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Dates Drying & De-Hydration

Plant
Dates Drying & De-Hydration Plant 2010

Table of Contents

1 INTRODUCTION 5

1.1 THE PRODUCT: DATES (KHAJOOR) 5


1.2 HISTORICAL BACKGROUND OF DATES 6
1.3 DATES MATURATION STAGES & RESPECTIVE USAGE 6
1.4 CONSUMPTION PATTERNS & VALUE ADDED PRODUCTS 7

2. SECTOR OVERVIEW 9

2.1 GLOBAL DATES PRODUCTION 9


2.2 DATES PRODUCTION IN PAKISTAN 9
2.3 MAIN DATES VARIETIES OF PAKISTAN 10
2.4 DATE PRODUCTION IN SINDH 11
2.5 COMMERCIALLY VIABLE SINDHI DATE VARIETIES 11
2.6 DRY DATE MAKING & THE MONSOON THREAT 12

3. MARKET OVERVIEW 13

3.1 LOCAL MARKETS & CONSUMPTION 13


3.2 INTERNATIONAL MARKETS OF DATES 13
3.3 DATES EXPORT FROM PAKISTAN 14
3.4 DATES IMPORT IN PAKISTAN 15

4. PROFITABLE INVESTMENT GAP 16

4.1 DATES DRYING & DEHYDRATION 16


4.2 MAJOR PROBLEMS FACED BY THE DATES GROWERS 16
4.3 CONCEPT OF DRYING & DEHYDRATION 17
4.4 PRESENT PRACTICES IN DRYING & DEHYDRATION 18
4.5 MAJOR ISSUES IN CURRENT PRACTICES 18
4.6 DRYING & DEHYDRATION PLANT: JUSTIFICATION 19

5. DATES DRYING & DEHYDRATION PLANT (DDP) 21

5.1 OPPORTUNITY RATIONALE 21


5.2 PROJECT BRIEF 23
5.3 PROCESS DESCRIPTION 24
Dates Drying & De-Hydration Plant 2010

5.4 LAND & BUILDING REQUIREMENT 28


5.5. LAYOUT PLAN OF DDP 28

5.6 KEY SUCCESS FACTORS 29

6. PROJECT INPUTS 30

6.1 PROPOSED PROCESSING CAPACITY OF THE DRYING AND DE-HYDRATION PLANT 30


6.2 LAND & LOCATION REQUIREMENTS 30
6.3 PLANT MACHINERY & EQUIPMENT 30
6.4 OFFICE EQUIPMENT 31
6.5 HUMAN RESOURCES 32
6.6 INFRASTRUCTURE REQUIREMENTS 32

7. PROJECT ECONOMICS 33

7.1 PROJECT COST 33


7.2 PROJECT RETURNS 33
7.3 CAPITAL STRUCTURE OF THE PROJECT 33

8. PROJECT FINANCIAL STATEMENTS 34

8.1 PROJECT INCOME STATEMENT 34


8.2 PROJECT BALANCE SHEET 35
8.3 PROJECT CASH FLOW STATEMENT 36

ANNEX A 37

IMPORTANT CONTATCS 42
Dates Drying & De-Hydration Plant 2010

DISCLAIMER

This Pre-Feasibility has been prepared by Sindh Board of Investment (SBI) and is for information
purposes only. This report does not constitute an offer, invitation or inducement to invest in any sector
or industry. Neither the information contained in this Pre-Feasibility nor any further information made
available with the subject matter contained herein will form the basis of any contract. Any
recommendations contained in this document must not be relied upon as investment advice based on
the recipient's personal circumstances. In the event that further clarification is required on the words or
phrases used in this material, the recipient is strongly recommended to seek independent legal or
financial advice.

The material in this Pre-Feasibility is general information intended for recipients who understand the
risks and opportunities associated with making investment in Sindh specifically in Livestock sector. It
does not take account of whether an investment, course of action, or associated risks are suitable for
the recipient.

This report does not purport to be comprehensive or to contain all the information on which a
prospective investor can make an investment decision. The information contained herein is based on
publicly available information and sources, which we believe to be reliable, but we do not represent it as
accurate or complete. The recipient of this report must make his own investigation and assessment of
the information presented herein. No representation, warranty or undertaking, express or implied, is or
will be made or given and no responsibility or liability is or will be accepted by SBI or by any of its
directors, officers, employees, agents or advisors, in relation to the accuracy or completeness of this
Pre-Feasibility or any other written or oral information made available in connection with the
information presented herein. Any responsibility or liability for any such information is expressly
disclaimed.
Dates Drying & De-Hydration Plant 2010

1 INTRODUCTION

1.1 The Product: Dates (Khajoor)

The date palm (Phoenix dactylifera L.) is considered as


one of the most important cash crop of the country
and holds a very significant position on the agricultural
horizon of Sindh. Wonderfully delicious, dates are one
of the most popular fruits with an impressive list of
essential nutrients, vitamins and minerals, required by
humans for normal growth, development and overall
well-being. Fresh date is made of soft, easily digestible
flesh with simple sugars like fructose and dextrose
that when eaten, replenishes energy and revitalizes the
body instantly; thus, for these qualities, dates are being
used to break fasts during the holy month of Ramadan all
across the Muslim world.

Date fruits have a very high nutritional value as one kg of dates possesses around 3000 calories. It
consist of 70% carbohydrates (mostly sugars), making it one of the most nourishing natural foods
available to man. It also contains proteins, fats, crude fibres, vitamins, mineral, enzymes and other
useful substances. The water content is between 15 to 30% depending on the variety and on the
maturity stage of the fruit. Due to genetic difference and growth conditions, dates show a wide variety
in their final shape and appearance more than any other fruit. Therefore, the quality profile of dates
involves a range of colour, shape, size, texture and pit to flash ration. The other important
determinists are weight, moisture contents, sugar and the fibre.
Dates Drying & De-Hydration Plant 2010

Having characteristics of low fats, appropriate moisture contents, carbohydrates and other nutritional
values with a sweet and supple taste & texture along with a chewing pleasure, dates are considered as
complete food and are cherished all around the world.

1.2 Historical background of dates

Date fruit is considered as one of the oldest fruits found on earth having the traces in prehistoric era.
Alphonse Pyrame de Candolle (1806-1893), a noted French-Swiss botanist claimed that in pre-historic
times date palm cultivation ranged from Senegal in the Western Africa to the basin of the River Indus in
South Asia. Apart from our own land, dates have been in cultivation in Senegal, Mauritania, Mali,
Nigeria, Algeria, Tunisia, Morocco, Libya, Egypt, Sudan, Chad, Iraq, Saudi Arabia, Yemen, UAE, Oman and
Iran since the ancient times. Arabs spread dates into Spain during their rule in that Southern European
country from the 12th to 15th centuries. Dates were introduced further west into the American
continent by the Spaniards in the 18th century. Currently, all the major dates producing countries form
part of the Muslim world. Generally, dates are considered as the fruit consumed mainly by the Muslims,
especially during the Holy month of Ramadan and also during their various religious ceremonies. In the
Magnificent Holy Quran, there are 22 mentions of this fruit. The Holy Prophet (PBUH) had a special liking
for this fruit due to its enormous benefits. Being grown in predominantly Muslim areas, this fruit has a
deep and lasting association with Muslims and Islamic traditions, around the world.

1.3 Dates Maturation Stages & respective usage

The activities related to dates cultivation start from the month of February every year and lasts till its
harvesting in the month of July. This makes almost a 200 days cycle from the pollination stage to
harvesting. Harvesting takes place from 15th of July and lasts till the end of August. For understanding
the business process of dates, it is important to understand various stages of date maturation. There are
five stages of fruit maturation starting from initial fruit (baby fruit) formation to the last stage of ready
to eat date. Names of these stages are in Sindhi, the local dialect.

Khasi: Formation of fruit takes place after the pollination has occurred. Khasi is the first stage when a
baby fruit emerges. I may appear light greenish in colour. Since this is only the first stage, special care is
taken for water and urea availability for gaining a better fruit.
Dates Drying & De-Hydration Plant 2010

Doka: Doka is the stage when the fruit has achieved a certain shape and hardness. It appears hard and
light yellow in colour and its taste starts getting sweeter. At this stage, the fruit is picked up from the
tree tops for its processing as a dry date or to turn it into a kharak. Doka is boiled in SFS for making it a
yellow dry date and is simply boiled for making it a brown dry date. If required, doka can be processed
for early ripening and turning it into a date or Kharak.

Wan Pakki: Wan Pakki is the stage when Doka gets more matured and starts taking a sweeter taste.
Basically, its an overlapping stage of Doka & Wan Pakki where special care is taken of the bunches and
the maturing doka. In Sindhi, Wan means hand and Wan Pakki is the process where the bunch is
physically adjusted with hands, bad fruits are gotten rid of, and every fruit is checked.

Dong: Most fruit is harvested at the Doka and Wan Pakki stages. Now, depending upon the free will or
market demand, the remaining fruit is left for attaining to this stage on the tree top. It turns the Doka
into a Dong when it starts getting ripened from lower end and reaches up to the half or more, of the
fruit. The upper half remains sweet and crunchy. Dong takes a most delicious taste in this stage of
maturation. It gets very sweet, half remain comparatively hard and yellow in colour and the rest is soft
and yellowish brown in colour. Reaching a certain maturity level with in this stage, it is picked up for
open markets sale and is fondly cherished by all. In a few dates producing countries, dates are frozen at
this stage and are exported for a higher price.

Kharak: Kharak is the synonym of date or Khajoor. According to the observed practice, growers or
farmers leave hardly a 5 to 7% of the fruit only for gaining this stage on the tree top and that too for a
few varieties only. Maximum quantity is processed on the ground for making it Kharak for time economy
and also for diminishing chances of any disaster due to rains. Kharak bears a brow colour and is too
sweet in taste with a very fascinating chewing mass with a fully made seed in the centre of the fruit.

Internationally, most commonly known stages of date maturation are in Arabic language. There are four
stages and are known as Kimiri, Khalal, Rutab and Tamar. Kimiri stands for the first stage when a baby
fruit emerges. Khalal is the second stage which equates with Doka and Wan Pakki stage in Sindhi. Rutab
is the stage when fruit gets matured and is soft and sweet in taste (Dong). Lastly, it is Tamar where the
Rutab turns into a proper date which is Khrak or Khajoor.

1.4 Consumption Patterns & Value Added Products

Dates are consumed in both fresh and processed forms. Generally, dates are taken as fresh table dates.
The biggest use of dates occurs in the month of Ramadan for breaking fast throughout the Muslim world
and in the Muslim households in the rest of the world. Dates may be consumed in many different ways
such as; Fresh table dates, frozen dong (Rutab) dates, stuffed dates with roasted nuts such as almond or
cashew nuts, dates with chocolate coatings, dates with sesame seeds etc. Value addition is another
important segment in the date consumption pattern in the world. The value added products may
include; dates blocks, dates energy bars, dates syrup, date honey, date pickles, date paste, date spread,
Dates Drying & De-Hydration Plant 2010

date dry powder, date sugar, date sparkling juice, date vinegar and date ethanol fuel. These value added
products are highly viable commercially. Many countries of the world, dates producers or not, acquire
good quality dates and export them after value addition. This helps them in generating high volumes of
revenues.
Dates Drying & De-Hydration Plant 2010

2. SECTOR OVERVIEW

2.1 Global Dates Production

Global date production is steadily growing from 1.85 million tons in 1965 to 7 million tons in 2005-6. It is
expected that the world production would have crossed 7.5 million tons mark due to aggressive efforts
made by the largest dates growing countries of the world during last five years. These countries include
Kingdom of Saudi Arabia, United Arab Emirates, Iran, Iraq, Tunisia, Algeria, Sudan, Oman, the USA and
Israel. The following table depicts the percentage share of the major dates growing countries in the
world.

2.2 Dates production in Pakistan

Pakistan is the fifth largest dates producing country in the world having a production quantum
fluctuating around 550,000 tons to around 650,000 tons per year. Dates are cultivated on over 90,000
hectors area in Pakistan. The following chart depicts the annual production figures:
Dates Drying & De-Hydration Plant 2010

2.3 Main Dates Varieties of Pakistan

There are more than 300 varieties of dates grown in Pakistan. Many of these dates are unique in taste
and texture and are commercially very viable. The following chart depicts the main date varieties found
in the four provinces

Dates are mainly produced in arid regions having high temperatures, low humidity and ample water for
growth. Baluchistan and Sindh are the two major provinces contributing around 85% to 90% to the total
date production of Pakistan. Some parts of Punjab and Khyber Pakhtunkhwah also produce a few
varieties and add up to the national total. Despite fluctuations in production on yearly basis, an average
production can be perceived in percentage terms. Accordingly, Sindhs production has gradually
increased and now ranges from 50% to 52%, Baluchistan has slightly declined and now produces around
38%, Punjab contributes around 10% and lastly, Khyber Pakhtunkhwah contributes 3% to 4% to the
overall date production of the country.
Dates Drying & De-Hydration Plant 2010

2.4 Date Production in Sindh

Sindh has become the largest dates producing province of Pakistan having produced around 329,900
tons4 of dates during 2009-10, which comes to around 52% of the total dates produced this year. These
dates are produced on an area of around 27,9855 hectors in Sindh. Khairpur and Sukkur are the main
districts having the highest production and the most suitable climatic and soil conditions. Almost 80% to
85% dates are produced in these two districts. Besides these main centres of date production, there are
a few more areas which produce around 15% of the total dates produced in Sindh.

Dates Production in Sindh

2007-08 2,73,000 Tons

2008-09 2,57,936 Tons

2009-10 3,29,900 Tons

The above table shows that dates production in Sindh is consecutively increasing. This is a very
encouraging sign for the date sector stakeholders.

2.5 Commercially Viable Sindhi Date Varieties

Dates sector offers a fascinating business opportunity to the investors in Sindh. The highest production
and long practiced date culture makes the two districts, Khairpur & Sukkur, as central venue for
successful business venturing. There are two modes of date utilization: a) as Fresh date and its variants
and b) dry dates (Chohara).

Fresh Dates: In Sindh, Aseel, Fasli, Karbalain and Kupro are the main varieties having significant
commercial value. Due to its characteristics, Aseel is known as the best Sindhi date variety. It has a very
sweet taste and a delectable texture along with a nice shiny surface. Aseel has a very good pit to flesh
ration. The pit is closely clinched with the flesh making it difficult for air and insects to intrude. Its
length varies between 4 to 5 cm having a diameter from 2.5 to 2.9 cm. On appropriate low
temperatures, it can be stored for at least 2 years. Due to its characteristics, Aseel is the most grown
date variety and almost 85% of the dates produces in Khairpur & Sukkur are consisted Aseel variety.
Good quality Aseel is used and traded as the Fresh Table Date in the local and international markets.
However, C and D quality of Aseel is traded as a popular industrial date variety. Like wise Fasli, Karbalain
and Kupro are also regarded as very good varieties due to their characteristics. According to the figures
Dates Drying & De-Hydration Plant 2010

collected from Trade Development Authority of Pakistan, Pakistan exported fresh dates worth US$ 3.3
million to various countries of the world.

Dry Dates: Pakistan is the biggest exporter of dry date to the world. Inida has become the major buyer
of Pakistani dry date in the recent years. According to the estimates, almost 70% dates are turned into
dry dates the major chunk is exported to India. According to the figures collected from Trade
Development Authority of Pakistan, Pakistan exported dry dates worth US$ 41.3 million to various
countries of the world.

2.6 Dry Date Making & the Monsoon Threat

There are two motivations for turning dates into dry dates. One is to capitalize on the worlds largest dry
date market next door, Inida, and the other one is to secure dates by processing it fast before the
monsoon rains and to get it into the markets (commercial activity) as fast as possible. An absence of
appropriate cold storages and processing facilities is also a contributing factor in this regard.

In Khairpur & Sukkur, despite favourable temperatures and enabling environmental conditions, there is
one big threat in the form of monsoon season which coincides with the harvesting season every year.
Although, this threat looms over the heads of stake holders every year, fortunately, such an occurrence
is found to be every three to four years. However, when ever this phenomenon takes place, it creates
lots of problems for the poor farmers in terms of loss of major portion of their ready crops. Rain water is
regarded as the major source of decay of dates present on the palms or lying over a vast land for drying
purposes. As a result of any such incident, the poor farmers have to face enormous financial losses
which take them back by at least three years. Hence, they are left with no choice but to borrow more
money to recover from the current losses and to further lead their lives till the next crop season.

Having this scenario, there is an urgent need of establishing such appropriate facilities where dates
could be secured by way of turning them into dry date or only by getting rid of their extra moisture due
to rains.
Dates Drying & De-Hydration Plant 2010

3. MARKET OVERVIEW

3.1 Local Markets & Consumption

Date production in Pakistan fluctuates due to climatic condition during the harvesting season. On an
average, the country produces around 550,000 tons of dates annually. In 2009, the total exports of fresh
and dry dates stand at around 110,000 tons. Therefore, the dates left for local consumption comes to
around 440,000 tons. The demand for dates reaches its peak during the month of Ramadan when the
dates are used to break the fast across the country. This market demand is met by importing dates to
Pakistan.

All the dates growing districts house a dates market as is Agha Qadir Dad Khan Agricultural Market in
Sukkur where mainly dry dates are traded and as Khajoor Anaaj Mandi in Khairpur where fresh dates are
traded. In Karachi, there is a Khajji Market (Khajoor Bazar) in Lea Market area where a major trade
activity takes place. On the other hand, in all the major urban centers, there is a small segment dealing
in sale of dates for satisfying the local area needs. Prices of dates in the local markets are fixed on the
basis of various factors including the demand and supply situation. Time also an important for setting
the price. Gradually, time of dates harvesting is closing up with the advent of Ramadan which makes
impacts on pricing. Currently, the prices have been noted from Rs. 1800/- to Rs. 4000/- per 40 Kg
depending upon the variety. Further adding up overheads, the prices go up to Rs.80/- to Rs. 180/- per
Kg.

3.2 International Markets of Dates

Major dates producing countries are fortunately the part of predominantly Muslim world. Egypt is in the
lead followed by Iran, Saudi Arabia, UAE, Pakistan, Algeria, Iraq, Sudan and Tunisia. According to the
statistics, India, France, Germany, United Kingdom, Malaysia, Italy, Spain, Russian Federation, Canada,
and the USA are the major dates importing countries of the world. Likewise, Tunisia, Pakistan, France,
the USA and Germany are the top exporting countries of dates in dollar terms.

In the world date markets, Tunisia is a bright example for success in business. Tunisia produces only 2%
dates of the world total production but has developed infrastructure complying international
agricultural and trade standards to only produce the prim verities of Deglet Nour & Medjool. Tunisia has
Dates Drying & De-Hydration Plant 2010

targeted the high end market of Europe and earns huge foreign exchange. Tunisia is the largest exporter
of dates in terms of dollar value and has exported its prime dates worth over US$ 170 in 2008 (Source:
ITC calculations based on COMTRADE statistics). Likewise, France, does not produce dates, instead,
imports dates from its old colonies and exports them after value addition to the European markets and
basket foreign exchange.

The price tag for good quality (Extra Class, A Class or B Class Quality) dates ranges between US$ 2500 to
as high as US$ 4500 per ton. However, Pakistani dates only fetch a very humble price from the
international market ranging from a mere US$ 600 to US$ 1500 in case of very good quality. Clearly,
Europe, the USA, the UK are the major high end markets for prime date varieties.

3.3 Dates Export from Pakistan

Pakistan is a major date exporting country and stand at 2nd in exports after Tunisia. Pakistani dates are
exported to Bangladesh, India, Germany, Canada, Japan, UAE, Denmark, South Africa, Australia, Saudi
Arabia, the USA and the UK.

Pakistani dates are mainly regarded as Industrial dates and fetch a humble price. Pakistani prime quality
Aseel fetch an FOB price between US$ 600 to US$ 1500 per ton in Europe and North American markets.
If the quality is better, these prices may go up to US$ 2000 a ton. Pakistani dates can easily get a
handsome price from the international markets if the overall sector is developed with setting specific
targets for process & quality improvement.

In 2008, the USA imported 1079 tons of fresh dates and 667 tons of dry dates from Pakistan. Recently,
Bangladesh has also emerged as a big date market for Pakistani dates. Bangladesh imported 1057 tons
of fresh dates and 557 tons of dry dates from Pakistan during 2008. The major revenue for Pakistan is
generated from the export of dry dates. Pakistan is the major supplier of dry dates to India. As the
statistics show, for the period July May 2008-9, Pakistan had exported over 100,125 tons of dry dates
to India worth US$ 38 million out of total dry date exports of US$ 39.9 million during that period.
Dates Drying & De-Hydration Plant 2010

3.4 Dates Import in Pakistan

Pakistan imported fresh and dried dates worth US$ 3.3 million in the year 2008, from different countries
of the world. These dates were imported from Iran, Iraq, Saudi Arabia, UAE, Qatar, Kuwait, China and
Bahrain. These imported dates do not make any significant effect on the prices of the local dates. Import
of dates, basically compliment the locally produced dates and offers more options for the end
consumer. According to the available data, Pakistan imported Dates in the following manner during last
three years.

High quality dates are imported from Saudi Arabia and UAE, to cater to the Super Markets and modern
shopping malls in the main cities such as Karachi, Lahore, Islamabad, Faisalabad and Sialkot. These dates
are found in very attractive wrappings in different types of packaging options. The mass market
consumes multiple options of locally produced dates. Varieties of Irani and Iraqi dates of different
qualities are also imported to make up the shortfalls during the steep rise in demand during Ramadan
season, offering a comparable price range.
Dates Drying & De-Hydration Plant 2010

4. PROFITABLE INVESTMENT GAP

4.1 Dates Drying & Dehydration

Monsoon rains often coincide with dates harvesting season which may fall during July to September
every year. Dates are harvested on various maturity levels according to the need. They may be picked up
at the doka stage for making a dry date or can be picked up at dong (half ripen) stage for markets or can
be picked up as soon as it turns to a Kharak (Khajoor). When monsoon rains fall during the dates
harvesting season, it brings along misery and devastation for the poor date growers and farmers. As
mentioned earlier, rains are extremely harmful for the standing dates crops. According to the sector
specialists, up to 60% of the dates are destroyed due to these rains. In some cases, experts say, that
damage may exceed as high as a 100% in full loss of the crop. This situation becomes extremely
troublesome for the poor dates growers and peasants who expect to earn some money for their
livelihood after a long period of continuous labour in the fields and taking pains for growing the crops.
Situation further worsens when the poor farmers are hardly able to save even only a minor part of their
crop from that full crop.

Having the aforementioned threatening situation in perspective, there is an emergent need to fill in the
gap through some effective, viable and practical means. Keeping both the scenarios in view, i.e., dates
drying (only to dry up the wet dates) and dehydration processes (to make a brown or yellow Chohara), it
is required to have an appropriate and practical antidotes against the rain threat. Since, any reasonable
solution for handling the monsoon threat and the business needs for drying or dehydration of dates is
inevitable, this gap can only be filled up with facilitation of relevant plants to be installed in multiple
locations as per the needs of the area.

4.2 Major Problems faced by the Dates Growers

Since long, there is no antidote available for countering this situation and hence, huge losses may be
incurred by the poor peasants, often. These losses can take many forms.

Generally, there are no roads available to & between the farms & markets. During heavy rains, this
creates huge problems of access to the farms or to the markets. Instead, sandy tracks turn into
heavy mud and add to the misery of a farmer by multiplying his problems. The farms become
inaccessible. If somehow, farmers reach to their farms, they find it extremely hard to pick the
remaining fruit from the tree tops and transport it to the markets. Small farmers having limited
resources are badly affected by this phenomenon. Loosing courage, they resort to let the nature
take its course.
Dates Drying & De-Hydration Plant 2010

If successful in doing so, when the farmers and growers take their wet produce to the markets, they
are bound to get no or only a minimal price. Resultantly, they try to secure the crop as much as
possible and try to turn it into dry dates to earn something out of their losses. Dry dates do not earn
a good price as fresh dates do. Therefore, facing the hardships of harvesting the crop during rainy
season and selling the wet fruit to the processors or to the commission agent, the poor farmer ends
up getting a fraction of original price from the produce.

Generally, the farmers and growers get advance loans from the commission agents. Commission
agents provide advances on not only very high rates but they also manipulate the growers at the
time when they bring their produce as against their advance loans. When the crop gets destroyed
due to rain falls, the poor growers come under enormous financial burden and find themselves in a
fix having no means to repay their debts and end up by trying to get yet another loan for their
livelihood for the rest of the year. To meet their daily expenses, they again take loans from the
Commission Agents, hence, come under three fold economic pressures and become susceptible to a
number of manipulations.

4.3 Concept of Drying & Dehydration

Drying of dates: Although, both the words, drying and dehydration, are used interchangeably during the
normal conversation but they denote different processes. Dates drying may only be limited to drying up
the wet dates due to rain or any similar reason. This would not change the chemical composition or the
maturity level from one stage to another. Drying up would involve a very brief exposure to heat and it
will just help in evaporating external water present over the date fruit. However, this process can also
be used to lessen the water contents as required by the consumers.

Dehydration of dates: Dehydration for a dry date (Chohara) making can be explained as, The aim of
dehydration is to remove moisture artificially from the fruit without affecting its desirable qualities. It is
a common process in the dried fruit industry (prunes, apricots, peaches, apples, etc.). Dehydration
becomes necessary when dates contain too much moisture and will not be consumed immediately or
stored under refrigeration. For instance, desirable moisture content for Deglet Noor, acceptable to the
consumer, is 23-25%, self-preserving with soft texture. 6 In our scenario, dehydration will aim reducing
water contents to around 10% to gain a rather harder physical condition.

In all cases the principle is the same: moving air of a certain temperature under controlled humidity over
to the dates. Moisture from the dates absorbed by the air has to be disposed of through air vents.
Drying time and drying rate is a function of temperature, relative humidity and velocity of the air.
Dates Drying & De-Hydration Plant 2010

4.4 Present Practices in Drying & Dehydration

Dry dates form a big part of our exports. Dry dates are hugely consumed in India and Pakistan in
religious ceremonies and otherwise. Almost 70% of Sindhs dates are turned into dry dates for exports.
There are two distinct types of dry dates produced / processed in Sindh.

1. Brown dry dates (Brown Chohara)


2. Yellow dry dates (Yellow Chohara)

Brown dry dates

Dehydration of date is a major process takes place in Khairpur and Sukkur every season. During the
season Khairpur district gives a pleasing feast to eyes when all around the town, there are dates on the
tree tops, on the sides of the motorway passing through the district and are spread all across the fields
for drying as brown or yellow dried date. Doka is processed in a big Karhao having a capacity of around
120 Kg at a time. This entails a simple boiling process for around 20 to 30 minutes. When boiled
properly, these dates are spread over on Chataies (Mats) over the vast open grounds. These dates
remain there for around 5 to 6 days, as the case may be, to be dried under the scorching sun
(temperatures exceed 45C to around 50C) with lowest levels of humidity, eventually turning them into
brown dry date.

Yellow dry dates

Yellow dry dates are also made from second stage of date maturation, the Doka stage. Doka is picked up
and is put through a lengthy process to ascertain a yellow colour. This colour is obtained by using a
chemical commonly known in the local dialect as Rang Kaat. Basically, this is Sodium Formaldehyde
Sulfoxylate (SFS). Doka is boiled in large Karhao in the SFS solution for around 20 to 30 minutes at high
temperatures. After this, it is taken out and is spread over the mats in the open fields for drying. This
processed doka remains there under the open sky; at temperatures reaching 45C to around 50C, for
around 5 to 6 days till it is reasonably dried and or dehydrated, taking the form of a yellow colour dry
date. This yellow dry date is exported to neighbouring India for an extensive use in their religious
ceremonies.

4.5 Major Issues in Current Practices

When the processed dates are spread over vast open lands all around Khairpur, following important
quality and processing issues arise having great importance for the product and the revenues:
Dates Drying & De-Hydration Plant 2010

Processed dates remain under the sun for around 5 to 6 consecutive days
Such prolonged exposure of dates in the open fields expose dates to dust, insects and flies making
the dry dates dangerously unhygienic.
Passing animals like dogs, donkeys, goats, hens or other birds and farm workers add to further
contamination of the fruit.
During the day, high temperatures prevail but as the night sets in, dew falls on the under process
dates. This occurs multiple times till these processed dates turn into complete dry dates. Therefore,
accumulated dust of the day and dew of the night, make unhygienic layers on the dates. This
phenomenon affects the texture, taste and contents.
Due to open exposure to dates under the open sky, evaporation of moisture can not be controlled
paving way for inconsistent quality and lost taste.
Due to this unhealthy processing, Pakistani dry dates cannot be introduced into the high end
international markets hence loosing on huge foreign exchange.
This type of processing consumes longer periods of time such as 6 days. This hinders speedy disposal
of the processed dry dates in big volumes.
Since the subject process takes longer time, it keeps occupied the land and eventually more land is
required for bigger processed lots.
Stake holder has to pay an additional sum of money as a rental for such pieces of land for the season
which contributes to the higher cost.
This lengthy process is carried out by a large number of workers which is an additional expense
making the product cost, less effective.

As evident from the above observations, the existing process is cumbersome, lengthy, and unhygienic,
distorts the quality of the fruit, outer and inner texture, is costly and involves time for around a weeks.

4.6 Drying & Dehydration Plant: Justification

Having aforementioned problems and limitations of the traditional, age old method for drying &
dehydration of dates, there is an emergent need to have a reasonable solution to this problem. A drying
& dehydration plant (DDP) would work as an important public utility service established for the use of
dates growers, farmers and other stake holders of district Khairpur, sukkur and other adjoining areas
producing dates. Sukkur and Khairpur would be the main beneficiaries getting the direct benefits of
these facilities. The need of a DDP was also identified by the audience of the seminar/exhibition on
Dates Exhibition and Seminar Khairpur 2010 (DESK 2010) comprising mostly of prominent growers,
farmers, traders and experts working in the dates sector. This seminar was arranged SBI and District
Government Khairpur in August 2010.
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Establishment of this DDP would be beneficial in the following ways:

It will drastically shorten the dehydration period from 6 full days to only 6 hours.
It will directly enhance the credibility of the dry dates to a 100% in terms of hygiene.
It will enhance the quality of the dry dates as required, batch to batch.
Better processed dry date will attract higher revenues from the markets
Higher revenues will improve the general economic scene of the cluster district
Job opportunities will be created for the young human resources of the area
Having enormous potential for dry date making, it offers successful business venturing
A huge dry date market next door ensures the continuity of profitable business
Current initiatives of Government would facilitate immensely to the investors in establishment of
such a facility which includes one window operation, subsidized land acquisition, tax exemptions,
zero rated machinery imports etc.
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5. DATES DRYING & DEHYDRATION PLANT (DDP)

5.1 Opportunity Rationale

Having this recurring threat of the nature every year, there is a need and a big gap to handle this
situation to secure the crop in case of monsoons. Monsoons not only destroy the whole crop of dates
but hugely impact the growers and farmers financial positions. These rains can deprive, in a blink of an
eye, many farmers and growers from their hard earned money but also deprive the country from
earning a sizeable sum of foreign exchange. Pakistan has earned around US$ 44.5 million (Source: TDAP)
during the year 2009-10 from the dates exports. This was only possible as this year; rains came after the
harvesting season. This year the total crop size has been recorded as 329,000 tons which is a record
production for Sindh.

1. Governments support

In consonance with various policy initiatives taken at the federal and provincial levels to attract
investments in the agricultural sector and to boost up economic activity in the province, with a focus on
agro based rural economies in Sindh, the Government of Sindh has mad aggressive plans. These plans
encompass facilitation of a number of input resources to the interested investors in the form of one
window operation, subsidized land availability, provision of utilities, tax exemptions and ensuring the
security of the investors and their properties.

2. Availability of Land

The Sindh government is establishing the Special Economic Zones (SEZs) in different districts including
Larkana, Benazirabad, Khairpur, Tharparkar, Hala, Thatta and Badin districts to promote rapid
industrialization to attract the Foreign Direct Investment (FDI). District Government Khairpur,
consequent to this initiative, is in the process of developing Khairpur Special Economic Zone. Plots of
multiple sizes would be available to the investors on subsidized rates.

3. Availability of Product

Since Khairpur and Sukkur are the prime date producing areas, the quantum of the crop would ensure
the continuous availability of the product and consequently would create drying & dehydration
requirements. Therefore, a DDP plant in the area would be extremely beneficial for growers & farmers.
Only a nominal transportation charges would be incurred for transporting the product to the location
due to proximity. This is also advantageous for saving time and would contribute to a high paced
business activity.
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4. Tax Exemptions

Government is very extensively planning to create an attractive economic environment for all the export
processing zones and special economic zones. The entrepreneurs investing in these special zones will be
granted miscellaneous tax exemptions such as tax free import of machinery, tax exemptions on utilities,
tax exemptions on revenues etc. these tax exemptions would certainly add to the profitability of the
project and will provide a reason for investment.

Sindh Board of Investments web site presents the following incentives to the investors in different
sectors:

Reducing minimum foreign equity requirement for a project from US$ 0.5 million to US$ 0.3 million
Repatriation of 100% capital, profits and royalty, technology and franchise fees allowed.
Zero import duties on capital goods, plant and machinery and equipment not manufactured locally.
Enhanced First Year Allowance for depreciation from 50% to 75% of plant, machinery & equipment
for infrastructure and agriculture projects
Zero-rated import tariff on agriculture machinery (not manufactured locally) for registered
corporate agricultural projects.
Zero import duties on raw materials used in the production of exports.
Sindh Development Fund (SDF) for agro-based industries
Subsidizes 100% KIBOR (Karachi Inter Bank Offer Rate) on Capital Cost
50% KIBOR on Working Capital

5. Infrastructure Facilities

Government has made aggressive plans to support interested investor in a meaningful way to facilitate
them with all the required infrastructure facilities. The KSEZ is being equipped with solid infrastructure
facilities which would include properly planned pieces of land along with a road network connecting the
area with rest of the city, adequate piped water network for industrial use, piped gas network to
support industrial consumption, efficient sewerage system, and most of all the supply of electricity to
the upcoming industrial units.

6. Safety & Security

Having a peculiar history of safety & security issues in the region, the District Government of Khairpur is
making special arrangements for safety and security of the men and material. These efforts will
eliminate not only the sense of insecurity but will also portray seriousness of the Government towards
making KSEZ a success.
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7. Establishment of New Dates Market

To fully capitalize on the enormous business potential available in Khairpur, the District Government is
working on a plan to establish a new dates market as per international standards to attract international
buyers. As per initial plans, this new market would be established near the outer periphery of the district
to avoid congestion of traffic and to facilitate the visitors with an open and clean environment. If
constructed, this market will definitely be a catalyst in the promotion of dates business in the region.

8. Quantum of Business Opportunity

Dates production in Sindh was around 329,900 tons in 2009-10. As estimated earlier, around 70 % dates
are turned into dry dates which give a huge business potential for dates dehydration operations. Having
not a single proper drying facility in the region for the dehydration purposes, immense untapped
opportunities are available for any potential investor. As the native experts and intellectuals of the field
have mentioned during various face to face interactions, the psyche of the target district will also
contribute to the steady business as the concerned stake holders first observe the benefits of any
innovation closely, when felt satisfactory, they gradually switch onto it. Besides above mentioned points
as opportunity rationale, this DDP was originally conceived by the stakeholders of the area at the back
drop of the devastation caused due to monsoon rains and the huge business potential of dry dates
export to the neighbouring India.

5.2 Project Brief

The proposed project is about establishing a Dates Drying & Dehydrating Plant (DDP) for the use of
various stakeholders including growers, farmers, middle men, traders, exporters, whole sellers and all
the people who want to secure their produce / crop from the devastation of rain and for those also who
want to use it for turning their dates into good quality dry dates. This facility will mentally free the
stakeholders from the devastating effect of the monsoon season.

The capacity of this plant would be around 143 tons a month. This will be a manual plant fuelled by
natural gas. The plant would be consisted of 5 individual units deployed under one roof for the sake of
ease and economy of operations. The temperatures and humidity controllers, heat generator and hot air
blower with a drying chamber are the main components of this plant. By utilizing this facility, the
stakeholders will be able to have a high level of consistency of moisture contents due to use of humidity
and temperature controlling gadgets and equipments. This facility will shorten the time of dry date
making from six day to a mere 6 hours. This facility will also increase the product credibility and quality
in terms of better hygiene standards and controlled moisture contents enabling to have better sale price
in the local and international markets.
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5.3 Process Description

The purpose of this processing facility is to provide the stakeholders with appropriate means to get their
drying needs fulfilled. These drying needs could arise in three different ways.

The following would be the procedures for these three types of dryings & dehydration requirements.

Dates Receiving
The product / dates would be brought to the facility and properly received by the staff noting the time
and date of arrival.

Weighing
These dates would go into a weighing process. The necessary recording regarding types and total weight
will be made.

Process Requirement
The customer would inform the staff regarding the needed process such as simple drying or complete
dehydration of the product.

Shifting to the trays


After knowing the exact requirements, the dates would be transferred to the trays and stacked in front
of the available drying unit.

Drying & Dehydration Process


These trays would be shifted to the available drying unit and the process would proceed by starting the
unit and setting its temperature and humidity controllers.

Quality Checks
Necessary quality checks will be carried out during the process by opening up a part of the drying unit
and physically checking it. This physical quality check with regard to required stage will be carried out on
individual request basis.
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Final Product Stage


On this stage, the dried or dehydrated product will be taken out and would be left for cooling down to
normal temperature before leaving the premises.

The process flow would be as follows:

Simple Drying Process


(To secure rain wet dates form instant loss)
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Dehydration for Brown Dates


(To make brown dry dates from doka)
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Dehydration for Yellow Dry Dates


(To make partially processed doka to Yellow Dry Dates)
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5.4 Land & Building Requirement

The total land requirement for the DDP has been estimated at around 16400 square feet which is
slightly over 1500 square meter plot. This land will house the following building infrastructure;:

Main Processing Area where five units of Drying & Dehydration will be installed
Preparatory Area and Weighing operations
Transitory Storage for the Processed Products
Owners Office
General Office
Staff Rest Room
Staff Wash Rooms
Store for miscellaneous items
Guard Room

5.5. Layout Plan of DDP


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5.6 Key Success Factors

Dates drying and dehydration would play a very pertinent role on the agricultural horizon of Khairpur
Mirs. This plant would not only be making significant difference for dates growers but would also be
used in drying other agricultural products too.

These products would include Potatoes, Onion and Garlic. Therefore, these opportunities would
increase the viability and profitability of the project. This facility can be of immense importance in
multiple weather conditions. In normal situations when the crop has been completely harvested before
the start of rains, this facility would be used as a dehydrator for making the dry date. However, during
the rainy seasons, this would support the stakeholders in getting the fruit dried with its hot air
blowing/circulation system.

There seem no issues of scarcity of raw materials as around 85% dates are grown in and around
Khairpur and Sukkur districts. As mentioned earlier, during 2009-10 season, Khairpur/Sindh has
experienced a bumper production of dates nearing 329,900 tons. Besides this, other crops of the area
also make a huge amount, too. One major component favouring the potential investors is the presence
of totally monopolistic opportunity present in the area as yet, there is no such facility whereby dates
could be dried commercially. This gives an open field for any incoming investor for a secured and
profitable venturing.

Since both, federal and provincial Governments are making all out efforts in creating a favourable and
enabling investment environment with special reference to agro based industries all across the country,
they are also working hard to facilitate the investors with better dispensation of utility services, tax
exemptions, duty free imports of machinery, provision of safety and security, guarantees and assurances
etc. Better and feasible financial assistance, guaranties and risk coverage options can be worked out
with institutions such as Sindh Board of Investment for higher viability and success of the project.

In brief, it can be said that if established, this DDP would add value on various accounts for the dates
sector of Khairpur and Sukkur:

Drying time reduction up to 75%


Best quality product as a result of a consistent & hygienic Drying up process under controlled
parameters
Surety of getting higher price in the local and international markets
Entry into new and high end markets due to product quality
Further strengthened market monopoly in dates and dry dates
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6. PROJECT INPUTS

6.1 Proposed Processing Capacity of the Drying and De-Hydration


Plant

This Drying and De-Hydration Plant will be installed with a view to cater to the needs of a diverse base of
customers from big farm owners to the smallest date grower and farmer. This facility would have five
independent sections. Every section will have a drying capacity of 550 Kgs dates per 6 hours. All five
sections would be producing 2.75 tons of processed date every six hours. Two shifts a day would take
this volume to 5.5 tons a day. Keeping a month of 26 days, this facility would process around (286) 143
tons of dates a month.

6.2 Land & Location Requirements

Khairpur is a big district having five talukas. This DDP can be established in any taluka or in the Khairpur
Special Economic Zone (KSEZ). The estimated land requirement is 16400 square feet. (16400 Sq.ft =
1523.609 Sq. metre)

6.3 Plant Machinery & Equipment

It would be a hot air circulated dryer having a close circuit and would be consisted of the following
major machinery components:
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The cost is inclusive of Fabrication, Transportation to the site and Installation in Khairpur.

6.4 Office Equipment

The following office equipment would be required for the operations:


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6.5 Human Resources

The following human resources would be utilized for the DDP operations. This resource would be semi
skilled and unskilled except Accountant and Warehouse Officer. A 10% benefits would also be added to
the salaries.

6.6 Infrastructure Requirements

The following important infrastructure resources would be required for the successful plant operations.
Water
Phone Lines
Electricity
Road network
Natural Gas
Security Support
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7. PROJECT ECONOMICS

7.1 Project Cost

7.2 Project Returns

7.3 Capital Structure of the Project


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8. PROJECT FINANCIAL STATEMENTS

8.1 Project Income Statement


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8.2 Project Balance Sheet


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8.3 Project Cash Flow Statement


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Annex A

Financial Assumptions

A-1. Production assumption


Proposed unit is feasible to de-hydrate 11 ton of the product per day. The basis of this assumption is the
capacity of one dryer i.e. 550 Kilogram in 5 hours using its 150 trays (in one dryer). Due to heavy work
load of input of the products the unit will be operative round the clock with two shifts of 12 hours with
one an hour break and two hour breaks. One shift completes the two cycles of production i.e. 1100
Kilogram (or 1.1 ton). Same quantity is being produced by the other shift. Other assumption in this
model is 5 dryers to be installed so the total quantity of one day will be 11 tons (550 x 2 x 2 x 5).
Excluding the weekends the plant will be operative for 26 days in a month.

A-2. Capacity Assumption


In early years there are need to train newly installed machines and newly appointed staff in the plant so
the machines could not provide 100% capacity so we assume that we will utilize only 80% of the
capacity in first year. After fully operative and trained staff, further the confidence of growers on the
quality and capacity of the plant the capacity will increase in next year and then the plant will produce
100% capacity.

A-3. Rate Assumption

The feasibility of plant based on its utilization of whole year in various products. Our major product for
this particular report is dates which have a very small harvesting period. To utilize the plant for whole
year we can use this unit for different vegetables according to its seasonal availability as follows:
a. Dates July and August
b. Garlic August to October
c. Onion November to February and June
d. Potato March to May

Another important aspect is the rate of dehydration to be charges from growers. It must be near to the
cost incurred using traditional way of dehydration (directly sun heat). The cost incurred by using
seasonal labour in Khaipur/ Sukkur area is approximately Rs.3.65 (It includes Rs.12,500 for rent of plot
and Rs.12,000 for labour cost) This cost incurred on one acre land production i.e. 168 Mounds (OR 6720
k.g.). On the basis of this calculation we assume the cost to be charged from grower for One kg will be
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Rs.4/- that is not much higher than the present cost. The quality of product (no human contact made
and dust free environment) will be the added advantage to the growers and exporters.

A-4. Cost of Land

2000 sq yard plot is available in Distt. Khairpur outer edges for Rs. 1,000,000 for installation of one unit
of 5 dryers. It also has the preparation area, weighing section, storage area, administration block and
some open space for waiting area.

A-5. Construction Cost Assumption

According to the present rate of construction at local market the total cost incurred on the plot will be
Rs.13,500,000 as follows:-

A-6. Plant & Machinery

As discussed in A-1 the best option is to erect five dryers in one unit of dehydration plant. The cost of
one de-hydrator is Rs.3,850,000. So total plant will incur a cost of Rs.19,250,000.

A-7. Other Fixed Assets

Following equipments are required for plant:


a. One Generator for office use only of 2.5 KvA Rs.50,000
b. Digital Weighing Scale (5 Ton) Rs.350,000
c. On Laptop computer for Owner Rs.65,000
d. One Desktop printer for office use Rs.40,000
e. Other equipments (Printer, Fax and networking) Rs.100,000
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A-8. Utilities

The machine to be used will be operative on natural gas, so the major utility expense is on the gas. The
other equipments utilization cost on monthly basis is as follows:-

A-9. Salary/Remuneration Assumption

This plant is totally automatic and no such huge staff is required for plant itself, however the
administration staff is required for the plant. We also assume the remuneration of the investor in the
monthly bill of Remunerations. Except the owner of the unit only 6 persons required to smooth running
of the plant are as follows:-

A-10. Furniture and Fixture Assumption

The unit has to incurred onetime cost on furniture and fixture for admin block and office block the
details of which are as follows:-
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A-11. Repair & Maintenance

We assumed that expenses against repair and maintenance on all fixed assets will be occurred on their
book value at following rates annually:-

A-12. Insurance Expenses

It is assumed that insurance expense will be occurred on cash for security of cash available at plant. That
will be with a rate of 1.5% of the available cash.

A-13. Promotional Expenses

We assumed that for promotion of newly introduced facility in the Distt. Khairpur the plant
management should advertise the benefits and features of plant to small growers of the area. For said
purpose 1% of revenue must be allocated against promotion of the de-hydration facility.
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A-14. Printing & Stationary and Misc. Expenses

For official usage and packing usage the Rs. 5,000/- will be the expenses on monthly basis. Other
miscellaneous expenses on refreshments and other unavoidable circumstance will be assumed at a rate
of Rs. 5,000/- per month.

A-15. Financial Results

On the basis of above assumptions the plant will produce following financial results in next five years
time.
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IMPORTANT CONTATCS

Sindh Board of Investment Economic Wing


Government of Sindh MINISTRY OF FOOD AND AGRICULTURE
108 F, PECHS-II rd
38-W, 3 Floor, Khalid Plaza, Blue Area
Karachi, Pakistan Islamabad
Tel: 021 34300971 3
Website: www.minfal.gov.pk
Fax: 021 - 34300974
Email: info@sbi.gos.pk E Mail : secretary@minfal.gov.pk
Website: http://www.sbi.gos.pk

Zarai Taraqiati Bank Limited Trade Development Authority of Pakistan


Zonal Chief (TDAP)
St.2/3,B-1,Sch-36, 5th Floor, Block "A", Finance & Trade Center,
Gulistan-e-Jouar, Shahra-e-Faisal, Karachi - Pakistan
Karachi Tel: (92-21) 9206462
TEL: 021 34610808 Fax: (92-21) 9206461
Email: contactus@ztbl.com.pk
PARC SMEDA
PARC-TARC, Old Block 9 & 10, 5 TH Floor, Bahria Complex II, M.T. Khan Road,
Karachi University Campus, Karachi-75270, Karachi.
Pakistan Tel: (021) 111-111-456
Tel: 0092 21 99243844 Fax: (021) 5610572
Fax No: 0092 21 99243838 Email: helpdesk.sindh@smeda.org.pk

Agriculture Department, Government of Sindh, Agribusiness Support Fund


Sindh Secretariat Building # 2, Ground Floor, Provincial Coordinator
Saddar, Karachi-74100. Sindh Office,Karachi
Tel: +92-21-9211510 PH.021-4313851 , 021-4313853
Fax: +92-21-9211805 Fax:021-4313852

Pakistan Horticulture Development & Export Food and Agriculture Organization of the United
Board Nations
House No. B-208, Block No 5, NARC Premises
Near NIPA Chowrangi Park Road, Chak Shahzad
Gulshan-E-Iqbal, P.O.Box 1476, Islamabad, Pakistan
Karachi Tel: +92 51 9255491-3, ext: 201
Tel: +92-21-4814168-58 & +92-21-4969507 Fax: + 92 51 9255454
Fax: +92-21-4969847 E-mail: FAO-PK@fao.org
Email: info_khi@phdec.org.pk
Sindh Agriculture University Sindh Development Fund (SDF)
Tandojam, Hyderabad, F-46/A, Street No. 4, Park Lane,
Sindh Block 5, Clifton, Karachi
Phone: + 92-22-2765870 Tel: +92-21-3583 0593 (Land Line)
Fax: + 92-22-2765300 Tel: +92-21-3429 8575 (V-Phone)
Email: info@sau.edu.pk Fax No.: +92-21-3583 0594
Email: info@sindhdf.org.pk
URL: www.sindhdf.org.pk

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