More information
Description
Founded in 1994 and proudly family-owned, Kasto Chairs Ltd. boasts over two decades of expertise in crafting wooden chairs. Specializing in catering to the unique requirements of the HORECA industry—comprising Hotels, Restaurants, and Cafés—the company has continually evolved. Despite recent upgrades to equipment, Kasto Chairs Ltd. still encounters challenges related to sawdust extraction, heating, and drying systems.
The primary goal of the project is to enhance the company''s competitiveness through the incorporation of innovative green technologies. Kasto Chairs Ltd. aims to invest in a state-of-the-art Sawdust Extraction and Heating System, alongside an advanced Drying System. Furthermore, the company will make a strategic investment in an Automatic Planer and Moulder, promising expedited operations, reduced energy consumption, and optimal use of wooden materials with minimal waste generation.
This project represents a substantial value addition for the company by significantly improving working conditions and optimizing resource utilization. As a direct outcome, the initiative is poised to create two new job opportunities, further contributing to the company''s growth and sustainability.
Summary of project results
Kasto Chairs Ltd. was facing multiple operational challenges, despite its recent investments in advanced machinery and equipment. Several critical production systems remained outdated or insufficient, and these limitations collectively hinder operational efficiency, workplace conditions, and the company’s ability to enter new markets. The issues faced by Kasto Chairs Ltd. were mainly related to the following:
- Sawdust Extraction Challenges: The outdated sawdust extraction system was a significant obstacle. With limited capacity, the system was failing to capture the full volume of sawdust generated during production, leaving substantial quantities of sawdust both inside and outside the facility. This deficiency resulted in poor workplace conditions and impact on productivity. Sawdust accumulation poses health and safety risks, potentially harming air quality and respiratory health of employees. Moreover, with sawdust interfering with workspace efficiency, workers may need to allocate additional time to manage debris, leading to operational slowdowns. Ineffective sawdust management can also affect product quality by increasing the risk of particulate contamination in the finished products.
- Inadequate Heating System: The company''s heating system was another critical area where infrastructure has not kept pace with modernization. The heating system’s inability to provide consistent warmth in the production hall negatively affects both working conditions and production capability. Furthermore, the outdated heating system is a bottleneck for the use of water-based lacquering, which has specific temperature requirements for effective application and drying. As such, this system''s limitations hinder the company from producing furniture for schools, kindergartens, and other institutions, where water-based lacquers are often mandatory. Temperature stability is essential not only for lacquering but also for material drying and other temperature-sensitive processes. Insufficient heating can lead to inconsistencies in the finish and durability of products, potentially increasing the rate of defects or requiring rework.
- Limited Production Capacity for New Designs: To remain competitive and cater to a broader clientele, Kasto Chairs Ltd. aims to offer diverse designs and layouts. The proposed addition of an automatic planer and molder would expand design flexibility and manufacturing capabilities, enabling the company to tap into new markets and meet the varied design specifications of institutional clients. However, the lack of a supportive heating infrastructure limits the effective deployment of such machines and hampers the company’s competitive positioning.
In summary, while Kasto Chairs Ltd. has invested in modern machinery, several foundational systems need upgrades to allow full deployment and optimal performance of these assets. Addressing these issues—specifically enhancing the sawdust extraction, heating, and drying systems was essential for Kasto Chairs to improve production quality, expand its market reach, and meet client standards, especially in the competitive institutional furniture sector.
The project enabled Kasto Chairs Ltd. to tackle production challenges and invest in advanced technologies, enhancing operational efficiency, reducing waste, and improving environmental sustainability. The key investments and their contributions include:
Enhanced Sawdust Extraction and Heating System:
- Capacity: Handles 125,000 cubic meters of sawdust per hour, addressing accumulation issues that previously hindered productivity and workplace safety.
- Sustainability: Channels sawdust into silos connected to heating boilers and drying chambers, creating a sustainable heating solution by using sawdust as fuel.
Automated Drying System:
- Efficiency: Reduced drying time for wood materials, lowering energy consumption and costs.
- Quality Assurance: Optimized drying cycles maintain high-quality standards while promoting sustainable production.
Automatic Planer and Molder:
- Increased Speed: Operates at twice the speed of previous equipment, doubling production output and meeting growing market demands.
- Precision and Waste Reduction: Cuts wood to a finer specification (0.5 cm vs. 1 cm), conserving raw materials and aligning with waste-minimization goals.
- Energy Efficiency: Designed for lower energy consumption, ensuring cost-effective and sustainable operations.
These investments improved product quality, operational efficiency, and environmental responsibility, supporting Kasto Chairs Ltd. in expanding its market reach and meeting client demands for sustainable and high-quality products.
The project significantly enhanced Kasto Chairs Ltd.’s operational efficiency, environmental sustainability, and market competitiveness. By investing in waste collection and reuse systems, the company will be able to repurpose approximately 450 tonnes of sawdust yearly for heating and drying processes, reducing waste and emissions. The transition to water-based lacquering has not only expanded the product range but also resulted in an annual reduction of around 900 tonnes of CO₂ emissions and 8 tonnes of VOCs. Additionally, the new equipment preserves approximately 50 cubic meters of wood each year, further promoting resource efficiency. Overall, these improvements has strengthen Kasto Chairs’ market position, improve workplace conditions, and contribute to a reduced environmental footprint.