Small-Scale Maize Milling (ILO - WEP, 1984, 160 p.): CHAPTER VI. METHODOLOGICAL FRAMEWORK FOR THE ESTIMATION OF PRODUCTION COSTS: III. METHODOLOGICAL FRAMEWORK FOR THE ESTIMATION OF MILLING COSTS: III.2 Maintenance and repair costs of equipment

Small-Scale Maize Milling (ILO - WEP, 1984, 160 p.)

CHAPTER VI. METHODOLOGICAL FRAMEWORK FOR THE ESTIMATION OF PRODUCTION COSTS

III. METHODOLOGICAL FRAMEWORK FOR THE ESTIMATION OF MILLING COSTS

		(introduction...)
		III.1 Depreciation costs of equipment and buildings
		III.2 Maintenance and repair costs of equipment
		III.3 Energy costs
		III.4 Rental cost of land
		III.5 Labour costs
		III.6 Packaging costs
		III.7 Interest payments on working capital
		III.8 Unit production cost of meal produced by small-scale mills
		III.9 Unit production cost of meal produced by roller mills

III.2 Maintenance and repair costs of equipment

Maintenance and repair costs include the cost of labour and that of spare parts. If maintenance is carried out by the miller and/or a skilled mill worker, the labour costs for maintenance may be included int the overall labour costs of the mill (see section III.5). On the other hand, if the miller must secure regular maintenance services from local fitters, he will need to obtain an estimate of the yearly cost of these services.

Table VI.1

Estimated “on-site” costs of milling equipment

Mill type	Output kg/hr	Motor kW	Country of origin	F.O.B.	C.I.F. and Inland freight
				(end 1980)
1. Stone, vert.	25	0.5	Belgium	383	420
2. Stone, vert.	35	0.7	Belgium	401	440
3. Plate	45	0.7	United Kingdom	200	220
4. Stone, vert.	50	0.7	Belgium	466	510
5. Hammer	85	4.0	United Kingdom	2,040	2,250
6. Plate	125	2.0	United Kingdom	217	240
7. Stone, horiz.	150	3.0	France	770	850
8. Plate	150	3.5	India	900	1,000
9. Hammer	160	7.5	United Kingdom	1,826	2,000
10. Plate	180	3.5	United Kingdom	207	230
11. Hammer	180	7.5	United Kingdom	3,150	3,500
13. Stone, vert.	200	2.0	Denmark	277	300
14. Stone, vert.	240	2.0	Fed. Rep. Germany	624	690
15. Stone, horiz.	250	5.0	France	1,000	1,100
16. Plate	250	5.0	India	1,000	1,100
17. Plate	270	5.0	United Kingdom	260	290
18, Hammer	300	5.5	United Kingdom	1,124	1,250
19. Plate	300	3.0	France	205	225
20. Stone, vert.	310	3.0	Fed. Rep. Germany	654	720
21. Hammer	320	15.0	United Kingdom	3,387	3,725
22. Plate	340	5.5	United Kingdom	520	570
23. Stone, vert.	350	3.0	France	470	520
24. Stone, vert.	410	5.0	Fed. Rep. Germany	970	1,100
25. Hammer	500	5.5	Brazil	430	475
26. Hammer	570	7.5	United Kingdom	1,276	1,400
27. Stone, horiz.	600	7.5	Denmark	447	490
28. Hammer	680	30.0	United Kingdom	6,400	7,000
29. Stone, horiz.	700	9.0	Denmark	603	660
30. Stone, vert.	750	5.5	France	604	660
31. Stone, vert.	950	15.0	Denmark	683	750
32. Hammer	1,000	11.0	Brazil	750	825
33. Hammer	1,260	56.0	United Kingdom	10,400	11,450
34. Roller	2,000	110.0	United Kingdom	250,000	275,000
35. Roller	5,000	300.0	United Kingdom	400,000	440,000
36. Roller	10,000	485.0	United Kingdom	700,000	770,000

Source: Machinery makers and authors' estimates.

Table VI.2

Estimated “on-site” costs of maize shellers

Output kg/hr	Drive	kW	Country of origin	f.o.b. cost	c.i.f. and inland freight cost
				(mid 1981)
100	Manual	-	United Kingdom	26	30
150	Manual	-	Fed. Rep. Germany	35	40
350	Treadle	-	Japan	243	270
500	Manual	-	United Kingdom	125	140
600	Motor	1.5	Fed. Rep. Germany	906	1,000
750	Motor	0.3	United Kingdom	174	190
1,125	Motor	1.5	Japan	580	640
1,300	Pedal	-	United Kingdom	180	200
2,500	Motor	4.5	United Kingdom	453	500
3,000	Motor	7.5	United Kingdom	2,650	3,000
2,600	Motor	5.5	Brazil	1,250	1,400
4,000	Motor	7.5	United Kingdom	2,950	3,200

Source: Machinery manufacturers and authors' estimates.

The cost of spare parts is a function of the equipment yearly utilisation rate, the quality of the grain and the care with which the equipment is maintained. As a general rule, the yearly cost of spare parts may be estimated at 10 per cent of equipment cost.