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Description
Presently, Valiyan OOD faces challenges associated with the limitations of its production facilities, encompassing issues related to heating, ventilation, air conditioning, and a notable percentage of CO2 and other emissions released directly into the atmosphere.
In 2018, Valiyan OOD strategically acquired a production facility in Sofia, with plans for substantial investments to transform it into an environmentally conscious space that simultaneously improves working conditions. The redesigned production facility will cater specifically to the enterprise''s needs, creating an appealing and sustainable workspace. Embracing the Zero Emission Factory concept, the project envisions a holistic approach where all inputs are treated as valuable outputs, either transformed into final products or contributing value to existing processes, thereby opening doors to new business opportunities. This transformative initiative not only enhances the company''s environmental performance but also boosts operational efficiency, contributing to elevated competitiveness through improved production capacity organization.
The project outputs will yield several benefits, including:
- Creation of an innovative production and facility organization, implementing a 24-hour flow to reduce production time and costs.
- Reduction of CO2 emissions, aligning with environmental sustainability goals.
- Improvement of working conditions for employees.
- Increased production capacity.
- Generation of 10 new green jobs.
In a strategic move to further enhance competitiveness, a new component has been approved. This entails the digitalization of the production process, aimed at optimizing resource utilization, minimizing waste from internal production, and expanding the production portfolio by introducing four new products. This comprehensive approach reinforces the company''s commitment to innovation, sustainability, and long-term competitiveness in the furniture production industry.
Summary of project results
The company was facing the following challenges:
- High production costs, due to lack of possibility to use the full capacity of the production equipment ( limitation of the facilities (not well structured layout)).
- There was also a high level of damaged production due to improper storing conditions because of damaged roofs and walls in the production facilities, as well as high renting and maintenance costs.
- Not very good working conditions in respect to heating, aspiration, air conditioning and high level of sawdust, generated from the production
- High percentage of CO2 and other emissions emit directly to the atmosphere through the process of lacquering and when heating with residues from production process due to the impossibility in the current facilities to implement appropriate filtering.
The main objective of the project was to improve the company''s competitiveness through organising an almost zero-emission factory for furniture production. In 2018 Valiyan OOD purchased a production facility in Sofia and has further invested in creating it in a way that it reduces the negative impact on the environment and improves the working conditions. The new production facility has been adjusted to the needs of the enterprise and turned into an attractive working place. Introducing Zero Emission Factory has contributed to strengthen the environmental performance of the company and to increase efficiency of the company operations.
- Close-to-zero emissions furniture production facility organised, including the following:
- - Central aspiration system
- - New roof system with hydro- and heat insulation; energy saving lighting; solar installation; boiler for direct sawdust burning
- - Filters for smoke and lacquer installed
- - Special floor for the working premises installed with a system for collecting the sawdust
- - Special roof windows for allowing the natural light in the production facility
- 10 new jobs open
Summary of bilateral results
The Norwegian partner, International Development Norway AS ( IDN), has been involved in the following activities:• Production Layout & Process Improvements (PLPI) • Zero Emission Factory Analysis delivered by IDN was covering four main areas: • End-of-pipe pollution control technologies and practices dealing with wastes and emissions after they have been created • Cleaner Production - application of integrated preventive environmental strategies to processes, products and services to increase efficiencies and reduce risks to the environment and humans. The goal is to avoid generating pollution in the first place and thus reduce costs and risks. • Zero Emissions – modeling altered production technologies and approaches which individually and collectively can move business toward greatly reduced inputs and resource consumption. E • Energy Monitoring Audit & technical specifications – based on the detailed energy consumption at the production facility we will draft recommendation for reduce its consumption and for possible energy management systems.The Norwegian partner had a crucial role in supporting the Bulgarian company to transfer its production facility in a green factory.