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Description
Established in 2018, Innova Top Green Ltd., a Bulgarian family-owned enterprise, specializes in pioneering comprehensive green roof solutions for both urban and rural settings, catering to residential, commercial, and industrial structures. The company stands as the sole Bulgarian producer of Sedum mats – essential vegetation layers for extensive green roofs. Moreover, it operates as a supplier to prominent green roofing companies in Germany, the Netherlands, and Romania.
In collaboration with UiT the Arctic University of Norway, Innova Top Green Ltd. endeavors to enhance its core business – green roof production, with the introduction of an innovative product: Green Roof Tiles. This groundbreaking solution promises distinct advantages over existing green roof concepts, offering simplified installation and maintenance. Furthermore, it is tailored to replace traditional ceramic tile roofs with minimal structural adjustments – a niche market prevalent in Bulgaria, along with steeply sloped roofs, where green tiles present a feasible alternative.
The modular tile-based green roof system aims to:
- Expand the application of green roof systems without the need for structural alterations, thus preserving the existing roof framework.
- Adapt green roofs to pre-constructed buildings with tile roofing, ensuring structural compatibility.
- Utilize recycled materials from construction waste, specifically old ceramic tiles, for the substrate.
- Feature a design that is equivalent or directly interchangeable with standard ceramic tiles.
- Serve as a supplementary component to existing roof tiles and accessories.
- Facilitate easy installation on sloped roofs, maintaining a lightweight build suitable for roof slopes ranging from 20º to 55º.
- Incorporate the benefits of conventional roof tiles while retaining all the advantages of a green roof, promising a dynamic and innovative approach to eco-conscious roofing solutions.
Summary of project results
The project aimed to address several pressing issues and challenges related to the adoption of green roof solutions in Bulgaria and Eastern Europe:
Lagging Adoption of Green Roofs:
Green roof technologies, widely used in Western Europe and Nordic countries, are perceived as exotic, costly, and underutilized in Eastern Europe. This region lacks widespread application of these solutions, which could significantly improve energy efficiency, reduce pollution, and enhance the environmental footprint of urban areas.
Information Gap:
There is a lack of awareness about the benefits of green roofs, including energy efficiency, noise insulation, rainwater retention, CO₂ capture, and pollution reduction. This knowledge gap hinders the adoption and appreciation of green roof technologies.
Lack of Local Expertise and Resources:
Few local companies specialize in installing green roofs using native plants. This scarcity leads to increased costs due to the need for transporting pre-grown mats from other regions and poses challenges to plant longevity as they may not be adapted to local climates.
Innovative Product Development:
To address these barriers, the project proposed a novel, cost-effective green roof solution suitable for DIY installation, aimed at substituting traditional ceramic tiles and providing an option for new constructions.
- The Applicant''s unique position as Bulgaria''s only Sedum mat producer enables the creation of green roof tiles using a substrate made from crushed old ceramic tiles, enhancing insulation and supporting Sedum growth.
- This design addresses practical challenges like wind and water displacement, making the solution more durable compared to conventional green roofs.
Market Creation and Awareness:
Beyond developing innovative products, the project seeks to foster a green roof culture by conducting awareness campaigns to highlight their environmental and economic benefits, thus creating demand and expanding the market.
By tackling these challenges, the project aims to advance sustainable building practices, reduce urban pollution, and promote energy efficiency in Bulgaria and Eastern Europe.
The project focused on the research, development, and production readiness of an innovative green roof tile, achieving significant activities and outputs:
1. Research and Development
Collaboration: Partnered with UiT The Arctic University of Norway and Splinepro Ltd. for ideation, material research, prototyping, and testing.
Testing and Validation: Developed a testing roof setup to evaluate parameters such as roof slope, water flow, and insulation.
Material Selection: Chose PP (30% glass-reinforced, UV-stabilized) for its durability, sourcing it through a reliable local distributor.
2. Development of Manufacturing Capabilities
Finalized the Design for Manufacturing (DFM) phase and selected Ansa Borima to produce tooling equipment through a public tender process.
Tooling production began in February 2023 with monitoring to ensure readiness for serial production by July 2023.
3. Construction of a New Production Hall
Successfully completed a state-of-the-art production hall.
4. Equipment Procurement and Installation
Compost Shredder: Delivered, installed, and operational, including a mobile conveyor to transfer shredded materials to the linear vibrating screen.
- Stone Crusher Machines: Imported from Henan Zhengzhou Mining Machinery Co., Ltd. (China) and fully operational, comprising a jaw crusher and double roller crusher.
- Substrate Mixing Line Equipment: Designed, purchased, and installed to support substrate preparation processes.
- Green Roof Tile Assembling Equipment: Delivered and installed, enabling production of green roof tiles.
5. Intellectual Property Achievements
Registered a utility model (No. 4459 U1) with the Bulgarian Patent Office.
Secured the trademark GREЙNA™ at the European Union Intellectual Property Office (EUIPO).
Outputs
Developed and tested prototypes, finalized a validated design, and prepared for serial production.
Constructed a production hall and procured essential production equipment.
Protected intellectual property, laying the foundation for market entry.
These activities established the infrastructure and processes necessary for commercializing the innovative green roof tile, addressing market needs with robust and sustainable solutions.
The project delivered impactful results across multiple dimensions, benefitting the company, the environment, and society as a whole. Key outcomes include:
Enhanced Company Competitiveness:
Infrastructure Development: A new production facility was established, equipped with advanced machinery, including a polymer base manufacturing tool, compost shredder, stone crusher, substrate mixing line, and green roof tile assembly equipment.
- Asset Sustainability: The equipment remains under the ownership of Innova Top Green EOOD for at least five years post-project, ensuring long-term operational efficiency.
Introduction of Innovative Technological Solutions:
- Developed two new, cutting-edge products: the Green Roof Tile and the Green Roof Substrate, providing innovative solutions for sustainable construction.
Intellectual Property Achievements:
- Secured utility model registration with the Bulgarian Patent Office (Registration No. 4459 U1).
- Obtained trademark registration for GREЙNA™, a modular landscaping system for pitched roof structures, at the European Union Intellectual Property Office (EUIPO).
Environmental Impact:
Reduced CO₂ emissions by an estimated 64,500 kg annually by the end of the project.
- Implemented measures to: Decrease CO₂ emissions; Reduce bin dust and air pollutants; Minimize construction waste from ceramic tiles.
Beneficiaries:
- Innova Top Green EOOD: Enhanced competitiveness through innovation, improved profitability, and expanded operations.
- Environment: Significant reductions in CO₂ emissions, air pollutants, and construction waste contribute to a healthier ecosystem.
- Workforce: Creation of sustainable job opportunities supports local employment and skills development.
- Construction Industry and End Users: Access to innovative, sustainable products like green roof tiles and substrates promotes energy efficiency and environmental responsibility.
This project has successfully advanced sustainability, innovation, and economic growth, delivering value to both stakeholders and the broader community.
Summary of bilateral results
The project fostered substantial bilateral results through the collaboration between Innova Top Green EOOD and UiT The Arctic University of Norway. This partnership enhanced research and development capabilities, with UiT contributing expertise in industrial engineering and producing 3D-printed prototypes that were instrumental in refining the innovative product.The collaboration facilitated knowledge exchange and skill development, benefiting both teams, who gained valuable hands-on experience.Additionally, the partnership strengthened international cooperation, highlighting the importance of cross-border collaboration in driving technical innovation and building lasting frameworks for shared growth. Both organizations reaped significant benefits, including accelerated product development for Innova Top Green and practical application of engineering expertise for UiT.