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Description
HUS Ltd. is a Bulgarian large enterprise operating in the sectors of wholesale of hardware, plumbing and heating equipment and supplies, manufacturing of tubes, pipes, hollow profiles and related fittings, of steel and manufacturing of other fabricated metal products.
The implementation of a technology, specifically a roller bending line, marks a significant stride in the production of electric welded products. Notably, this innovative approach employs a single set of working rollers for forming and calibrating profiles across various sizes. Although the welding process for sizes 80x80-200x200 mm/t3-10mm has been successfully incorporated through a recent project funded under the OP "Innovation and Competitiveness," the introduction of this technology remains novel on a national scale.
The key feature of this modern technology lies in its adaptability, where a set of working rollers is manipulated by servomotors and an electronic system to ensure precise movement and positioning. This setup facilitates rapid adjustments between different sizes, enabling the development of new profiles and sizes upon request, with a remarkable increment precision of 5 mm.
This approach allows for heightened production speeds in tube manufacturing. Unlike conventional methods that require changing roller systems for each tube size, the new machine, specifically the Line for direct forming of tubes for sizes 40x40-80x80/t3-6mm, can produce the entire range of tubes with a single roller system. This computerized system not only enhances product precision but also eliminates the need for purchasing calibration and forming profiles for each tube size, resulting in cost efficiency and increased productivity. The technology not only positions the company at the forefront of industry standards but also sets a benchmark for the nation, showcasing the potential for streamlined and efficient tube production processes.
Summary of project results
The project aimed to address several key challenges:
Technological Advancement: Introducing a new technology for electric welding that allows for the formation and calibration of profiles of all sizes with just one set of working rollers. This innovation is expected to significantly improve production efficiency and flexibility.
Economic Development: The project is located in the Northwest Region of Bulgaria, which is one of the most economically lagging regions in the country. By investing in this area, the project aims to provide permanent employment and stimulate economic growth.
Market Expansion: HUS Ltd. has established business relationships with contractors across Europe. The project aims to increase the company’s presence in international markets, particularly in Central and Eastern Europe.
Environmental Impact: The new production line is designed to be more energy-efficient, reducing energy demand for technological purposes by 89.53% compared to the existing Tube Line. This is expected to lead to a significant reduction in CO2 emissions.
Resource Efficiency: The project aims to achieve a reduction of up to 7% in the raw materials used in the production process through automation and the elimination of the need to change working rollers for forming and calibrating profiles.
Productivity and Cost Reduction: By implementing the new technology, the project aims to increase productivity, reduce the prime cost and total production costs, and launch the production of “green” products with high quality and functional advantages.
These challenges are addressed through the investment in high-tech equipment and the implementation of innovative production processes, which are expected to bring about significant improvements in efficiency, environmental sustainability, and economic development.
The introduction of the roller bending line marked a significant technological advancement in the production of electric-welded products. This modern technology utilized a single set of working rollers for forming and calibrating profiles across all specified sizes. The rollers were precisely positioned by servomotors and monitored through an advanced electronic system, enabling exact movement and positioning. This innovation dramatically reduced the time required to adjust the machine for different sizes and allowed for the development of new profiles and sizes upon demand, with cross-section dimension increments as small as 5 mm.
The implementation of this technology significantly enhanced the company''s production capabilities. Unlike conventional systems that required individual roller sets to produce tubes of specific sizes and shapes (round, square, rectangular), this new line produced an entire assortment of tubes—sizes ranging from 40x40 mm to 80x80 mm with wall thicknesses of 3-6 mm—using a single roller system. This eliminated the need for frequent and costly roller replacements, which previously incurred expenses of approximately €50,000 per calibration set and demanded at least 60 minutes of downtime for each changeover.
Furthermore, the new process enabled high-speed production of tubes, a stark contrast to traditional methods. The technology''s precision was supported by computerization, ensuring excellent product quality and uniformity. As a result, the company realized cost savings, improved efficiency, and enhanced competitiveness.
The welding process, already in place for sizes 80x80 mm to 200x200 mm with thicknesses of 3-10 mm, was also expanded under this project, made possible through funding from the Operational Programme "Innovation and Competitiveness." This addition not only bolstered the company''s production range but also introduced a novel technology to the national industry, positioning it as a benchmark for innovation.
Overall, the roller bending line revolutionized production processes, offering unmatched flexibility, speed, and precision while reducing operational costs and setting a new standard in the sector.
The project achieved significant results, benefiting various stakeholders:
Technological Innovation: The introduction of the roller bending line revolutionized the production process. This modern technology allowed for the formation and calibration of profiles of all sizes with just one set of working rollers, significantly improving production efficiency and flexibility.
Economic Impact: The project provided a boost to the Northwest Region of Bulgaria, one of the most economically lagging regions in the country. By investing in this area, the project created permanent employment opportunities and stimulated economic growth.
Market Presence: HUS Ltd. strengthened its business relationships with contractors across Europe and increased its presence in international markets, particularly in Central and Eastern Europe.
Environmental Benefits: The new production line was designed to be more energy-efficient, reducing energy demand for technological purposes by 89.53% compared to the existing Tube Line. This led to a significant reduction in CO2 emissions.
Resource Efficiency: The project achieved a reduction of up to 7% in the raw materials used in the production process through automation and the elimination of the need to change working rollers for forming and calibrating profiles.
Productivity and Cost Reduction: The implementation of the new technology increased productivity, reduced the prime cost and total production costs, and launched the production of “green” products with high quality and functional advantages.
These results are particularly beneficial for:
- HUS Ltd.: The company realized cost savings, improved efficiency, and enhanced competitiveness.
- Employees: The project created new job opportunities and contributed to the professional development of the workforce.
- Local Community: The economic stimulation in the region had a positive impact on the local community.
- Environment: The reduction in energy consumption and CO2 emissions contributed to environmental sustainability.
- Customers: The production of high-quality “green” products provided customers with more sustainable choices.
Overall, the project had a positive impact on the company, the local economy, the environment, and the market, setting a new standard in the sector and positioning HUS Ltd. as a benchmark for innovation.