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Description
Popchev Stone Design Ltd., established in 1999, is undertaking a vital initiative to enhance its sustainability and resource efficiency within the framework of the Business Development Programme in Bulgaria. Specializing in cutting, shaping, and finishing natural stones for various applications, the company faces a challenge with the unused bottoms of stone blocks, constituting about 10-15% waste. Through this project, Popchev Stone Design aims to utilize this waste, transforming it into balusters and other stone details for mosaics and panels. The introduction of a Computer Numerical Control (CNC) machine for processing marble and limestone, along with a water cutting machine, aligns with the company''s long-term strategy for sustainable growth and resource efficiency. This green production process not only minimizes waste but also expands the company''s production range, meeting the growing demand for stone-based interior decorations. The project is a testament to Popchev Stone Design''s commitment to environmentally conscious practices and optimizing resource utilization.
Achieving these goals requires a variety of key activities, including:
1. Delivery of equipment 10/17 - CNC machine for processing of marble and limestone. - water cutting machine
2. Project management activity - Project management will also be outsourced, as the company''s management and employees are in charge of the company''s core business and do not have the free capacity to undertake the activities for the preparation of the package of documents for the public procurement, as well as the interim and final program report.
3. Publicity and visualization.
Summary of project results
Popchev Stone Design faced several challenges related to:
Inefficient Use of Resources: The company was unable to process the remaining bottoms of stone blocks effectively. These unutilized portions became waste, leading to increased material waste. Significant portions of raw material were discarded, representing a loss of potential value. In addition, waste material had to be transported and disposed of in dedicated landfills, incurring additional costs.
Dependence on Competitors: The lack of adequate equipment forced the company to rely on competitors to process residual stone bottoms. Additionally, the company had to assign parts of its production to competitors to fulfill contracts and meet client demands.
Environmental and Sustainability Concerns: Disposing of stone waste in landfills contributed to environmental degradation and higher CO2 emissions associated with transport and landfill operations. The available processes were not aligned with modern sustainable and resource-efficient practices, posing risks to the company’s reputation in an increasingly eco-conscious market.
Insufficient Production Capacity: The company’s inability to handle its production demands internally pointed to capacity constraints, which could lead to dependence on external suppliers and potentially slow down project timelines.
This green production process was introduced through the purchase of two pieces of equipment: a Computer Numerical Control (CNC) machine for processing marble and limestone, and a water cutting machine.
CNC Machine for Processing Marble and Limestone: This machine is capable of processing material on 5 axes. Its main functionalities included orthogonal and segment cutting, profile cutting by interpolation of 5 axes, cutting simple shapes, cross lines, and creating reliefs, as well as sculpturing and carving.
Water Jet Machine: This machine is able to cut stones using a high-pressure jet of water mixed with an abrasive substance. It could cut hard materials by pressurizing water to ultra-high pressures and creating a powerful cutting stream (up to 6000 bars). The stream moved at a velocity of up to three times the speed of sound. When focused on a precise point, this high-speed water could cut nearly everything. At the same time, the process was environmentally friendly, as it did not produce smoke, dust, vapor, or gases.
The project significantly enhanced the competitiveness of Popchev Stone Design Ltd., as reflected in several key outcomes:
Application of an Innovative Green Production Process: The project successfully introduced one innovative green production process, incorporating advanced equipment that transformed waste materials into valuable products.
Reduction of CO2 Emissions: A measure to decrease CO2 emissions was implemented through the acquisition of eco-friendly equipment. This step aligned with the company’s commitment to sustainability and environmental responsibility.
Reuse of Raw Materials: The project implemented a measure to reuse raw materials, allowing the company to repurpose stone waste effectively. This not only reduced material costs but also minimized environmental impact by diverting waste from landfills.
The adoption of these measures positioned Popchev Stone Design Ltd. as a more competitive and sustainable company within the industry. The integration of advanced, eco-friendly technology allowed the company to enhance resource efficiency, meet growing customer demands for environmentally conscious products, and align its operations with modern sustainability standards.