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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 Several critical production systems remained outdated or insufficient, and these limitations collectively hinder operational efficiency, workplace conditions, and the company’s ability to enter new markets.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:
1. Sawdust Extraction Challenges: The outdated sawdust extraction system was a significant obstacle.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.
2. 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.
3. 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 allowed Kasto Chairs Ltd. to address its production challenges and invest in advanced technologies. The investment made has also enhanced the operational efficiency, reduction of the waste, and improved environmental sustainability. Here’s a closer look at the specific investments, made within the project:
- New Enhanced Sawdust Extraction and Heating System that can handle approximately 125,000 cubic meters of sawdust per hour. This high capacity ensures that sawdust accumulation, which has previously hindered productivity and workplace safety, and more effective management that creats a cleaner and safer work environment. The system channels the extracted sawdust into silos that are connected directly to heating boilers and drying chambers. This integrated design provides the company with a sustainable heating solution by using stored sawdust as fuel.
- Automated Drying System: The new drying system has reduced the drying time of wood materials, cutting down on energy consumption and costs associated with prolonged drying periods. The system''s automation ensures optimal drying cycles, which are crucial for maintaining the high-quality standards necessary in wood manufacturing. This sophisticated drying technology will enhance product quality, control operational costs, and contribute to a more sustainable production process.
- Automatic Planer and Molder: which allows the company to increase production speed, reduce waste, and enhance product quality: The machine operates at twice the speed of the previously available equipment, effectively doubling the production output. The faster operations help Kasto Chairs to meet growing demand and facilitate expansion into new markets without compromising quality or turnaround time. The new planer and molder are designed to cut wood to a finer size specification (0.5 cm instead of the current 1 cm). This precision not only saves raw material but also aligns with the company’s objective of minimizing waste, as each piece of wood is used more efficiently. This enhanced accuracy in wood cutting maximizes the utility of each log, conserving resources and reducing the company’s environmental impact. The automatic planer and molder are engineered for lower energy consumption, contributing to cost-effective and sustainable production. This addition will ensure that Kasto Chairs can operate with a more resource-efficient process, meeting the demands of clients who prioritize environmental responsibility and cost savings.
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.