Process Vegetable Cost of Production Comparison Tasmania and New Zealand A report prepared for the Department of Economic Development, Tourism and the Arts February 2011 Davey & Maynard Agriculture and resource management consultants ABN 59 009 537 839 E-mail [email protected] Postal address: PO Box 31, Devonport Tasmania 7310 AUSTRALIA Telephone: +61 (3) 6424 9311 Facsimile: +61 (3) 6424 9826 Author(s): Lance Davey This report may be cited as: Process Vegetable Cost of Production Comparison – Tasmania and New Zealand, Davey & Maynard, 2011. This report has been prepared in accordance with the scope of services described in the contract or agreement between Davey & Maynard (D&M) and the Client. Any findings, conclusions or recommendations only apply to the aforementioned circumstances and no greater reliance should be assumed or drawn by the Client. Furthermore, the report has been prepared solely for use by the Client and Davey & Maynard accepts no responsibility for its use by other parties. TABLE OF CONTENTS Page EXECUTIVE SUMMARY ................................................................................................................ I 1. INTRODUCTION ................................................................................................................... 1 1.1 1.2 1.3 2. INPUT COSTS ....................................................................................................................... 3 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3. INTRODUCTION ........................................................................................................................... 3 LAND ........................................................................................................................................ 3 INTEREST RATES .......................................................................................................................... 4 MACHINERY PRICES ..................................................................................................................... 4 WAGE RATES .............................................................................................................................. 4 FUEL ......................................................................................................................................... 5 FERTILISER ................................................................................................................................. 5 SPRAYS ...................................................................................................................................... 6 ELECTRICITY................................................................................................................................ 6 WATER .................................................................................................................................. 7 CROP INCOME ..................................................................................................................... 8 3.1 3.2 3.3 3.4 4. BACKGROUND ............................................................................................................................ 1 EXCHANGE RATE ......................................................................................................................... 1 REPORT STRUCTURE..................................................................................................................... 2 INTRODUCTION ........................................................................................................................... 8 CROP YIELDS ............................................................................................................................... 8 PRICES PAID ............................................................................................................................... 9 CROP INCOME .......................................................................................................................... 10 COST OF PRODUCTION .......................................................................................................12 4.1 4.2 4.3 4.4 4.5 4.6 4.7 INTRODUCTION ......................................................................................................................... 12 COST OF PRODUCTION METHODOLOGY ......................................................................................... 12 BEANS ..................................................................................................................................... 14 CARROTS ................................................................................................................................. 17 PEAS ....................................................................................................................................... 20 POTATOES................................................................................................................................ 23 SUMMARY ............................................................................................................................... 26 5. GROSS & NET MARGINS .....................................................................................................28 6. CONCLUSIONS ....................................................................................................................32 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Executive Summary Following recommendations of the McCain community taskforce, The Department of Economic Development, Tourism and the Arts (DEDTA) commissioned Davey & Maynard (D&M) to undertake a process vegetable cost of production comparison between Tasmania and New Zealand. The findings of this report are based on D&M experience and contacts within the local industry alongside information obtained from consultants and farmers in New Zealand. This report is a comparison of on-farm costs of production in Tasmania and New Zealand. It does not consider processing costs which reportedly make up 40-50% of the ex factory price of process vegetables. EXCHANGE RATE The cost of production comparisons in this report are based on the current (January 2011) exchange rate of NZ$ 1.31 for A$1.00, or A$0.76 for NZ$ 1.00. All prices appearing in the report have been converted to Australian dollars at these exchange rates. INPUT PRICES Land prices Land prices in New Zealand are higher on average than in Tasmania, particularly in the North Island (Hawkes Bay and Auckland). However, in the South Island where around two thirds of New Zealand’s processed beans, carrots, peas and potatoes are grown, prices are similar to North West Tasmania. Interest rates Interest rates in New Zealand are similar to those in Tasmania, with farm lending rates currently quoted at around 7.5% to 8%. Machinery prices Machinery prices are similar in both places. Wage rates Effective farm wage rates in New Zealand are around 35-40% lower than in Tasmania. This is due to a combination of lower base rates, lower employer superannuation contributions and lower workers compensation insurance rates. Fuel Net farm diesel prices are similar in both places. Fertiliser Fertiliser prices are significantly lower in New Zealand compared to Tasmania. A simple average of the list prices of nine base fertilisers was almost 20% lower. Given that fertilisers are imported from overseas for both areas it is not immediately obvious why prices are lower in New Zealand. Sprays While prices for a range of sprays used in both areas was found to vary greatly there was no consistent trend of higher or lower prices for either area. Irrigation electricity The cost of irrigation electricity is typically around 40% less in New Zealand than in Tasmania. However there is potential for larger users in Tasmania to approach the New Zealand rate under recently introduced competitive tendering processes. ES.i DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Water charges Growers in both places access most of their water supply from dams, bores or streams and therefore do not pay significant water charges. Actual costs paid are a combination of the level of inputs used and the unit price of those inputs. So while machinery prices are similar in both places, New Zealand’s flatter topography and generally larger paddocks favours the use of larger and faster machinery for cultivation, spraying and harvesting. Similarly, for irrigation New Zealand farmers can often use larger units and, in addition, application rates are lower for some crops. On the other hand, many growers need to pump from relatively deep bores which increases both capital and pumping costs. CROP YIELDS Yields vary both within and between Tasmania and New Zealand – between farms, between districts and between years. Hence it is difficult to be definitive about the overall differences that may exist between the two areas. However, on the basis of the available information it appears that New Zealand bean and carrot yields are somewhat less than in Tasmania and that pea and potato yields are higher (Figure 1). The apparent slightly higher pea yield in New Zealand is possibly due, at least in part, to different factory weight assessment methods. Figure 1: Crop yields (t/ha) 100.0 90.0 80.0 70.0 60.0 t/ha 50.0 Tas 40.0 NZ 30.0 20.0 10.0 Beans Carrots Peas Potatoes PRICES PAID ES.ii DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Prices paid for all four crops are around 40% lower on average in New Zealand than in Tasmania (Figure 2) - varying from 34% less for beans to 48% less for peas. Figure 2: Prices paid (A$/t) 500 450 400 350 300 $A/t 250 Tas 200 NZ 150 100 50 Beans Carrots Peas Potatoes CROP INCOME Crop income per hectare in New Zealand is around 40% lower on average than in Tasmania - varying from 32% less for potatoes to 46% less for carrots (Figure 3). The difference is largely due to the lower prices paid in New Zealand. Figure 3: Income received (A$/ha) 18,000 16,000 14,000 12,000 10,000 $A/ha Tas 8,000 NZ 6,000 4,000 2,000 - Beans Carrots Peas Potatoes ES.iii DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Because yield is variable between farms, between districts and between years for both Tasmania and New Zealand, caution needs to be taken in interpreting these figures. COST OF PRODUCTION Costs of production per hectare for the four crops are around 25% less in New Zealand than in Tasmania, varying from 13% less for carrots to 33% less for beans (Table 1 & Figure 4). Table 1: Cost of production (A$/ha) Item Tas NZ A$/ha A$/ha A$/ha (%) Beans 3,765 2,535 -1,230 -33% Carrots 7,525 6,525 -1,005 -13% Peas 2,550 1,790 -760 -30% 11,640 9,220 -2,420 -21% average -24% Potatoes Difference Figure 4: Cost of production (A$/ha) 14,000 12,000 10,000 8,000 $A/ha Tas 6,000 NZ 4,000 2,000 Beans Carrots Peas Potatoes Costs of production per tonne for the four crops are around 21% less in New Zealand than in Tasmania, varying from 1% less for carrots to 34% less for peas (Table 2 & Figure 5). The relatively close cost of production for carrots on a per tonne basis is a result of a higher yield in Tasmania offsetting the 13% higher per hectare cost. ES.iv DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Table 2: Cost of production (A$/t) Item Tas NZ A$/t A$/t Difference A$/t (%) Beans 327 253 -74 -23% Carrots 79 78 -1 -1% Peas 418 275 -143 -34% Potatoes 212 159 -53 -25% average -21% Figure 5: Cost of production (A$/t) 450 400 350 300 250 $A/t Tas 200 NZ 150 100 50 Beans Carrots Peas Potatoes CROP MARGINS Two crop margins are described in this report: Gross margin Gross income less variable growing costs such as land preparation, seed & seeding, fertiliser, sprays, irrigation running costs, and harvesting & cartage; and ‘Net margin’ Gross income less cost of production or gross margin less overheads (land rental, irrigator ownership and interest on crop outlay). ES.v DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand While costs of production per hectare are broadly around 25% lower in New Zealand than in Tasmania they are not sufficiently low to offset the 40% lower income received, so New Zealand gross and net margins are lower than in Tasmania. The gross margin per hectare for the four crops is around 50% less in New Zealand than in Tasmania with a range from 41% less for potatoes through to 73% less for carrots (Figure 6). The net margin per hectare for the four crops is around 80% less in New Zealand than in Tasmania with a range from 62% less for potatoes through to 100% less for carrots (Figure 7). Figure 6: Gross margin (A$/ha) 7,000 6,000 5,000 4,000 $A/ha Tas 3,000 NZ 2,000 1,000 0 Beans Carrots Peas Potatoes Figure 7: Net margin (A$/ha) 5,000 4,500 4,000 3,500 3,000 $A/ha 2,500 Tas 2,000 NZ 1,500 1,000 500 0 Beans Carrots Peas Potatoes ES.vi DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand In the case of carrots and peas, the very low New Zealand net margins suggest that the gross margins being earned are sufficient to cover land rental, irrigation ownership and interest on crop outlay – but not other overheads (eg management wage) or to contribute to an overall profit. There is also no margin for risk. A sustainable business in this situation would require other enterprises to cover these additional overheads and to produce an overall profit for the cropping business1. Assuming that the margins being earned in New Zealand are sustainable, the question arises as to how that is achieved, given that Tasmanian farmers are not achieving high profit levels with significantly higher margins. Possibilities include: Remaining overheads such as management costs are lower cost in New Zealand and therefore require less margin to cover the cost and produce a profit; The lower margins earned are applied to a higher number of tonnes or hectares – ie a low margin/high volume business model; and Better integration of enterprises may produce an overall business profit despite inclusion of some lower returning enterprises. CONCLUSIONS Without a significant reduction in effective wage rates or a devaluation of the Australian dollar (both unlikely) it is difficult to see that Tasmania will be able to equal New Zealand’s lower cost of production. However, there are a number of areas that might be addressed to close the gap. To become more competitive Tasmanian growers need to either (1) reduce costs of production per tonne and/or (2) develop business models that can survive lower prices and lower margins. The cost of production per tonne can be reduced by either increasing yield relative to cost, or reducing input costs without a significant loss of yield. Some areas worthy of further investigation include: 1 Ongoing research, development and extension aimed at improving crop yields; Reasons behind lower fertiliser prices in New Zealand; The potential for reduced fertiliser inputs; Lowering irrigation costs, including the potential benefits from a competitive market for electricity; Reducing potato seed costs; and The potential for high volume potato harvesting systems in Tasmania; The profit for the cropping enterprise need not include any return for land which is covered in the land rental overhead cost, or for a return on the machinery investment which is covered in the machinery contracting cost, but there should be a return over and above these to cover other overheads and risk and contribute to profit. ES.vii DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand At the same time research should be undertaken in relation to business models that can potentially operate profitably with lower margins. For example: The potential for larger scale businesses through increased land ownership, land leasing or some form of co-operative farming operation; and Better integration of enterprises to produce an overall business profit despite inclusion of some lower returning enterprises. ES.viii DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 1. Introduction 1.1 Background The Department of Economic Development, Tourism and the Arts (DEDTA) commissioned Davey & Maynard (D&M) to undertake a process vegetable cost of production comparison between Tasmania and New Zealand. This project stems from recommendations of the McCain community taskforce established in November 2009 to explore economic and business opportunities in areas affected by McCain Foods’ decision to close its Smithton vegetable processing plant over 2010. The taskforce recommended a range of projects from funding business development activities to further research into opportunities for the region. In response to these recommendations the Premier of Tasmania announced a range of initiatives including a cost comparison study between the Tasmanian and New Zealand vegetable processing industries. The purpose of the overall vegetable cost comparison study project is to: Identify and quantify the cost of common key inputs into vegetable production and processing in Tasmania and NZ at major points along the supply chain, and To identify any other distinctive competitive advantages or points of difference between the two growing regions. Detailed vegetable processing cost information is unavailable. Tasmanian processing companies have identified the cost of labour, raw materials, power (and other infrastructure such as water) as areas of concern. The efficiency of plant and equipment is also an area of concern. This relates, at least in part, to labour award structures in Tasmania that tend to limit out of hours operation and thereby overall throughput. This report is restricted to a comparison of on-farm costs of production in Tasmania and New Zealand. It does not include processing costs which reportedly make up around 4050% of the ex factory price of process vegetables. 1.2 Exchange rate The cost of production comparisons are based on the current (January 2011) exchange rate of NZ$ 1.31 for A$1.00, or A$0.76 for NZ$ 1.00. Figure 1.1 shows movements in the exchange rate over the past 10 years. While the exchange rates in the early 2000s were similar to present, there has been a 20% appreciation in the A$ versus NZ$ since around 2005. This has led in part to the current more competitive situation prevailing for New Zealand. 1 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Figure 1.1 Exchange rate movements over the past 10 years 1.40 1.20 1.00 0.80 A$/NZ$ 0.60 0.40 0.20 0.00 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 1.3 Report structure The structure of this report is as follows: Section 2 Presents a summary of input costs for both Tasmania and New Zealand. Section 3 Shows average yields and prices – and gross income per hectare. Section 4 Shows cost of production Section 5 Outlines gross margins and net margins. Section 5 Presents overall conclusions. 2 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 2. Input costs 2.1 Introduction The cost of production for each crop is a combination of input levels and input prices. This section examines input prices by comparing per unit costs of the major crop production inputs – in Australian dollar terms. 2.2 Land The land price is defined as bare land price per hectare including water and irrigation infrastructure, but not including irrigators (travelling gun, rotary boom, linear irrigator or centre pivot). Land prices in Canterbury, where around two thirds of New Zealand’s processed bean, carrot, pea and potato production occurs, are similar to those on the North West Coast (Table 2.1). Land prices in Hawkes Bay and Auckland are significantly higher than Canterbury, and in Tasmania the Meander Valley and Northern Midlands have lower prices than the North West. So while the Canterbury land price is similar to the North West Coast, overall land prices in New Zealand are higher than in Tasmania. In assessing vegetable costs of production a nominal land rent has been determined as 4% of land value. This is considered to be a reasonable long-term rent for a whole farm. In both Tasmania and New Zealand actual one-year rent payment for a higher value crop can be significantly greater than the figures shown. For example, in Canterbury a short term lease was quoted as being around A$1,370/ha with an additional payment of A$1.15-$1.50/mm for irrigation – irrigator, labour, electricity and repairs. Depending on exactly what is supplied in terms of water and irrigation equipment, a one year rent for potatoes in Tasmania may be as high as A$2,000 – A$2,500/ha. Table 2.1: Land costs (A$) Tasmania North West Deloraine Northern Midlands New Zealand Canterbury Hawkes Bay Auckland Land price Nominal land rent (4%) A$/ha A$/ha $23,500 $19,000 $13,500 $940 $760 $540 $23,000 $30,500 $38,000 $920 $1,220 $1,520 3 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 2.3 Interest rates Interest rates in New Zealand are similar to those in Tasmania. Farm lending rates were quoted at around 7.5-8.0%. 2.4 Machinery prices After adjustment for currency, plant and machinery purchase prices in New Zealand are similar to those in Tasmania. As an example tractor and potato planter purchase prices (excluding GST) are compared in Table 2.2. Table 2.2: Plant & machinery prices (A$) Tractors 125 hp 150 hp 205 hp Potato planter 4 Row Tas NZ A$ A$ Difference A$ % (ML) 87,100 111,000 202,600 85,500 111,000 174,000 84,500 84,500 -1,600 0 -28,600 -2% 0% -14% 0 0% Where New Zealand does have a machinery advantage over Tasmania, however, is in its scope to use larger and faster machines. For example, because of the large flat paddocks in Canterbury, potato harvesting rates were quoted at up to 20-40 tonnes/hr using a windrower and Lockwood two row harvester. While capital costs are higher, these rates are significantly higher than those being achieved in Tasmania. Another example is in pea harvesting where in the 2009-10 season a similar number of pea harvesters in Canterbury was able to harvest almost double the amount compared to Tasmania. This was due to a combination of paddock size and topography. Furthermore, with no weekend penalty rates, the New Zealand harvesters operated seven days a week. 2.5 Wage rates Farm wage rates in New Zealand are around 35-40% lower than in Tasmania. This is due to a combination of lower base rates and lower add-ons (Table 2.3). The minimum wage in New Zealand is currently A$9.70/hr compared to A$15.00/hr in Tasmania. For a reasonably skilled farm operator in Tasmania (Horticulture Award Level 5) the all up hourly rate is almost A$25.00/hr. For a similar person in New Zealand the rate is around A$15.80/hr. 4 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Table 2.3: Wage rates (A$) Tas NZ A$ A$ Difference A$ Level % (ML) Minimum wage Base Superannuation Workers Comp. Insurance Total 15.00 1.35 0.68 17.03 9.70 0.19 0.18 10.08 -5.30 -35% -6.95 -41% Skilled worker (Level 5) Base – casual rate Superannuation Workers Comp. Insurance Total 21.13 1.90 0.95 24.93 15.22 0.30 0.28 15.81 -5.91 -28% -8.17 -34% For Tasmania the casual rate under the Horticulture Award includes a 21% allowance for holidays, sick leave etc. Superannuation is 9% and workers compensation insurance for farm workers is around 4.5%. For New Zealand, the KiwiSaver superannuation scheme is set at a minimum of 2% (with 4% and 8% options), and there is a national Accident Compensation Commission (ACC) Levy of 1.9%. 2.6 Fuel Fuel prices are similar in Tasmania and New Zealand (Table 2.4). Table 2.4: Diesel price (A$) Base Tas NZ A$/L A$/L 1.37 1.01 Less diesel fuel rebate -0.38 Net price 0.99 1.01 Difference A$/L % (ML) 0.02 +2% 2.7 Fertiliser Fertiliser list prices in New Zealand in January 2011 were around 19% lower than in Tasmania. Table 2.5 includes are range of commonly used fertilisers and of those, urea is the only one with a similar price in both locations and even this may be an anomaly because of a recent price rise in New Zealand. Given that the base materials are imported into both countries it is not immediately obvious why such a difference prevails. Further investigation of the apparent difference would be worthwhile. 5 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Table 2.5: Fertiliser prices (A$) Fertiliser Lime Super Triple super DAP (18-20-0) MAP (10-22-0) Urea Sulphate of Ammonia Muriate of Potash Potassium Sulphate Simple average Tas NZ Difference Crop A$/t A$/t A$/t % 35 392 871 871 871 574 519 766 1,080 24 247 726 769 784 549 410 672 843 -11 (ML) -145 -145 -102 -87 -25 -109 -94 -237 -33% -37% -17% -12% -10% -4% -21% -12% -22% -19% January 2011 list prices 2.8 Sprays Spray prices were compared for a range of products used in both Tasmania and New Zealand. While there were significant differences between prices in both locations it was difficult firstly, to determine whether exactly the formulations were being compared, and secondly, lower prices for some chemicals in each area were roughly balanced by higher prices for others. For these reasons it is not possible to conclude that there are any overall difference in spray prices between Tasmania and New Zealand. This is an area that might also warrant closer inspection. 2.9 Electricity The cost of irrigation electricity in New Zealand is around 40% less than in Tasmania. Table 2.6 shows an indicative cost of electricity for a 40 hectare linear irrigator operating for 1,500 hours to apply 4.0 Ml/ha, and using 58,500 kWh. The New Zealand costing assumes an overall cost of A$0.11/kWh as quoted by local consultants and farmers. Table 2.6: Irrigation electricity (A$) Service charge Power cost* Total Average c/kWh Tas NZ A$ A$ $955 $10,045 $11,000 18.8c Difference A$ Crop % (ML) $6,700 11.5c -$4,300 -7.3c -39% -39% * For Tasmania 45% peak/55% off-peak While the cost of electricity is significantly less in New Zealand than in Tasmania, the overall cost of irrigating may or may not be. The overall pumping cost is impacted by a 6 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand range of other factors including the type of irrigation system (travelling gun, rotary boom, linear irrigator and centre pivot) and the total head required to get water to the irrigator. On average, New Zealand may have greater static head because much of its water comes from relatively deep wells. However, there will be a wide range of irrigation pumping costs both within each area as well as between them. For larger operators in Tasmania there is scope for price reductions under competitive tendering. A recent quote under Tranche 4 (150 MW pa) was for an effective price of around A$0.10/kWh, including off peak rates of A$0.06/kWh for 8 hours per day during the week plus for the whole weekend, with the remainder of the irrigation season being able to be covered by the shoulder rate of A$0.15/kWh. Apparently a new Tranche 4a tender will be available shortly which will allow total consumption of 50 MW per annum. 2.10 Water Most vegetable growers in both New Zealand and Tasmania obtain their irrigation water for “free”. That is they use water from their own dams or bores or directly from a stream. However, this is not uniformly so. Some vegetable growers in Tasmania’s Northern Midlands currently pay around A$30-40/ML for water from the Cressy Longford Irrigation Scheme. Some North West Coast growers are currently paying significantly more than this for water from Cradle Mountain Water, and in the future will be paying for at least some of their water from the Sassafras Wesley Vale Scheme and other proposed schemes. No cost has been included for buying water in the cost of production estimates in this report. 7 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 3. Crop income 3.1 Introduction The crop income for each crop is a influenced by yield levels and output prices. This section compares crop income for the four process vegetable crops under consideration. For Tasmania, the yields and prices used in calculating gross income per hectare are based on Simplot average yields and contract prices for 2010-112. New Zealand yield and price estimates were provided by local consultants and farmers, with some backup from Horticulture NZ gross margin estimates and the Lincoln University Financial Budget Manual. Yield figures in this report are a composite of these sources. While these figures are likely to be reasonably accurate, they are possibly not as reliable as the Tasmanian estimates. The New Zealand figures were provided by contacts in the South Island and will therefore mainly reflect the Heinz Wattie factory in Christchurch for beans, carrots and peas, and the McCains factory in Timaru for potatoes. 3.2 Crop yields Yields vary significantly within both Tasmania and New Zealand – between farms, between districts and between years. Hence it is difficult to be definitive about the overall differences that may exist between the two areas. However, it appears that New Zealand bean and carrot yields are less than in Tasmania and that pea and potato yields are higher than Tasmania (Figure 3.1). The slightly higher pea yield in New Zealand is at least partly due to different factory weight assessment methods in both areas. 8 2 Jeff Yost, Simplot, December 2010. DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Figure 3.1: Crop yields (t/ha) 100.0 90.0 80.0 70.0 60.0 t/ha 50.0 Tas 40.0 NZ 30.0 20.0 10.0 Beans Carrots Peas Potatoes 3.3 Prices paid Prices paid for the four crops are around 40% lower on average in New Zealand than in Tasmania (Figure 3.2) - varying from 34% less for beans to 48% less for peas. Figure 3.2: Prices paid (A$/t) 500 450 400 350 300 A$/t 250 Tas 200 NZ 150 100 50 Beans Carrots Peas Potatoes 9 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 3.4 Crop income In broad terms crop income per hectare in New Zealand is around 40% lower than in Tasmania - varying from 32% less for potatoes to 46% less for carrots (Table 3.1 and Figure 3.3). The difference is largely due to the lower prices paid in New Zealand. Table 3.1: Crop yields and prices (A$) Crop Tas NZ Difference Amount Beans Yield Price Income Carrots Yield Price Income Peas Yield Price Income Potatoes Yield Price Income (t/ha) (A$/t) (A$/ha) (t/ha) (A$/t) (A$/ha) (t/ha) (A$/t) (A$/ha) (t/ha) (A$/t) (A$/ha) Percent 11.5 444 5,110 10.0 294 2,940 -1.5 -150 -2,170 -13% -34% -42% 95 127 12,065 83 79 6,545 -12 -48 -5,520 -13% -38% -46% 6.1 471 3,070 6.5 244 1,815 +0.4 -227 -1,255 +7% -48% -41% 55.0 287 15,780 58.0 186 10,800 +3.0 -101 -4,980 +5% -35% -32% Figure 3.3: Income received (A$/ha) 18,000 16,000 14,000 12,000 10,000 A$/ha Tas 8,000 NZ 6,000 4,000 2,000 - Beans Carrots Peas Potatoes 10 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Some caution needs to be taken in interpreting these figures, because yield is variable between farms, between districts and between years for both Tasmania and New Zealand. 11 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 4. Cost of production 4.1 Introduction As outlined below (Section 4.2) the cost of production described in this report includes land rent, land preparation, seed and seeding, fertiliser, sprays, irrigation, harvest and cartage and interest on crop outlay. In effect the methodology used treats the overall farm business as three distinct operations -land ownership, machinery contracting and cropping. The cropping cost of production outlined here includes land ownership and machinery contracting as costs along with seed, fertiliser, sprays etc. A nominal land rent has been included at 4% of bare land value including water supply, pumps, and irrigation mains but not irrigators. Whereas some higher value crops may pay more than this on a one-year basis the longer-term rent used here is a more appropriate figure when multiple crops are being considered. Ultimately what is important is that the crop rotation is able to at least cover this average annual rent. For the shorter term crops (peas and beans) where there is the ability to earn further income in the same year, the rent cost has been included at 50% of the annual total. As far as possible all cropping operations have been included on a contract basis. This effectively includes a machinery ownership component as well as fuel repairs and wages. In addition the irrigation cost includes a component for ownership of the irrigation equipment (amortised over 10 years). The irrigation ownership costs used are for typical linear irrigators applicable to either area. However, irrigation ownership and application costs are quite variable. This variability is the result of of different in irrigation systems (travelling gun, rotary boom, linear irrigator and centre pivot) and the total head required to get water to the irrigator as well as power costs etc. This is an area where further assessment of options for minimising total costs could be worthwhile. 4.2 Cost of production methodology For the purposes of this report, farm cost of production is made up of the following components: Land rent Nominal land rent determined as 4% of bare land value including water supply, pumps, and irrigation mains but not irrigators; Land preparation Contract rates; Seed Cost of seed including any seed storage and treatment plus the contract cost of drilling/planting; Fertiliser List price of fertiliser plus contract cartage and spreading; 12 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Sprays List price of sprays plus contract application; Irrigation Electricity, repairs and labour plus an irrigator ownership cost for either centre pivot and/or gun irrigator; Harvesting & cartage Contract rates; and Interest Interest on growing costs. When deducted from total income received the calculated cost of production results in a ‘net margin’ which is required to cover management and other farm overheads. The net margin is less than a gross margin in that it allows for land rent, irrigator ownership and interest on crop growing costs which are not normally included in a gross margin calculation. In addition the use of contracting rates in determining growing costs allows for machinery ownership costs as well as fuel, repairs and labour. In effect this methodology treats the overall farm business as three distinct operations land ownership, machinery contracting and cropping. Land ownership and machinery contracting form part of the cost of production for the cropping enterprise. 13 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 4.3 Beans Bean cost of production per hectare The calculated cost of production for beans in New Zealand is 33% less on a per hectare basis than in Tasmania (Table 4.1 and Figure 4.1). Table 4.1: Cost of production – beans (A$/ha) Item Tas NZ Difference A$/ha A$/ha A$/ha (%) Land rent 432 507 +75 +17% Land preparation 195 154 -41 -21% Seed & planting 686 866 +180 +26% Fertiliser 826 293 -533 -64% 1,024 346 -678 -66% 540 330 -209 -39% 0 0 0 0% 62 38 -24 -39% 3,765 2,535 -1,230 -33% Sprays Irrigation Harvesting & cartage Interest Total Figure 4.1: Cost of production – beans (A$/ha) 4,000 62 3,500 540 3,000 2,500 1,024 A$/ha 2,000 826 Interest 38 330 Harvest/Cartage 346 Sprays/Spraying 293 Fertiliser 1,500 Irrigation Seed/Drilling 866 1,000 686 500 195 154 432 507 Tas NZ Land Preparation Land Rent 0 14 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Bean cost of production per tonne The calculated cost of production for beans in New Zealand is 23% less on a per tonne basis than in Tasmania (Table 4.2 and Figure 4.2). Table 4.2: Cost of production – beans (A$/t) Item Tas NZ A$/t A$/t A$/t Land rent 38 51 +13 +35% Land preparation 17 15 -2 -9% Seed & planting 60 87 +27 +45% Fertiliser 72 29 -42 -59% Sprays 89 35 -54 -61% Irrigation 47 33 -14 -30% Harvesting & cartage 0 0 0 0% Interest 5 4 -2 -30% 327 253 -74 -23% Total Difference (%) Figure 4.2: Cost of production – beans (A$/t) 350 5 300 47 250 89 200 4 33 Harvest/Cartage 35 A$/t 29 150 Interest Irrigation Sprays/Spraying Fertiliser 72 Seed/Drilling 87 100 60 50 17 38 Land Preparation Land Rent 15 51 0 Tas NZ 15 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Bean summary – per tonne New Zealand’s overall A$74/t lower cost of production is made up as follows: Land rent A$13/t higher - higher land prices (on average); Land preparation A$ 2/t lower - lower contracting costs; Seed and seeding A$27/t higher - higher seed price; Fertiliser A$42/t lower - lower overall application and prices; Sprays A$54/t lower – fewer applications, less expensive fungicides: Irrigation A$14/t lower – mainly in ownership costing; Harvesting & cartage no cost to farm; Interest A$2/t lower – lower input costs. 16 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 4.4 Carrots Carrot cost of production per hectare The calculated cost of production for carrots in New Zealand is 13% less on a per hectare basis than in Tasmania (Table 4.3 and Figure 4.3). Table 4.3: Cost of production – carrots (A$/ha) Item Tas NZ A$/ha A$/ha Difference A$/ha (%) Land rent 850 1,013 163 +19% Land preparation 410 459 49 +12% Seed & planting 350 296 -54 -15% Fertiliser 686 815 129 +19% Sprays 857 745 -112 -13% Irrigation 747 702 -45 -6% 3,420 2,310 -1,110 -32% 206 182 -24 -11% 7,526 6,524 -1,003 -13% Harvesting & cartage Interest Total Figure 4.3: Cost of production – carrots (A$/ha) 8,000 206 7,000 182 6,000 Interest 3,420 2,310 5,000 Harvest & cartage Irrigation A$/ha 4,000 747 3,000 857 2,000 686 1,000 350 410 850 702 Sprays/Spraying Fertiliser 745 Seed 815 Land Preparation 296 459 Rent 1,013 17 0 Tas NZ DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Carrot cost of production per tonne The calculated cost of production for carrots in New Zealand is 1% less on a per tonne basis than in Tasmania (Table 4.4 and Figure 4.4). This is less than the 13% on a per hectare basis because of the assumed higher yield. Table 4.4: Cost of production – carrots (A$/t) Item Tas NZ Difference A$/t A$/t A$/t (%) Land rent 8.9 12.2 +3.3 +36% Land preparation 4.3 5.5 +1.2 +28% Seed & planting 3.7 3.6 -0.1 -3% Fertiliser 7.2 9.8 +2.6 +36% Sprays 9.0 9.0 -0.1 -1% Irrigation 7.9 8.5 +0.6 +7% 36.0 27.8 -8.2 -23% 2.2 2.2 -0.0 +1% 79.2 78.6 -0.7 -1% Harvesting & cartage Interest Total Figure 4.4: Cost of production – carrots (A$/t) 90.0 80.0 2.2 2.2 70.0 60.0 27.8 36.0 Harvest & cartage Irrigation 50.0 A$/t 8.5 40.0 30.0 Interest 7.9 9.0 20.0 7.2 10.0 3.7 4.3 8.9 9.0 Sprays/Spraying Fertiliser Seed 9.8 Land Preparation 3.6 5.5 Rent 12.2 0.0 18 Tas NZ DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Carrot summary – per tonne New Zealand’s overall similar cost of production for carrots is made up as follows: Land rent A$3.30/t higher - higher land prices (on average); Land preparation A$1.20/t higher – some destoning costs; Seed and planting A$0.10/t lower – NZ seed cost requires confirmation (could in fact be higher); Fertiliser A$2.60/t higher - higher overall application partly offset by lower prices; Sprays A$0.10/t lower – more applications but less expensive fungicides: Irrigation A$0.60/t higher – despite slightly lower application; Harvesting & cartage A$8.20/t lower – lower contract costs and lower wastage factor used; Interest A$0.00/t lower – lower input costs per hectare offset by lower yield. 19 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 4.5 Peas Pea cost of production per hectare The calculated cost of production for peas in New Zealand is 30% less on a per hectare basis than in Tasmania (Table 4.5 and Figure 4.5). Table 4.5: Cost of production – peas (A$/ha) Item Tas NZ A$/ha A$/ha Land rent 348 502 154 +44% Land preparation 200 68 -132 -66% Seed & planting 590 558 -32 -5% Fertiliser 465 100 -365 -78% Sprays 366 166 -200 -55% Irrigation 540 371 -168 -31% 0 0 0 0% 41 24 -17 -41% 2,549 1,790 -760 -30% Harvesting & cartage Interest Total Difference A$/ha (%) Figure 4.5: Cost of production – peas (A$/ha) 3,000 2,500 41 540 Interest 2,000 366 Harvest/Cartage 24 371 A$/ha 1,500 465 Sprays/Spraying 166 100 Fertiliser 558 Land Preparation 1,000 590 Irrigation Seed/Drilling Land Rent 500 200 348 68 502 20 0 Tas NZ DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Pea cost of production per tonne The calculated cost of production for peas in New Zealand is 34% less on a per tonne basis than in Tasmania (Table 4.6 and Figure 4.6). Table 4.6: Cost of production – peas (A$/t) Item Tas NZ A$/t A$/t A$/t Land rent 57 77 +20 +35% Land preparation 33 11 -22 -68% Seed & planting 97 86 -11 -11% Fertiliser 76 15 -61 -80% Sprays 60 25 -35 -58% Irrigation 88 57 -31 -35% Harvesting & cartage 0 0 0 0% Interest 7 4 -3 -44% 418 275 -143 -34% Total Difference (%) Figure 4.6: Cost of production – peas (A$/t) 450 400 7 88 350 300 Interest 60 4 250 A$/t 57 76 150 Irrigation Sprays/Spraying 25 15 200 Harvest/Cartage Fertiliser Seed/Drilling 97 86 Land Preparation Land Rent 100 33 50 57 11 77 0 Tas NZ 21 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Pea summary – per tonne New Zealand’s A$143/t lower cost of production for peas is made up as follows: Land rent A$20/t higher - higher land prices (on average); Land preparation A$22/t lower - lower contracting costs; Seed & seeding A$11/t lower - lower seed /drilling cost; Fertiliser A$61/t lower - lower overall application and prices; Sprays A$35/t lower –lower overall cost; Irrigation A$31/t lower – mainly in ownership costing; Harvesting & cartage no cost to farmer; Interest A$3/t lower – lower input costs. 22 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 4.6 Potatoes Potato cost of production per hectare The calculated cost of production for potatoes in New Zealand is 21% less on a per hectare basis than in Tasmania (Table 4.7 and Figure 4.7). Table 4.7: Cost of production – potatoes (A$/ha) Item Tas NZ A$/ha A$/ha Difference A$/ha (%) Land rent 835 1,094 +259 +31% Land preparation 335 380 +45 +13% Seed & planting 2,210 1,558 -652 -30% Fertiliser 2,060 1,702 -358 -17% Sprays 1,940 1,102 -838 -43% 830 702 -128 -15% 3,110 2,424 -686 -22% 320 258 -62 -19% 11,640 9,221 -2,419 -21% Irrigation Harvesting & cartage Interest Total Figure 4.7: Cost of production – potatoes (A$/ha) 14,000 12,000 320 10,000 Interest 3,110 258 8,000 830 2,424 1,940 702 A$/ha Harvest & cartage Irrigation Sprays/Spraying 6,000 4,000 Fertiliser 1,102 Seed 1,702 Land Preparation 2,060 Rent 2,000 0 2,210 1,558 335 835 380 1,094 Tas NZ 23 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Potato cost of production per tonne The calculated cost of production for potatoes in New Zealand is 25% less on a per tonne basis than in Tasmania (Table 4.8 and Figure 4.8). Table 4.8: Cost of production – potatoes (A$/t) Item Tas NZ A$/t A$/t A$/t 15 19 +4 +24% Land preparation 6 7 +1 +8% Seed & planting 40 27 -13 -33% Fertiliser 37 29 -8 -22% Sprays 35 19 -16 -46% Irrigation 15 12 -3 -20% Harvesting & cartage 57 42 -15 -26% 6 4 -1 -23% 212 159 -53 -25% Land rent Interest Total Difference (%) Figure 4.8: Cost of production – potatoes (A$/t) 250 200 6 57 150 A$/t Interest 4 15 42 12 Fertiliser 19 Seed 37 29 50 0 Irrigation Sprays/Spraying 35 100 Harvest & cartage 40 27 6 15 7 19 Tas NZ Land Preparation Rent 24 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Potato summary – per tonne New Zealand’s A$53/t lower cost of production for potatoes is made up as follows: Land rent A$4/t higher - higher land prices (on average); Land preparation A$1/t higher – NZ cost includes some destoning; Seed & planting A$13/t lower – lower seed price & lower rate; Fertiliser A$8/t lower – similar rate, lower prices; Sprays A$16/t lower – lower pest & disease cost despite precautionary spray for TPP(Tomato Potato Pysillid) Irrigation A$3/t lower – mainly lower rate; Harvesting & cartage A$15/t lower – contracting rates lower; Interest A$1/t lower – lower input costs. 25 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 4.7 Summary Costs of production per hectare for all four crops are around 25% less in New Zealand than in Tasmania, varying from 13% less for carrots to 33% less for beans (Table 4.9 and Figure 4.9). Table 4.9: Cost of production (A$/ha) Item Tas NZ A$/ha A$/ha A$/ha (%) Beans 3,765 2,535 -1,230 -33% Carrots 7,525 6,525 -1,005 -13% Peas 2,550 1,790 -760 -30% 11,640 9,220 -2,420 -21% average -24% Potatoes Difference Figure 4.9: Cost of production (A$/ha) 14,000 12,000 10,000 8,000 A$/ha Tas 6,000 NZ 4,000 2,000 Beans Carrots Peas Potatoes 26 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Costs of production per tonne for all four crops are around 21% less in New Zealand than in Tasmania, varying from 1% less for carrots to 34% less for peas (Table 4.10 and Figure 4.10). Table 4.10: Cost of production (A$/t) Item Tas NZ A$/t A$/t Difference A$/t (%) Beans 327 253 -74 -23% Carrots 79 79 -0 -1% Peas 418 275 -143 -34% Potatoes 212 159 -53 -25% average -21% Figure 4.10: Cost of production (A$/t) 450 400 350 300 250 A$/t Tas 200 NZ 150 100 50 Beans Carrots Peas Potatoes 27 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 5. Gross & net margins Two crop margins are described in this report: Gross margin Gross income less variable growing costs such as land preparation, seed & seeding, fertiliser, sprays, irrigation running costs, and harvesting & cartage; and ‘Net margin’ Gross income less cost of production or gross margin less overheads (land rental, irrigator ownership and interest on crop outlay). While costs of production per hectare are broadly 20-25% lower in New Zealand than in Tasmania they are not sufficiently low enough to offset the 40% lower income received, so New Zealand gross and net margins are lower than in Tasmania (Table 5.1, Figures 5.1 and Figure 5.2). The gross margin per hectare for all four crops is around 50% less in New Zealand than in Tasmania with a range from 41% less for potatoes through to 73% less for carrots. The net margin per hectare for all four crops is around 80% less in New Zealand than in Tasmania with a range from 62% less for potatoes through to 100% less for carrots. 28 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Table 5.1: Gross & net margins per hectare (A$) Crop Beans Gross income Variable costs Gross margin Overheads Net margin % income Carrots Gross income Variable costs Gross margin Overheads Net margin % income Peas Gross income Variable costs Gross margin Overheads Net margin % income Potatoes Gross income Variable costs Gross margin Overheads Net margin % income Tas NZ A$/ha A$/ha 5,110 2,730 2,380 1,035 1,345 2,940 1,780 1,160 750 405 26% 14% 12,065 6,055 6,010 1,470 4,540 6,545 4,915 1,630 1,610 20 38% 0% 3,070 1,745 1,325 805 520 1,815 1,130 680 660 25 17% 1% 15,780 10,070 5,710 1,580 4,135 26% 10,800 7,455 3,345 1,770 1,580 Difference A$/ha % -2,170 -950 -1,220 -280 -70 -940 -42% -35% -51% -27% -70% -5,520 -1,140 -4,375 140 -4,515 -46% -19% -73% +9% -100% -1,255 -615 -645 -145 -495 -41% -35% -49% -18% -95% -4,980 -2,615 2,360 195 -2,560 -32% -26% -41% +13% -62% 15% 29 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Figure 5.1: Gross margin (A$/ha) 7,000 6,000 5,000 4,000 A$/ha Tas 3,000 NZ 2,000 1,000 0 Beans Carrots Peas Potatoes Figure 5.2: Net margin (A$/ha) 5,000 4,500 4,000 3,500 3,000 A$/ha 2,500 Tas 2,000 NZ 1,500 1,000 500 0 Beans Carrots Peas Potatoes In the case of carrots and peas, the very low New Zealand net margins suggest that the gross margins being earned are sufficient to cover land rental, irrigation ownership and interest on crop outlay – but not other overheads (eg management wage) or to contribute to an overall profit. There is also no margin for risk. A sustainable business in this situation would require other enterprises to cover these additional overheads to produce an overall profit for the cropping business3. 30 3 The profit for the cropping enterprise need not include any return for land which is covered in the land rental overhead cost, or for a return on the machinery investment which is covered in the machinery contracting cost. DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Assuming that the margins being earned in New Zealand are sustainable, the question arises as to how this is achieved, given that Tasmanian farmers are not achieving high profit levels with significantly higher margins. Possibilities include: Remaining overheads such as management costs are lower cost in New Zealand and therefore require less margin to cover the cost and produce a profit; The lower margins earned are applied to a higher number of tonnes or hectares – ie a low margin/high volume business model; and Better integration of enterprises may produce an overall business profit despite inclusion of some lower returning enterprises. 31 DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand 6. Conclusions In general terms New Zealand costs of production for process vegetables (beans, carrots, peas and potatoes) are around 20-25% less than Tasmania, while their growers are paid 40% less than in Tasmania. This report has highlighted a number of the factors driving these differences. The main drivers include: New Zealand’s lower input prices in A$ terms for wages (35-40%), fertiliser (20%) and irrigation electricity (40%) Machinery prices, interest rates and diesel prices are similar in both areas, but New Zealand’s generally flat topography and larger paddocks allow for larger machinery and more efficient operation. On average, land prices are higher in New Zealand, however prices in North West Tasmania are similar to those in the South Island, where around two thirds of New Zealand’s process beans, carrots, peas and potatoes are grown. While it is difficult to be definitive, it appears that New Zealand bean and carrot yields may be somewhat less than in Tasmania whereas pea and potato yields are higher than Tasmania. Adverse exchange rate movement over the past five or so years has reduced Tasmania’s competitiveness by around 20%. Despite the lower costs of production in New Zealand, margins per hectare and per tonne are also less than for Tasmania – because of the low prices received. This tends to suggest that the remaining overheads that need to be covered are less, or that the lower margins earned are able to spread over a larger number of hectares or tonnes, or that an integrated rotation may still produce an overall profit despite inclusion of some lower returning enterprises. Without a significant reduction in effective wage rates or a devaluation of the Australian dollar (both unlikely) it is difficult to see that Tasmania will be able to equal New Zealand’s lower cost of production. However, there are a number of areas that might be addressed to close the gap. To become more competitive Tasmanian growers need to either (1) reduce costs of production per tonne and/or (2) develop business models that can survive lower prices and lower margins. The cost of production per tonne can be reduced by either increasing yield relative to cost, and/or reducing input costs without a significant loss of yield. Some areas worthy of further investigation include: Ongoing research, development and extension aimed at improving crop yields; 32 While electricity prices in New Zealand are lower than for Tasmania, the overall irrigation cost differential is not clear cut. New Zealand growers often access water from relatively deep (expensive) bores but on the other hand application rates are lower and with the advent of competitive tendering in Tasmania, larger users may be able to access rates similar to those in New Zealand. DEDTA Process Vegetable Cost of Production Comparison – Tasmania and New Zealand Reasons behind lower fertiliser prices in New Zealand; The potential for reduced fertiliser inputs; Lowering irrigation costs, including the potential benefits from a competitive market for electricity; Reducing potato seed costs; and The potential for high volume potato harvesting systems in Tasmania; At the same time research should be undertaken in relation to business models that can potentially operate profitably with lower margins. For example: The potential for larger scale businesses through increased land ownership, land leasing or some form of co-operative farming operation; and Better integration of enterprises to produce an overall business profit despite inclusion of some lower returning enterprises. 33
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