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Description
As a result of the project, RECELLO will offer a new service on the Polish market: recycling waste from the manufacturing of non-woven textiles through defibration (tearing) to a form close to the original raw material. This service will enable technological conversion of raw material in sanitary products manufacturers, thus preventing the generation of waste, which will result in more efficient material management and, indirectly - more energy-efficient production.
The project consists in the purchase and start-up of a defibering line where the key component of the line, a defibering machine, will be specially adapted to process non-wovens with synthetic fibres. In addition, our service will be energy-supplied from new photovoltaic panels, thus contributing to a reduction in CO2 emissions into the atmosphere of 38.37 tons per year.
The Norwegian partner of the project, InnoBiz AS, will mentor our project leader, and will suggest ways of identifying new business partners in Scandinavian countries, with particular emphasis on Norway. Due to the high demand on the domestic market, our offer will be addressed primarily to Polish enterprises in the initial period after launching the service, later to be followed by customers from nearby European markets.
Summary of project results
The main issue was to offer an innovative tearing service of particularly difficult materials - nonwovens made of synthetic materials and viscose-cellulose nonwovens. The project answered the problem of reusing the postproduction waste of nonwovens (e.g. starting rolls, improper cutting or winding rolls) in the production of hygienic products. Such tearing service focused on the quality of the torn material which should be close to the virgin fibre was not available in Poland. The postproduction waste disposal was the problem of all manufactures of hygienic products who tried to sell the waste for other applications at very low prices or disposed it as a waste. The project is fully in line with the CEAP 2020 and the Polish “Road Map towards circular economy”.
As a result of the project the new innovative tearing line was launched,. The line consists of the two linear tearing units, rotary filter and baling press. The first unit is armed with pins, the second with carding wire, such sequence has been developed at the first months of the project during the trials ran at different equipment manufacturers. The modern rotary filter allows to separate the short fibre (pulp) (which can be reused) from the dust. The powerful bale press at the end of the line improves the economics of the logistic and transportation process.
The line is partly powered by the renewable energy. The photovoltaic installation (49,8 kWh) provides -depending on the month and on the weather conditions- up to 100% new line energy consumption, thus reducing the CO2 emission by 38 tonnes per year.
Having the new line RECELLO can offer wider and more comprehensive services what should be reflected in the substantial growth of sales and the profitability.
Indirect beneficiaries are the producers of hygienic products who got the possibility to recycle new batches of nonwovens what counteracts the generation of waste.
Last but not least the beneficiaries are our employees who got the opportunity to be acquainted and work on the new generation of tearing equipment and bale press.
The results of the project have been reflected in the following project indicators:
Number of innovative technologies applied (new-to-the-enterprise) – 1
Number of innovative products commercialized – 1
Number of innovative processes – 1
Number of mentoring services applied/supported in the enterprise -1
Number of jobs created (in total) – 3
Estimated reduction of annual CO2 emission – 38 tonnes
Summary of bilateral results
The partnership in the project was limited to the mentorship provided by the experienced retired manager and consultant. The project leader Agnieszka Girzejowska who had a vast experience in marketing from previous jobs, lacked the experience in the project development in the small family business. The Mentor provided regular consultancy for the key elements of the project. Thanks to them Agnieszka Girzejowska has significantly improved her managerial skills. The contact with the Mentor is maintained, however the form of the further cooperation has not been defined yet.