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Description
The primary objective of the project is to enhance the competitiveness of KASKADA Ltd. through the introduction of an innovative product—an irrigation drip tape manufactured from an 80% recycled compound. The project aims to establish a circular approach in the production and distribution of irrigation pipes, leading to the transformation of KASKADA Ltd. into an almost zero-emission factory. By closing the value chain for drip-type irrigation pipes, the company not only streamlines its own processes but also makes the entire irrigation system more cost-effective and efficient for farmers. The innovative production concept involves replacing 80% of the typically used prime-grade high-density polyethylene with a recycled polymer compound, derived from HDPE waste collected from various sources. This green production approach offers multiple advantages, including a simplified production process, cost savings, high levels of purification, and the creation of a high-quality end product. The project is expected to increase annual net revenue and profits, create six new job positions, and position KASKADA Ltd. as a more competitive player in both local and international markets, contributing to the bilateral relations between Bulgaria and Norway. Furthermore, the long-term impact of the project aims to transform KASKADA Ltd. into an environmentally sustainable, (almost) zero-waste and emission-free factory.
Collaborating with Norwegian partner International Development Norway is crucial for the project''s success. They bring expertise and technological solutions, enhancing the beneficiary''s capabilities. The partnership extends beyond the current project, focusing on future initiatives involving advanced technologies and best practices. The collaboration began with a visit by International Development Norway to KASKADA''s production plant in September 2018, where they discussed the GaIN project and laid the foundation for ongoing and future collaborations.
Summary of project results
The global polymer industry experienced robust growth over the last five years and is expected to further grow in the future. The demand for polymers is driven by the growth in end-user market, increasing plastic consumption, and increasing demand for essential light weight and significant low cost materials, as compared to its alternative. The application segment in the global polymer market includes industrial sectors, such as horticulture, consumer goods, packaging, building & construction, medical, packaging, automotive, transportation, food industry, and electronics and communication. Polymers are replacing metals, glass, paper and other traditional materials in various applications, due to their strength, design flexibility, along with low cost.
The main issue faced by the polymer market is to address the concern related to environmental issues, limited use as engineering materials, and the feedstock supply.
The weak demand for recycled plastics was another major obstacle to transforming the plastics value chain. While there are an increasing number of new processes for recycling polymers, the reality is that a majority of recyclable materials still end up in landfills or get incinerated, due to logistical or geographical issues, lack of awareness and a lack of appropriate, readily available processing facilities.
The main challenges that the company was facing are:
- small local and regional markets, strong competition
- poor plastic waste management, lack of extended producer responsibility
- low domestic demand for recycled products
- long distance from attractive export markets
- high logistic costs, high energy costs and high cost of input material were highlighted.
KASKADA Ltd. has invested in a new e new irrigation drip-tape extrusion line. The deployment of advanced technologies has led to increase automation, improve resource efficiency and efficacy by optimization of resources used in the production- polymeric raw materials, electric power and production time.
As a result of implementing of Project Activity 3 the following outputs will be generated:
• Extending existing recycling process of used irrigation pipes and introducing to new for KASKADA Ltd irrigation drip tape extrusion line.
• Increasing the re-use of processed waste in production of plastic irrigation pipes by introducing a method for production of 80% recycle polymer irrigation pipes.
• Improving the material efficiency by using an innovative material for production od polymer irrigation pipes that is a result of 80% recycled materials.
• Increasing the re-use of recycled materials by reorganizing the production and operational process in KASKADA Ltd. the context of circular economy.
Summary of bilateral results
The Norwegian partner, International Development Norway has been involved in assessing product performance of KASKADA Ltd. in the context of circular economy and focusing on the new product introduced as the result of the project i.e. fully recyclable irrigation pipes. For the product circularity assessment, The basis for measuring the current situation (baseline) at the company was a material and energy flow analysis. Then, the analysis has been extended by detailed modelling of supply chain outlining the full value chain and logistics, storage and product loss.Based on its rich experience in the field International Development Norway contributed to an increased green performance of the new production line, both in terms of energy efficiency cycles and applied compounds. Additionally, IDN involvement was extended to general overview and performance based assessment of the whole company in the context of the circular economy concept.