Investment for greener and zero waste production in Techceramic-M JSC

Description

 

The Techceramic-M JSC project, funded under the Business Programme in Bulgaria and Norway Grants, aims to enhance the competitiveness of the company, specializing in manufacturing refractory and technical ceramic products. The project focuses on adopting greener production processes, introducing the innovative greentape casting technology, and launching three new products. This initiative aligns with the broader goal of reducing economic disparities and promoting sustainable practices. With a solid financial foundation, Techceramic-M JSC seeks to diversify its production portfolio, strengthen market position, and contribute to the environmental and socio-economic well-being of the North-Western region of Bulgaria. The project is poised to make a positive impact on the company''s competitiveness, environmental performance, and overall market presence.

The current project will strengthen the bilateral relations between the partners Techceramic-M JSC and Norsk Energi AS, which were established 2 years ago when the two companies signed a partnership agreement to implement a project under the first call for proposals. The current project is contributing to strenghten the bilateral relation between Bulgaria and Norway through facilitating international knowledge exchange and cooperation. Through preparing a review and technological assessment of the greentape casting process, the Norwegian partner will have an important role in supporting the Bulgarian company when introducing resource efficient technologies in the company which will improve its competitiveness and lead to sustainable growth

Summary of project results

The project by Techceramic-M JSC aimed to address several critical issues and challenges related to production efficiency, environmental sustainability, and competitiveness in the technical ceramics industry. Here’s an elaboration on the main challenges the project targeted:

1. Environmental Impact and Waste Reduction

• The core issue was the waste-intensive nature of traditional ceramic production. The project proposed the introduction of a zero-waste production process called green tape casting, which significantly minimizes or eliminates production waste.

• The new process allows scrap material to be recycled by dissolving the gelatin binder used in the casting process, improving the environmental footprint of the company.

2. Production Innovation and Product Diversification

• The company needed to diversify its product portfolio to stay competitive and meet emerging market demands, particularly in high-tech industries.

• The project planned to develop and manufacture three new products: ceramic substrates, ceramic sensors, and multilayer ceramic cells—products with significant market potential in sectors such as electronics and energy storage.

3. Market Competitiveness and Scaling Capacity

• Techceramic-M JSC faced the challenge of limited production capacity, making it difficult to meet the increasing global demand for technical ceramics.

• The project’s investment in new, more efficient equipment would enable the company to scale up production, reduce costs, and improve product quality, thereby strengthening its market position—especially against larger international competitors.

4. Socio-Economic Development in a Poor Region

• The company operates in North-West Bulgaria, the poorest region in both Bulgaria and the EU. The project aimed to support regional economic development by creating jobs and fostering innovation in an underdeveloped area.

5. Energy Efficiency

• Existing processes were energy-intensive. The project aimed to reduce energy consumption by 20% (about 211 MWh annually) by implementing the new production method and equipment, thereby addressing both cost and environmental concerns.

The project proposed upgrading production with green tape casting technology, supported by new equipment such as:

• Tape casters, lamination press, screen printer, and high-temp chambers for zero-waste ceramic sheet production

• Ball mill, viscometer, and electrochemical testers for material processing and quality control

• Consultancy and simulation from Norsk Energi to optimize the process and develop three new products: ceramic substrates, sensors, and multilayer cells.

This setup aimed to boost efficiency, reduce waste, and enable production of high-tech ceramics.

The project implemented by Techceramic-M JSC focused on introducing an innovative and environmentally friendly production process—green tape casting—to manufacture high-tech ceramic components. Here''s a concise overview of the key activities and outputs:

Main Activities:

1. Procurement and Installation of Equipment:

   • Purchased and installed specialized machinery, including tape casters, lamination press, screen printer, viscometer, ball mill, high-temperature chambers, and testing systems.

   • Equipment enabled the implementation of green tape casting with significantly reduced waste and energy usage.

2. Consultancy and Research:

   • Engaged experts to prepare two reports:

     • Design and realization of ceramic substrates and sensors

     • Development of multilayer ceramic rechargeable cells

   • These guided the development of new products and optimized the production process.

3. Technical Collaboration:

   • Partnered with Norsk Energi (Norway) to conduct a technological assessment and process simulation, enhancing energy efficiency and ensuring process viability.

Key Outputs:

• 1 new innovative production technology (green tape casting) applied.

• 3 new ceramic products developed and introduced:

  1. Ceramic substrates

  2. Ceramic sensors

  3. Multilayer ceramic cells

• 4 new jobs created in a high-unemployment region.

• Energy savings of 211 MWh/year (~20% reduction in consumption).

• Increased annual turnover and net operational profit (projected outcomes).

The project achieved significant economic, environmental, and social results benefiting both Techceramic-M JSC and its broader regional and international stakeholders.

Outcomes and Impacts:

1. For Techceramic-M JSC (Direct Beneficiary):

• Increased Competitiveness:

  • Introduced an innovative, energy-efficient, zero-waste green tape casting technology.

  • Diversified product portfolio with 3 high-value products: ceramic substrates, sensors, and multilayer cells.

  • Improved market position in the global technical ceramics industry.

• Financial Growth:

  • Projected increase in annual turnover.

  • Projected growth in net operational profit.

  • Better productivity and cost-efficiency through modernized production.

• Employment:

  • Created 4 new skilled jobs in the production line.

• Environmental Performance:

  • Reduced energy consumption by 211 MWh annually (~20% of previous usage).

  • Achieved zero-waste production, contributing to sustainability goals.

2. For the Local Community (Regional Impact – North-West Bulgaria):

• Socioeconomic Development:

  • Job creation and industrial investment in Bulgaria’s poorest region.

  • Strengthened local economy and manufacturing sector.

• Skill Development:

  • Increased technical capacity and R&D activity, enhancing the local talent pool.

3. For International Partners and the Sector:

• Knowledge Transfer and Innovation:

  • Collaborated with Norsk Energi (Norway), promoting bilateral cooperation.

  • Shared expertise in energy efficiency and process simulation.

• Broader Industry Impact:

  • Contributed to advancing green manufacturing practices in technical ceramics.

  • Demonstrated a scalable model for sustainable production in SMEs.

In summary, the project delivered a strong combination of economic uplift, environmental stewardship, and innovation-driven growth benefiting the company, its employees, the regional economy, and industry stakeholders.

Summary of bilateral results

The collaboration between Techceramic-M JSC from Bulgaria and Norsk Energi from Norway yielded good bilateral results, reinforcing the overarching objectives of the Norway Grants programme to foster cross-border cooperation and innovation. The project significantly strengthened the existing partnership between the two organizations, which had previously worked together under the Green Industry Innovation initiative. This deepened relationship highlights a successful model of transnational cooperation between a donor and a beneficiary country.One of the key outcomes of the partnership was the effective transfer of knowledge and technology. Norsk Energi, with its extensive experience in energy efficiency and industrial process optimization, played a critical role in developing a technological assessment and process simulation for the new green tape casting production model. This expertise was essential in ensuring the successful implementation of energy-efficient technology, optimizing the process design, and minimizing implementation risks. By integrating advanced Norwegian practices in sustainable manufacturing, Techceramic-M JSC was able to enhance its environmental performance and production quality.The project also facilitated joint innovation, with both partners contributing to the development of three new high-tech ceramic products. Norsk Energi’s involvement helped ensure that these products were not only commercially viable but also aligned with best practices in environmental sustainability and energy efficiency.Beyond technical achievements, the project supported institutional and cultural exchange, enriching the professional capabilities of both organizations. It fostered mutual understanding, trust, and the sharing of best practices, ultimately reinforcing bilateral ties between Bulgaria and Norway.