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Description
WavErest Ltd. is a small company specializing in the production of neoprene apparel for water sports and fashion products under its brand "Runawave." Additionally, the company serves as an Original Equipment Manufacturer (OEM) for over 30 international brands. WavErest''s production facility is situated in the picturesque village of Smiliyan, Bulgaria.
The primary goal of this project is to enhance the company''s competitiveness by optimizing the management of neoprene waste generated during the manufacturing process. This approach ensures that the economic value of products, materials, and resources is maintained. WavErest plans to invest in an innovative neoprene recycling technology and introduce a new brand, "RAW," featuring a range of products crafted from recycled neoprene materials, including yoga mats, cup pads, flooring pads, and more.
Collaborating with the Norwegian partner, Pivot Industridesign AS, a design agency renowned for its project portfolio emphasizing environmental sustainability, functionality, and aesthetics, is a key component of this endeavor. Pivot boasts a team of highly experienced experts specializing in sustainability management, industrial design, and engineering. The primary role of this partner in the project is to analyze material properties and design products using recycled neoprene. This collaboration holds the potential to become a strategic asset for both companies and contribute to the promotion of environmentally friendly solutions.
Furthermore, an additional project component has been approved, aiming to implement an innovative green technology involving a high-pressure steam installation for the production of various grades of recycled neoprene. This project carries significant value for WavErest Ltd. and the region. Notably, it will lead to the creation of eight new job opportunities, providing a substantial social benefit for the residents of this small countryside village.
Summary of project results
More than 95% of the produced wetsuits globally are non-biodegradable, chemical-based and end up in landfills at the end of their lifecycle. However, as the consumers are becoming more demanding and conscious of their impact, many companies are trying to implement innovations in their manufacturing process and explore alternatives for neoprene foam e.g. natural rubber. But even after taking into consideration the projected expansion of such practices, in the long run, neoprene is still estimated to remain a defining factor in the water apparel industry. Sustainable, cost-effective and long-term solutions for disposal and/or recycling of neoprene - based products at the end of their lifecycle simply do not exist.
The neoprene waste generated from the company’s operations was more than 1 tone per year. This, on the one hand, had negative economic consequences for the company - incured additional expenses for the enterprise, reduces profits, and hence affects the company overall competitiveness. On the other hand, the environmental footprint that the company leaves behind was significant. The project has addressed precisely these needs for improving production efficiency through minimising waste leftovers and maintaining the economic value of products, materials and resources as long as possible in order to achieve higher competitiveness.
The company invested n an innovative technology for neoprene recycling and launched a new brand “RAW” consisting of products from recycled material ( yoga mats, cup pads, flooring pads, etc. ) . The following positive impact is observed :
Modernize Infrastructure: The project has upgraded and renewed existing facilities to meet the economic and environmental standards for functionality, safety, and efficiency.
Expand Capacity: The project outcomes have led to increased production capacity. It will allow WavErest Ltd. to handle the increasing customers'' demand more effectively and accommodate future growth.
Enhance Operational Efficiency: Through modernization and redesign, the project helped to streamline operations, improve workflows, and reduce operational costs over time.
Incorporate Future-Proof Solutions: The results achieved provide with the flexibility to adapt to future technological advances and evolving service needs.
Improve Working Environment: The project outcomes also created better, safer, and more functional workspaces for staff, contributing to improved employee satisfaction and productivity.
Through the project the company has applied new green technology and processes which are directly contributing to recycling and reusing of the neoprene waste. The project results has also contributed to the reduction of CO2 emissions. The investment has led to:
- utilization of waste raw materials;
- diversification of the product range of the company
- strengthening the company’s position on the market
- mitigating the environmental impact.
Summary of bilateral results
The Norwegian partner in the project is Pivot Industridesign AS. has been involved in a transfer of know-how and expertise. It has contributed to the assessment of the recycled material features and the industrial design of the new products from recycled neoprene.