,00 Rp15.840.000,00 Rp6.624.000,00

9 Product

Planning and

Rp6.000.000,00 1 Rp6.000.000,00 Rp15.840.000,00 Rp8.424.000,00

10 Rp6.000.000,00 1 Rp6.000.000,00 Rp15.840.000,00 Rp8.424.000,00

67


11 Development

Department

Rp6.000.000,00 1 Rp6.000.000,00 Rp15.840.000,00 Rp8.424.000,00

12 Sales and

Marketing

Department

Rp4.000.000,00 1 Rp4.000.000,00 Rp15.840.000,00 Rp4.824.000,00

13 Rp4.000.000,00 1 Rp4.000.000,00 Rp15.840.000,00 Rp4.824.000,00

Total per Month 13 Rp67.000.000,00 Rp89.712.000,00

Total per Year Rp134.000.000,00 Rp422.658.000,00

Table 5.26 Patent Fee

Patent Request Rp 1.725.000

Pendaftaran Pencatatan Perjanjian

Lisensi

Rp 2.000.000

Lisence Obligation Request Rp 6.000.000

List of patent request Rp 300.000

Patent maintenance fee Rp 2.150.000 year 1

Rp 2.150.000 year 2

Rp 2.150.000 year 3

Rp 3.100.000 year 4

Rp 3.100.000 year 5

Rp 4.650.000 year 6

Rp 6.200.000 year 7

Rp 6.200.000 year 8

Rp 7.950.000 year 9

Rp 10.750.000 year 10

Administration fee Rp 1.000.000

Regional Patent Implementation fee Rp 3.000.000

Total Patent fee Rp 62.425.000

Table 5.27 Copyright Fee

Copyright request fee Rp 200.000

Copyright certification fee Rp 100.000

List of copyright request Rp 50.000

Copyright lisence fee Rp 75.000

Total copyright fee Rp 425.000

Table 5.28 Industry Design Fee

Industry design registration fee Rp 600.000

List of Industry design certificate fee Rp 100.000

Design Industry Priority Document Request Rp 100.000

Copy of Industry Design Certificate Request Rp 100.000

Agreement Letter of Design Industry Lisence Rp 250.000

Total Industry Design Fee Rp 1.150.000

68


Table 5.29 Brand Fee

Request of Brand Registration Rp 600.000

Extention of Brand Protection Fee Rp 2.000.000

Brand Certificate fee Rp 100.000

Lisence Agreement Record Rp 500.000

Brand Registration Request Fee Rp 150.000

Total Brand Fee Rp 3.350.000

Table 5.30 Distribution Cost From Factory to Distribution Center

Factory Location Cost Bali Yogyakarta-Solo-

Semarang-Surabaya

Jabodetabek

Cikarang Fuels Rp6.000.000,00 Rp4.000.000,00 Rp700.000,00

Ship Fee Rp400.000,00 - -

Driver's fee Rp2.300.000,00 Rp1.700.000,00 Rp500.000,00

Port fee Rp100.000,00 - -

Toll fee Rp300.000,00 Rp200.000,00 Rp150.000,00

Rp6.800.000,00 Rp4.900.000,00 Rp950.000,00

Total distribution cost from factory to distribution centre per month Rp29.000.000,00

Total distribution cost from factory to distribution centre per year Rp348.000.000,00

Table 5.31 Distribution Cost From Distribution Center to Retailer (Jabodetabek Area)

Location Traditional market Cost

Jakarta Pasar RayaKramat Jati Rp367.196

Pasar Jatinegara Rp239.964

Pasar Pagi Mangga Dua Rp367.196

Pasar Cijantung Rp239.964

Pasar Grogol Rp239.964

Pasar Pramuka Rp239.964

Tanggerang Pasar Anyar, KecTanggerang Rp367.196

Pasar Bandeng, Kec Karawaci Rp239.964

Pasar Jatiwurung, Kec. Priuk Rp239.964

Pasar Malabar, Kec. Cibodas Rp239.964

Gasar Gerendeng, Kec. Karawaci Rp239.964

Bogor Pasar Kebon Kembang, Jl Dewi Sartika Rp331.460

Pasar Bogor, JL. Surya Kencana Rp331.460

Pasar Induk Cimanggu, Jl. Baru Kemang Rp331.460

Pasar Induk Jambu Dua, Jl. Pajajaran Rp331.460

Pasar Induk TU Kemang, Jl.Baru Kemang Rp331.460

Depok PasarMusi Rp331.460

Pasar KemirimukaKel.Kemirimuka, Kec. Beji Rp331.460

Pasar Cisalak Kel. Cisalak Pasar, kec. Cimanggis Rp331.460

Pasar Agung Kel. Depok Jaya, Kec. Pancoran Mas Rp331.460

69


Pasar CinereKel.Cinere, Kec. Limo Rp331.460

Bandung Pasar Puyuh, Kec Coblong Rp459.120

Pasar Wastukencana, Kec. Bandung Waten Rp300.080

Pasar Binong, Kec. Kiaracondong Rp300.080

Pasar Saerun, Kec. Batununggal Rp300.080

Pasar Taman Senang, Kec. Bojongloa Kaler Rp459.120

Total per Week Rp8.154.380

Total per Year Rp424.027.760

Table 5.32 Distribution Cost From Distribution Center to Retailer (Java Area)

Location Traditional Market Cost (Rp)

Solo Pasar Lengking Rp580.470,00

Pasar Tawangkuno Rp700.892,00

Yogyakarta Pasar Beringharjo Rp570.780,00

Pasar Giwangan Rp589.660,00

Semarang Pasar Johar Rp307.484,00

Pasar Prambean Rp307.484,00

Surabaya Pasar Kapasari Rp250.130,00

Pasar Aswatomo Rp156.278,00

Rp156.278,00

Total per week Rp3.619.456,00

Total per year Rp188.211.712,00

Table 5.33 Distribution Cost From Distribution Center to Retailer (Bali Area)

Area Retailer Cost (Rp)

Bali Pasar Kumbasari Rp604.408,00

Pasar Ubud Rp604.408,00

Total per week Rp1.208.816,00

Total per year Rp62.858.432,00

Table 5.34 Marketing Cost in Printed Media

No Printed Media Types Dimension

(mmk)

Cost per

Dimension

Time

(day/year)

Total Cost

1 Harian Media

Indonesia

Display

Full Color

400 Rp 65,500.00 3 Rp

78,600,000.00

2 Nova Display

Full Color

600 Rp 76,000.00 4 Rp

182,400,000.00

Total Printed Media Cost Rp

386,200,000.00

Table 5.35 Marketing Cost in Online Media

No Web Address Time Price

1 Google Adsense - Free

70


2 http://www.kaskus.us/ 30 hari Rp. 1,800,000

3 www.detik.com 30 hari Rp. 2,300,000

4 http://www.iklan-gratis.com/ 30 hari Free

Total Advertising Online Rp. 4,100,000

Table 5.36 Marketing Cost in Radio

No Radio Station Period Time Duration Cost per

duration

Cost per year

1 Gen FM Prime

Time

06.00-

10.00

60 detik Rp.

525000

Rp7.875.000

Prime

Time

15.00-

21.00

60 detik Rp.

525000

Rp7.875.000

2 101 Jak FM Prime

Time

06.00-

10.00

60 detik

x 2

Rp.

750000

Rp7.500.000

Prime

Time

16.00-

20.00

60 detik

x 2

Rp.

50000

Rp11.250.000

Prime

Time

10.00-

14.00

60 detik

x 2

Rp.

600000

Rp9.000.000

Total Radio Advertising Cost Rp43.500.000

Table 5.37 Creating an Developing Website Cost

No Types Cost

1 Creating Website Cost Rp500,00

2 Design Website Cost Rp500,00

3 Annual Cost Rp 1,200,000

Total cost of creating and developing website Rp 2,200,000

Table 5.38 Detail of Employee Insurance Cost

Insurance Type Total Cost

Jaminan Kecelakaan Kerja Rp10.195.680,00

Jaminan Hari Tua Rp80.945.400,00

Jaminan Pemeliharaan

Kesehatan

Rp75.186.000,00

Total Biaya Asuransi Rp166.327.080,00

Table 5.39 Product Pricing

Low (85%) Moderate (100%) High (115%)

Sales Volume (unit) 228.033.750 268.275.000 308.516.250

Direct Material (DM) Rp 109.161.119.100,00 Rp 128.424.846.000 Rp 147.688.572.900,00

Direct Labor (DL) Rp 763.470.000,00 Rp 898.200.000 Rp 1.032.930.000,00

Factory Overhead (FOH) Rp 3.629.572.259,55 Rp 4.270.085.011 Rp 4.910.597.762,92

Marketing Expenses

(ME)

Rp 427.635.000,00 Rp 503.100.000 Rp 578.565.000,00

http://www.kaskus.us/

http://www.detik.com/

http://www.iklan-gratis.com/

71


Distribution Expenses Rp 869.633.218,40 Rp1.023.097.904,00 Rp 1.176.562.589,60

Invest (CAPEX) Rp 5.789.003.074,53 Rp 5.789.003.075 Rp 5.789.003.074,53

General & Adm.

Expenses

Rp 25.500.000,00 Rp 25.500.000 Rp 25.500.000,00

Total Cost (COGs)

(100%)

Rp 120.665.932.652,48 Rp 140.933.831.990 Rp 161.201.731.327,06

Expected π (1%) Rp 1.206.659.327 Rp 1.409.338.320 Rp 1.612.017.313

Expected Sales Revenues Rp 121.872.591.979,01 Rp 142.343.170.310 Rp 162.813.748.640,33

Gross Value (in Rp/unit) Rp 534,45 Rp 531 Rp 527,73

Net Value (PPN 10%) Rp 587,89 Rp 584 Rp 580,50

Table 5.40 Loan From Bank

Year Bank Loan Nominal Interest Loan Paying Salvage

0 Rp

2.723.147.046

1 Rp

2.723.147.046

Rp

285.930.440

-Rp727.558.161 Rp

2.281.519.325

2 Rp

2.281.519.325

Rp

239.559.529

-Rp727.558.161 Rp

1.793.520.693

3 Rp

1.793.520.693

Rp

188.319.673

-Rp727.558.161 Rp

1.254.282.205

4 Rp

1.254.282.205

Rp

131.699.632

-Rp727.558.161 Rp

658.423.675

5 Rp

658.423.675

Rp

69.134.486

-Rp727.558.161 Rp

-

Total Paying Nominal Interest Rp

914.643.759

Table 5.41 Loan From Investor

Year Investor Loan Nominal Interest Loan Paying Salvage

0 Rp

4.084.720.569

1 Rp

4.084.720.569

Rp

408.472.056,94

-Rp1.077.538.996 Rp

3.415.653.630

2 Rp

3.415.653.630

Rp

341.565.363,04

-Rp1.077.538.996 Rp

2.679.679.997

3 Rp

2.679.679.997

Rp

267.967.999,75

-Rp1.077.538.996 Rp

1.870.109.001

4 Rp

1.870.109.001

Rp

187.010.900,12

-Rp1.077.538.996 Rp

979.580.905

5 Rp

979.580.905

Rp

97.958.090,54

-Rp1.077.538.996 Rp0

Total paying investor nominal

interest

Rp

1.302.974.410

72


Table 5.42 Depreciation of Main Equipment

Tools n Total Price Life Time R Depreciation

(Rp) 2016

Salvage Value

(Rp)

Depreciation

(Rp) 2017

Salvage Value

(Rp)

Depreciation

(Rp) 2018

Grinder 1 Rp 37.929.873 10 0,2 Rp 7.585.975 Rp 30.343.898 Rp 6.068.780 Rp 24.275.119 Rp 4.855.024

Oven Drier 7 Rp 371.225.889 10 0,2 Rp 74.245.178 Rp 296.980.712 Rp 59.396.142 Rp 237.584.569 Rp 47.516.914

Hot Press Machine 1 Rp 22.131.307 10 0,2 Rp 4.426.261 Rp 17.705.046 Rp 3.541.009 Rp 14.164.037 Rp 2.832.807

Moulding Machine 4 Rp 526.768.239 10 0,2 Rp 105.353.648 Rp 421.414.591 Rp 84.282.918 Rp 337.131.673 Rp 67.426.335

Total Depretiation Rp 191.611.062 Rp 153.288.849 Rp 122.631.080

Salvage Value

(Rp)

Depreciation

(Rp) 2019

Salvage Value

(Rp)

Depreciation

(Rp) 2020

Salvage Value

(Rp)

Depreciation

(Rp) 2021

Salvage Value

(Rp)

Depreciation (Rp)

2022

Rp 19.420.095 Rp 3.884.019 Rp 15.536.076 Rp 3.107.215 Rp 12.428.861 Rp 2.485.772 Rp 9.943.089 Rp 1.988.618




Rp 98.104.864 Rp 78.483.891 Rp 62.787.113 Rp 50.229.690

Salvage Value (Rp) Depreciation (Rp)

2023


2024


2025

Salvage Value (Rp)

Rp 7.954.471 Rp 1.590.894 Rp 6.363.577 Rp 1.272.715 Rp 5.090.861 Rp 1.018.172 Rp 4.072.689

Rp 77.851.712 Rp 15.570.342 Rp 62.281.369 Rp 12.456.274 Rp 49.825.095 Rp 9.965.019 Rp 39.860.076

Rp 4.641.272 Rp 928.254 Rp 3.713.017 Rp 742.603 Rp 2.970.414 Rp 594.083 Rp 2.376.331

Rp 110.471.307 Rp 22.094.261 Rp 88.377.045 Rp 17.675.409 Rp 70.701.636 Rp 14.140.327 Rp 56.561.309

Rp 40.183.752 Rp 32.147.002 Rp 25.717.601

73


Table 5.43 Depreciation of Supporting Equipment

No Tools n Total Price Life Time R Depreciation

(Rp) 2015

Salvage Value

(Rp)

Depreciation

(Rp) 2016

Salvage Value

(Rp)

1 Computer 6 Rp 24.100.000 8 0,25 Rp 6.025.000 Rp 18.075.000 Rp 4.518.750 Rp 13.556.250

2 Fax 1 Rp 1.000.000 8 0,25 Rp 250.000 Rp 750.000 Rp 187.500 Rp 562.500

3 Photocopy Machine 1 Rp 10.000.000 8 0,25 Rp 2.500.000 Rp 7.500.000 Rp 1.875.000 Rp 5.625.000

4 Scanner 1 Rp 600.000 8 0,25 Rp 150.000 Rp 450.000 Rp 112.500 Rp 337.500

5 Printer 6 Rp 8.500.000 8 0,25 Rp 2.125.000 Rp 6.375.000 Rp 1.593.750 Rp 4.781.250

6 Projector 1 Rp 3.200.000 8 0,25 Rp 800.000 Rp 2.400.000 Rp 600.000 Rp 1.800.000

7 Chair 20 Rp 8.200.000 8 0,25 Rp 2.050.000 Rp 6.150.000 Rp 1.537.500 Rp 4.612.500

8 Table 20 Rp 10.300.000 8 0,25 Rp 2.575.000 Rp 7.725.000 Rp 1.931.250 Rp 5.793.750

9 Cabinet 3 Rp 4.800.000 8 0,25 Rp 1.200.000 Rp 3.600.000 Rp 900.000 Rp 2.700.000

10 Fan 3 Rp 1.650.000 8 0,25 Rp 412.500 Rp 1.237.500 Rp 309.375 Rp 928.125

11 Air Conditioner 1 Rp 2.500.000 8 0,25 Rp 625.000 Rp 1.875.000 Rp 468.750 Rp 1.406.250

12 Trash Can 5 Rp 125.000 8 0,25 Rp 31.250 Rp 93.750 Rp 23.438 Rp 70.313

13 Office Equipment 100 Rp 2.000.000 4 0,5 Rp 1.000.000 Rp 1.000.000 Rp 500.000 Rp 500.000

14 Alarm Bell 5 Rp 750.000 8 0,25 Rp 187.500 Rp 562.500 Rp 140.625 Rp 421.875

15 Fire Extuingisher 5 Rp 1.250.000 8 0,25 Rp 312.500 Rp 937.500 Rp 234.375 Rp 703.125

16 Masker 100 Rp 100.000 4 0,5 Rp 50.000 Rp 50.000 Rp 25.000 Rp 25.000

17 Helm 40 Rp 8.150.000 8 0,25 Rp 2.037.500 Rp 6.112.500 Rp 1.528.125 Rp 4.584.375

18 Gloves 40 Rp 100.000 8 0,25 Rp 25.000 Rp 75.000 Rp 18.750 Rp 56.250

19 Safety Shoes 40 Rp 8.100.000 8 0,25 Rp 2.025.000 Rp 6.075.000 Rp 1.518.750 Rp 4.556.250

20 Dispenser 3 Rp 3.100.000 8 0,25 Rp 775.000 Rp 2.325.000 Rp 581.250 Rp 1.743.750

21 Truck 4 Rp 577.100.000 5 0,4 Rp 230.840.000 Rp 346.260.000 Rp 138.504.000 Rp 207.756.000

74


22 Operational Car 1 Rp 115.300.000 5 0,4 Rp 46.120.000 Rp 69.180.000 Rp 27.672.000 Rp 41.508.000

23 Motorcycle 1 Rp 12.200.000 5 0,4 Rp 4.880.000 Rp 7.320.000 Rp 2.928.000 Rp 4.392.000

24 Electrical Generator 1 Rp 7.100.000 5 0,4 Rp 2.840.000 Rp 4.260.000 Rp 1.704.000 Rp 2.556.000

25 Lamp 72 Rp 3.700.000 8 0,25 Rp 925.000 Rp 2.775.000 Rp 693.750 Rp 2.081.250

26 Room Air Freshener 8 Rp 720.000 8 0,25 Rp 180.000 Rp 540.000 Rp 135.000 Rp 405.000

27 CCTV 8 Rp 2.800.000 8 0,25 Rp 700.000 Rp 2.100.000 Rp 525.000 Rp 1.575.000

Total Depretiation Rp 311.641.250 Rp 190.766.438

Depreciation

(Rp) 2017

Salvage Value

(Rp)

Depreciation

(Rp) 2018

Salvage Value

(Rp)

Depreciation

(Rp) 2019

Salvage Value

(Rp)

Depreciation

(Rp) 2020

Salvage Value

(Rp)


Rp 140.625 Rp 421.875 Rp 105.469 Rp 316.406 Rp 79.102 Rp 237.305 Rp 59.326 Rp 177.979

Rp 1.406.250 Rp 4.218.750 Rp 1.054.688 Rp 3.164.063 Rp 791.016 Rp 2.373.047 Rp 593.262 Rp 1.779.785


Rp 1.195.313 Rp 3.585.938 Rp 896.484 Rp 2.689.453 Rp 672.363 Rp 2.017.090 Rp 504.272 Rp 1.512.817

Rp 450.000 Rp 1.350.000 Rp 337.500 Rp 1.012.500 Rp 253.125 Rp 759.375 Rp 189.844 Rp 569.531


Rp 1.448.438 Rp 4.345.313 Rp 1.086.328 Rp 3.258.984 Rp 814.746 Rp 2.444.238 Rp 611.060 Rp 1.833.179

Rp 675.000 Rp 2.025.000 Rp 506.250 Rp 1.518.750 Rp 379.688 Rp 1.139.063 Rp 284.766 Rp 854.297


Rp 351.563 Rp 1.054.688 Rp 263.672 Rp 791.016 Rp 197.754 Rp 593.262 Rp 148.315 Rp 444.946


Rp 250.000 Rp 250.000 Rp 125.000 Rp 125.000 Rp 62.500 Rp 62.500 Rp - Rp -

75




Rp 12.500 Rp 12.500 Rp 6.250 Rp 6.250 Rp 3.125 Rp 3.125 Rp - Rp -







Rp 1.756.800 Rp 2.635.200 Rp 1.054.080 Rp 1.581.120 Rp 632.448 Rp 948.672 Rp 379.469 Rp 569.203

Rp 1.022.400 Rp 1.533.600 Rp 613.440 Rp 920.160 Rp 368.064 Rp 552.096 Rp 220.838 Rp 331.258

Rp 520.313 Rp 1.560.938 Rp 390.234 Rp 1.170.703 Rp 292.676 Rp 878.027 Rp 219.507 Rp 658.521



Rp 117.322.378 Rp 72.553.439 Rp 45.158.634 Rp 28.285.578

Depreciation (Rp)

2021

Salvage Value

(Rp)

Depreciation (Rp)

2022

Salvage Value

(Rp)

Rp 1.072.321 Rp 3.216.962 Rp 804.240 Rp 2.412.721

Rp 44.495 Rp 133.484 Rp 33.371 Rp 100.113

Rp 444.946 Rp 1.334.839 Rp 333.710 Rp 1.001.129

Rp 26.697 Rp 80.090 Rp 20.023 Rp 60.068

Rp 378.204 Rp 1.134.613 Rp 283.653 Rp 850.960

76


Rp 142.383 Rp 427.148 Rp 106.787 Rp 320.361

Rp 364.856 Rp 1.094.568 Rp 273.642 Rp 820.926

Rp 458.295 Rp 1.374.884 Rp 343.721 Rp 1.031.163

Rp 213.574 Rp 640.723 Rp 160.181 Rp 480.542

Rp 73.416 Rp 220.248 Rp 55.062 Rp 165.186

Rp 111.237 Rp 333.710 Rp 83.427 Rp 250.282

Rp 5.562 Rp 16.685 Rp 4.171 Rp 12.514

Rp - Rp - Rp - Rp -

Rp 33.371 Rp 100.113 Rp 25.028 Rp 75.085

Rp 55.618 Rp 166.855 Rp 41.714 Rp 125.141

Rp - Rp - Rp - Rp -

Rp 362.631 Rp 1.087.894 Rp 271.973 Rp 815.920

Rp 4.449 Rp 13.348 Rp 3.337 Rp 10.011

Rp 360.406 Rp 1.081.219 Rp 270.305 Rp 810.915

Rp 137.933 Rp 413.800 Rp 103.450 Rp 310.350

Rp - Rp - Rp - Rp -

Rp - Rp - Rp - Rp -

Rp - Rp - Rp - Rp -

Rp - Rp - Rp - Rp -

Rp

(439.014)

Rp 1.097.534 Rp (1.536.548) Rp 2.634.082

Rp 32.036 Rp 96.108 Rp 24.027 Rp 72.081

Rp 124.585 Rp 373.755 Rp 93.439 Rp 280.316

Rp 4.008.002 Rp 1.798.714

77


Table 5.44 Cashflow Calculation

Year Income

Loan Sales Percentage Revenue Salvage Value

Bank Investor

0 Rp 1.784.699.046 Rp 2.677.048.569

1 50% Rp 114.016.875.000

2 70% Rp 159.623.625.000

3 100% Rp 228.033.750.000

4 100% Rp 228.033.750.000 Rp 62.500

5 100% Rp 228.033.750.000

6 100% Rp 228.033.750.000

7 100% Rp 228.033.750.000

8 100% Rp 228.033.750.000 Rp 12.702.367

9 100% Rp 228.033.750.000

10 100% Rp 228.033.750.000 Rp 220.982.006

Year Outcome

Capital Cost Operating Cost Loan Payment Interest Payment

Bank Investor Bank Investor

0 Rp

(4.461.747.616)

1 Rp

178.380.958.679

Rp

476.827.852

Rp

706.198.669

Rp

187.393.400

Rp

267.704.857

2 Rp

178.380.958.679

Rp

476.827.852

Rp

706.198.669

Rp

86.313.446

Rp

223.855.476

78


3 Rp

178.380.958.679

Rp

476.827.852

Rp

706.198.669

Rp

45.309.434

Rp

175.621.156

4 Rp

178.380.958.679

Rp

706.198.669

Rp

122.563.405

5 Rp 2.100.000 Rp

178.380.958.679

Rp

706.198.669

Rp

64.199.879

6 Rp

711.700.000

Rp

178.380.958.679

7 Rp

178.380.958.679

8 Rp

178.380.958.679

9 Rp

103.645.000

Rp

178.380.958.679

10 Rp

178.380.958.679

Year BTCF Depreciation Pendapatan

Kena Pajak

Income Tax ATCF Cumulative Tax

0 Rp

(4.461.747.616)

Rp

(4.461.747.616)

Rp

(1.115.436.904)

1 Rp

(66.002.208.456)

Rp

723.252.312

Rp

(66.725.460.768)

Rp

(10.008.819.115)

Rp

(56.716.641.652)

Rp

(61.178.389.268)

Rp

(14.179.160.413)

2 Rp

(20.250.529.121)

Rp

520.055.287

Rp

(20.770.584.408)

Rp

(3.115.587.661)

Rp

(17.654.996.747)

Rp

(78.833.386.015)

Rp

(4.413.749.187)

3 Rp

48.248.834.211

Rp

126.160.127

Rp

48.122.674.083

Rp

7.218.401.113

Rp

40.904.272.971

Rp

(37.929.113.044)

Rp

10.226.068.243

79


4 Rp

48.824.091.748

Rp

283.298.302

Rp

48.540.793.445

Rp

7.281.119.017

Rp

41.259.674.428

Rp

3.330.561.384

Rp

10.314.918.607

5 Rp

48.880.292.774

Rp

213.754.525

Rp

48.666.538.248

Rp

7.299.980.737

Rp

41.366.557.511

Rp

44.697.118.896

Rp

10.341.639.378

6 Rp

48.941.091.321

Rp

163.162.291

Rp

48.777.929.031

Rp

7.316.689.355

Rp

41.461.239.676

Rp

86.158.358.572

Rp

10.365.309.919

7 Rp

49.652.791.321

Rp

111.909.372

Rp

49.540.881.949

Rp

7.431.132.292

Rp

42.109.749.657

Rp

128.268.108.229

Rp

10.527.437.414

8 Rp

49.665.493.689

Rp

88.119.810

Rp

49.577.373.879

Rp

7.436.606.082

Rp

42.140.767.797

Rp

170.408.876.025

Rp

10.535.191.949

9 Rp

49.549.146.321

Rp

69.056.877

Rp

49.480.089.444

Rp

7.422.013.417

Rp

42.058.076.028

Rp

212.466.952.053

Rp

10.514.519.007

10 Rp

49.873.773.328

Rp

55.245.502

Rp

49.818.527.826

Rp

7.472.779.174

Rp

42.345.748.652

Rp

254.812.700.705

Rp

10.586.437.163

Green Food Packaging As Breakthrough To Replace Styrofoam

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