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Description
TM Technology JSC, established in 2003, is a medium-sized Bulgarian enterprise that specializes in metalworking and the production of large metal products. These products include metal structures for various industries, metal components for machinery, and large-scale constructions weighing up to 80 tons and spanning up to 30 meters. With a diverse catalog, TM Technology JSC offers over 620 customer-specific products tailored for use in industries such as energy, construction, and more.
The primary focus of the current project is to implement an innovative and environmentally friendly technological line dedicated to cleaning, preparing, and painting metal surfaces for welded structures. This integrated system comprises a conveyor blasting machine, a degreasing and drying chamber, a shot blasting booth, and a combi spray booth. By introducing this advanced technological line, the company aims to streamline its production processes and meet the growing demand from its clientele.
The proposed investment is expected to yield several positive outcomes for the company. Notably, it is projected to have a significant impact on the company''s financial performance, leading to increased turnover and enhanced net operational profits. Simultaneously, the initiative will contribute to improved production efficiency and enhanced environmental performance across the enterprise.
In May 2023, the company received an additional grant, which will be used to acquire equipment essential for the transportation of welded structures to and from the various chambers involved in the cleaning, preparation, and painting processes. This includes an automated paint system for applying paint to large sheet materials and a paint mixing device, which are integral components of the overall technological line dedicated to preparing, cleaning, and painting metal surfaces for welded structures.
Summary of project results
The project aimed to address several critical challenges faced by TM Technology JSC related to its manual production processes, which negatively impacted efficiency, product quality, worker safety, and environmental sustainability. Key challenges were related to:
Inefficient Manual Processes:
- Cleaning, Degreasing, and Painting: The manual execution of these tasks was time-consuming, resource-intensive, and inefficient.
- Health Risks: Manual processes emitted harmful substances, posing significant health risks to workers and contributing to environmental pollution.
Product Quality Issues:
- Surface Pores: Manual cleaning often led to the formation of pores in the metal structures, compromising the quality and safety of products, particularly those used in lifting constructions and transport equipment.
- Oily Residue Penetration: Blasting oiled surfaces after machining caused microscopic oily droplets to seep into the metal structure. These droplets could later condense and cause cracks in the paint or primer layer, necessitating costly defect correction.
Customer Expectations and Safety Requirements:
- Defect Remediation: Significant resources and effort were required to remove defects and meet stringent customer expectations, placing additional strain on the company’s operations.
- Safety Standards: Ensuring high-quality and defect-free components was critical, given the application of these products in safety-sensitive industries.
By addressing these issues, TM Technology JSC aimed to establish a more sustainable and competitive production system that safeguarded its workforce, improved product quality, and reduced environmental harm.
The project modernized TM-Technology JSC’s cleaning, preparation, and painting processes by implementing advanced, energy-efficient equipment to enhance productivity, improve product quality, and reduce environmental impact. The project encompasses the following activities:
Installation of New Equipment:
- Conveyor Blasting Machine: Replaced manual cleaning with an automated system for large metal sheets, enhancing precision and efficiency.
- Degreasing and Drying Chamber: Automated removal of grease and oil to prevent paint defects, improving surface quality and reducing manual labor.
- Shot Blasting Booth: Added for cleaning complex welded structures with filtration and ventilation for a safer environment.
- Combi Spray Booth: Designed to function as both a spray booth and a dryer, capable of simultaneous operations for increased throughput.
Process Innovations:
- Electric Tug System: Enabled safe and efficient transportation of heavy welded structures in and out of the chambers, using a compact and powerful electric vehicle with specialized modules.
- Automated Paint System: Implemented high-pressure paint pumps for consistent coating of large sheet materials, protecting surfaces post-cleaning from corrosion.
- Paint Mixing Equipment: Installed a centralized system for automatic mixing and supply of lacquer materials, improving operational control and reducing material waste.
Green and Sustainable Technology: Introduced environmentally friendly processes, including automated cleaning and painting systems that minimize energy consumption and reduce harmful emissions.
Outputs:
Optimized cleaning, preparation, and painting processes.
- Enhanced product quality with defect-free surfaces.
- Safer workplace with reduced manual labor and exposure to harmful substances.
- Increased production capacity and competitiveness through innovative technologies.
By implementing these advancements, the project transformed TM-Technology JSC’s operations, ensuring higher efficiency, product reliability, and sustainability.
The project delivered substantial outcomes, addressing productivity, cost efficiency, environmental sustainability, and competitiveness, benefiting both the company and its stakeholders.
- Increased Productivity and Quality: The new equipment significantly improved operational efficiency, reducing processing time and increasing production output. Enhanced product quality with defect-free surfaces, meeting safety and reliability standards for metal structures used in lifting equipment and transport.
- Lower Production Costs: Automation and efficient resource utilization reduced costs associated with manual labor, material wastage, and energy consumption.
- Expanded Market Reach and Competitiveness: Strengthened the company’s position in domestic and international markets by increasing the share of exports. Competitive advantage was achieved through the integration of advanced, environmentally friendly technologies.
- Resource Efficiency and Sustainability: Energy consumption decreased by 503.7 MW/h annually, lowering operational costs and reducing the carbon footprint. Improved raw material utilization through the reuse of blasting and degreasing materials, contributing to resource conservation.
- Environmental Impact: Achieved an annual reduction of 149 tons of CO2 equivalents, aligning with green business practices and global sustainability goals. Other harmful emissions (e.g., xylene, toluene, butyl, ethyl alcohol) decreased by 9,349 kg annually, creating a healthier work environment and reducing pollution. Processes like automated double-sided shot blasting and use of special painting chambers equipped with local filters minimized pollutants.
- Improved Workplace Conditions: Replaced manual, hazardous processes with automated systems, ensuring safer and more ergonomic working conditions.
Beneficiaries:
TM-Technology JSC: Improved production capacity and reduced costs strengthened its market position and financial performance.
Employees: Safer working conditions and reduced exposure to harmful substances enhanced worker health and productivity.
Customers: Received higher-quality, durable products that comply with stringent safety standards.
Environment and Society: Significant reductions in emissions and energy usage contributed to a greener, more sustainable industrial footprint.