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Description
ZARPOL manufactures specialised parts of machinery and equipment for the power industry, in particular power turbine components, manufactured by means of machining processes. We cooperate with large international power engineering corporations (such as GE Power and MAN) which are the main customers for our products and services. The project is about the implementation of an innovative manufacturing process and the introduction of new and improved turbine components to our company’s offer, e.g. components containing heat-resistant stellite and nickel hard facing layers while maintaining specific shape and dimensional accuracy. The process of machining elements with the use of machines purchased under the project will have higher efficiency, and speed and automation levels, which will ensure better cost-effectiveness. That, combined with the installation of renewable energy systems (photovoltaic panels and heat pumps), will contribute to increased profitability of the company and reduced emissions of pollutants into the atmosphere. As a result of the project implementation, the annual electricity consumption of our plant will be reduced by 0.03 GWh, as well as the annual CO2 emissions by 36.5 tons.
Summary of project results
The subject of the project was the implementation of an innovative machining process of elements containing heat-resistant stellite and nickel weld deposits, resulting in a significant, twofold - increase in shape-dimensional accuracy and repeatability, what is the answer to diagnosed customer needs and will strengthen the company''s market position.
The result of the project is the expansion of the company''s offer through introduction of significantly improved products: turbine components, incl containing heat-resistant stellite and nickel weld deposits, maintaining shape and dimensional accuracy in the range of 0.005-0.01 mm and positioning accuracy of holes within 0.005 mm and new products for the company: turbine blades and spacers.
The new machining process was focused on increase in efficiency, speed and level of automation of production, and therefore better cost effectiveness, which, combined with the installation of renewable energy systems for electricity production and thermal energy for the plant was aimed at increasing profitability activities and reducing emissions of pollutants into the atmosphere, as well as reducing CO2 emissions.
The project has been completed and the planned goals achieved: implementation of innovative solutions production processes translated into new production possibilities and expansion of the offer of ZARPOL for products unique in the country - turbine elements, including those containing heat-resistant ones stellite and nickel overlays, maintaining shape and dimensional accuracy 0.005-0.01 mm and turbine blades and spacers.
This was possible by purchasing specialized fixed assets machines:
- 5-axis machining center with instrumentation
- horizontal CNC drilling, milling and boring machines with a control system
- pillar crane, conducting staff training, implementation of new production processes and carrying out promotional activities.
The company continues its pro-environmental activities: it was purchased as part of the project a heat pump that will produce "clean" thermal energy for the plant''s heating needs ZARPOL, contributing to the reduction of CO2 emissions.
The implementation of the project contributed to increasing the competences of key employees, including: management staff and contributes to the development of the company''s environment.
The result of the project implementation is the strengthening of the market position, improvement of competitiveness and development business activity of the Applicant, in particular an increase in revenues, limitation a decline in profitability (related to the deterioration of external economic conditions) and employment increase by 1 average annual position.
The effect of implementing process innovation in ZARPOL''s production processes is:
- extension of the offer with innovative products on a national scale: components for turbines with shape and dimensional accuracy in the range of 0.005-0.01 mm and positioning accuracy holes in the range of 0.005 mm and turbine blades and spacers not yet produced in the plant;
- improving the efficiency and speed of technological processes -
- development of employee and management competences,
- increase in employment.
The new product and service offer, which is a response to market expectations, will enable the expansion of cooperation with the plant''s existing customers as well as the acquisition of new ones, which should translate into an increase in revenues by 9.39% and profit by 8.73% in 2024.
Pro-environmental activities carried out as part of the project - installation of a heat pump that will produce "clean" thermal energy for the plant''s heating needs ZARPOL - contribute to reducing CO2 emissions.
According to the above, the beneficiaries of the project results are the owners of the ZARPOL plant, employees, customers and the local community.