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Description
We manufacture busbars for modular single-phase low-voltage apparatus which are used as elements of electrical devices and installations, mainly by companies producing electrical installation equipment and electrical safety devices. The aim of the project is to modernise our production process, and applying environment-friendly solutions at the same time. ELKAT has developed a PVC extrusion technology which will be implemented under the project. Research will need to be conducted leading to the formulation of an improved PVC mix. Also, a new production line for extrusion from PVC regranulate will be purchased and installed.
We will cooperate with a Norwegian partner, Avitron Norway Limited Company, that will be responsible for the delivery and installation of a heat pump, a photovoltaic system and an EV charging station.
Thanks to the project, we will reduce the emission of substances harmful to the environment (CO2 emission smaller by 14,06 tons), reuse waste for production (10 tons of waste recycled in 2023). In addition, recovery of heat from plastic production machines located in the new hall will be possible, and the surplus of energy will be used for heating. Energy recovery will also come from devices accompanying the production such as the compressor, the ice water aggregate and the dryer for plastics.
Summary of project results
The main challenge of the project was to increase the competitiveness of Elkat by introducing modernisation in the production process and at the same time applying environmentally friendly solutions:
(a) development of a technology for secondary processing of plastic waste - PVC extrusion enabling the use of technological waste;
b) development of a heating and cooling system using the recovery of heat energy from the plastics production machines located in the new hall and thus utilising surplus heat energy for heating.
a)A scientific unit with a physico-chemical laboratory, specialising in the synthesis of suspension polyvinyl chloride, with experience in chemical structures and materials research and a team of high-level specialists in the area of polyvinyl chloride (PVC) synthesis and processing, was invited to cooperate.
The main task of the research unit was to establish the composition, the formulation of the granulate that can be reused so that a minimum of 99% of the waste from the plant is reused.
b)A partner, the Norwegian company Avitron, was engaged to carry out the task. This company was responsible for the design and implementation of a consistent energy supply system for the production hall. The main challenge was to plan a zero-carbon solution.
The project enabled production of current busbars with a new profile shape, more compact in terms of ergonomics (occupying less space in low-voltage switchgear), lower in price by about 4-5%. The new busbars have the following characteristics:
- improved dielectric properties;
- ease of installation - thanks to improved profile shape and better elasticity, profile shape memory;
- greater repeatability of series of products, repeatable quality of products, shorter order realization,
- reduction of deficiencies - the resulting deficiencies reused in the recycling process.
We reduced the demand for electricity consumption for the installed machines and improved the ratio of demand for material in relation to the quantity of produced products. The new process is designed as energy-efficient, with the use of waste reuse. Developing a PVC extrusion technology enabled the use of technological waste in the process of production of PVC profiles - we will reuse 99.5 % of technological waste from our plant for production. Innovative and economical energy solutions were applied - as a result, we created a zero - emission space. As part of the project, photovoltaic system and a heat pump were installed. Heating of the new hall is now based on heat energy recovery from the installed machines and equipment. The main task of the pump is to cool down the machines working in the hall by aggregating ice water. There is no air conditioning installed but only efficient ventilation. There is no need for water heating in production hall. This is a proprietary concept developed by partners from Norway in agreement with Elkat. It also allows charging via the installed plug-in charging station with clean energy from the sun.
The most important project results are as following:
- As a result of the project, the competitiveness of the Beneficiary has significantly increased. We have introduced to the market improved products characterised by significant benefits for buyers and for us as a manufacturer. In Poland, no one uses PVC extrusion lines to create chamber profiles for busbars;
- Thanks to the project implementation, the company''s revenues will increase significantly - we expect an increase of more than 10% per year.
- As part of the project we established cooperation with new Partner - Avitron Norge. The Partner''s share brings significant added value - the company operates in the same market, we gain the opportunity to use our power rails in switchgears that Avitron sells;
- A innovative plastics processing line enabled the production of components of the highest technological quality while maintaining the highest environmental standards and norms applicable abroad: the product has a high potential for export sales. Currently in the sales structure, sales to foreign markets are about 18%, we plan to increase to 23%.
- We will reuse 99.5 % of technological waste from our plant for production (10 tonnes per year) – we plan to save 14.06 tonnes of CO2 per year
- We increased employment by 2 people. As a result, the project will contribute to achieving the objectives planned under the Norwegian Financial Mechanism 2014-2021, which include contributing to the reduction of economic and social disparities within the European Economic Area and strengthening bilateral relations between Norway and the Beneficiary States.
Summary of bilateral results
The Partner was actively involved in the project concept preparation process. During the project we held several joint consultation sessions in which we considered different options for the energy supply of the plant. Various technological options were considered; in the end, the partner proposed a solution based on the use of a coherent heating, cooling and electricity supply system through the use of photovoltaics and a heat pump. Heating of the new hall is carried out on the basis of heat energy recovery from the installed machines and equipment. The main task of the pump is to cool down the machines working in the hall by aggregating ice water. There is no air conditioning installed but only efficient ventilation. There is no need for water heating in the planned hall. This is an original concept developed by partners from Norway.The partner assisted in developing the technical specifications for the components of the energy supply system; took part in the installation of the equipment and optimisation of the parameter settings of the energy management system; and trained the company''s employees.Partner - Avitron - is a company in the field of electro-automation solutions and specialises in green energy and electromobility. Avitron provides innovative engineering solutions. The company combines international experience and Norwegian quality to create unique and energy efficient solutions. It has over 10 years of experience in the power sector. By establishing cooperation with a Norwegian partner, we plan to significantly expand our sales to the Norwegian market. We have already established initial contacts and participated in trade missions in Scandinavia. We are currently negotiating with Avitron on the establishment of a joint company set up to sell into the Norwegian market.