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Description
Plast Commerce is poised to make their mark on the construction industry by addressing the persistent challenge of roof structures and their frequent repair and reconstruction needs. Conventionally, the underlying grid beneath roof tiles is crafted from wood, but the inherent drawback is its susceptibility to rotting, necessitating replacement every 10-15 years and resulting in leaky roofs. In response to this, the project introduces an innovative solution—a substitute construction profile made entirely from 100% recycled PVC material that is also fully recyclable.
The primary objective of the project is to introduce a sustainable and eco-friendly product derived from 100% recycled PVC, ensuring recyclability. To achieve this, strategic investments in equipment are imperative. The plan includes the acquisition of an extruder line dedicated to producing these innovative PVC construction profiles and a shredder for repurposing PVC waste as a material for product manufacturing. The project unfolds in two key phases.
Firstly, for the production of the new product, Plast Commerce will utilize 100% waste material sourced not only internally but also from other PVC companies. To maintain product quality and stability, given the diverse sources and ingredients of the recycled material, the company aims to develop an in-house sustainable recipe. This recipe is crucial to ensuring that the second-hand material matches the performance of virgin material, guaranteeing consistent product quality.
The second phase involves substantial investment in technological equipment, specifically an extruder line and shredder, to enable the production of these groundbreaking PVC construction profiles. Through this comprehensive approach, Plast Commerce aims not only to contribute to a greener construction industry but also to establish a new standard of excellence in the realm of sustainable and recyclable building materials.
Summary of project results
The project aimed to address a major challenge faced by Plast Commerce – 93 Ltd. in the recycling of second-hand PVC materials, which often arrive in dirty and non-homogeneous conditions. These contaminated materials frequently contain steel, stones, and other debris that clog the production equipment, particularly the tools that shape the PVC profiles. This led to repeated interruptions in the manufacturing process, requiring extensive cleaning and maintenance, and ultimately reducing production efficiency.
Another significant issue was the company''s limited ability to process such low-quality waste with existing technology, forcing reliance on more expensive virgin materials even in cases where recycled materials could otherwise be used. This not only increased production costs but also hindered the company’s goal of improving its environmental sustainability and competitiveness.
To overcome these challenges, the project focused on introducing greener, more efficient production processes tailored to handle dirty PVC waste. This included the implementation of advanced machinery such as a new-generation screen changer system equipped with multiple filters and pressure sensors, which allowed for the rapid and automatic replacement of clogged filters without stopping production. Combined with specialized extruder tools, this innovation enabled the company to recycle a broader range of PVC waste materials, increase production speed, and reduce energy consumption and CO₂ emissions.
Ultimately, the project addressed the dual challenge of technical inefficiency in waste recycling and the environmental impact of using virgin materials. It provided a solution that not only increased production capacity and product quality but also aligned with broader goals of sustainability and resource efficiency.
The project implemented by Plast Commerce – 93 Ltd. focused on modernizing and improving its production processes to enable efficient recycling and utilization of dirty PVC waste. The company carried out a set of structured activities starting with project management and publicity efforts to ensure smooth execution and visibility of the initiative. A critical component of the project involved conducting a tender procedure to procure new machinery, specifically a screen changer system and two sets of tools for an extruder. These technologies were selected to address the challenges of processing contaminated PVC waste and to enhance production efficiency.
Once procured, the new equipment was delivered, installed, and tested under supervision to ensure it functioned as intended within the production line. The innovative screen changer system featured pressure sensors and quick-change mechanisms that allowed filters to be automatically replaced without halting production. This advancement enabled continuous operation even when processing dirty and non-homogeneous materials. Additionally, the new tools were specially designed for mass production of profiles using recycled material, significantly improving output while maintaining durability.
As a result of these activities, the company was able to put into operation a more energy-efficient and environmentally friendly recycling process. The outputs included the installation of advanced machinery, the implementation of innovative filtering technology, and the integration of these systems into the existing production line. These developments allowed Plast Commerce – 93 Ltd. to double its production speed, increase the use of recycled PVC, reduce energy consumption, and minimize CO₂ emissions, while also enhancing product quality and strengthening its market position.
The project achieved a range of impactful results that benefited both Plast Commerce – 93 Ltd. and its wider network of stakeholders, including customers, suppliers, and the environment. For the company itself, the implementation of new equipment and technologies led to a substantial increase in production efficiency and capacity. By enabling the recycling of dirty and previously unusable PVC waste, the company significantly reduced its dependence on virgin raw materials, which in turn lowered production costs and improved profit margins. This also allowed the company to enhance the quality and sustainability of its products, thereby raising its competitiveness on the Bulgarian market and opening new opportunities for business growth.
From an environmental perspective, the project had a good impact. The newly implemented systems allowed Plast Commerce – 93 Ltd. to recycle approximately 50 additional tonnes of PVC waste annually, which would have otherwise been discarded. This contributed to an estimated reduction of 146 tonnes of CO₂ emissions per year and improved energy efficiency, as the new machinery enabled continuous production without frequent stoppages for cleaning. These results support the transition toward a more circular and sustainable industrial model.
Customers and partners also benefited from the project outcomes. The ability to produce higher-quality recycled PVC profiles in greater volumes meant that clients received more consistent, eco-friendly products with shorter lead times. The project also positioned the company as a leader in green innovation within the industry, enhancing its reputation among environmentally conscious clients and business partners.
Overall, the project not only reinforced the company’s operational capacity and environmental responsibility but also contributed to broader sustainability goals and economic development in the region.