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Description
Ansa Borima Ltd., an established market leader since 2012 in the manufacturing of plastic products, aims to expand its market reach and offer innovative, competitive products by introducing an innovative equipment acquisition project.
The company plans to reinforce its market position in thermosetting plastics, adhere to UL selling standards, and venture into the USA market. Their strategy also includes an increase in market share within Bulgaria, the EU, and international markets like Tunisia, Egypt, and India. In the long term, they aim to diversify their product portfolio, introduce new competitive items, purchase new equipment for an injection molding facility, and develop a modern warehouse system for material traceability.
Primary production facilities are in Borima, with a gradual expansion into Lovech due to resource constraints in the former. The Borima site mainly houses molding equipment, while the Lovech location focuses on assembly lines.
The company, operating at full capacity and securing long-term contracts with international companies, is well-positioned for this project. The innovative equipment acquisition will help maintain the "Preferred Supplier" status with international brands while improving product quality and addressing cost concerns.
Summary of project results
The project aimed to address several issues and challenges:
- Growth and Capacity: The company was experiencing growth in its operations and needed further investments to increase production capacity. As the company continued to expand, it became increasingly clear that existing facilities were insufficient to handle the surge in demand. This necessitated strategic investments not only in physical infrastructure but also in advanced machinery and technology. By doing so, the company aimed to scale up its production capabilities while maintaining operational efficiency and meeting the growing market needs.
- Meeting higher requirements for eco-friendly production processes and high-quality materials. The shift towards sustainable and eco-friendly production methodologies posed a significant challenge. The company had to overhaul its processes to comply with stringent environmental regulations. This involved integrating green technologies, sourcing sustainable raw materials, and ensuring that every step of the production chain aligned with eco-friendly practices. Such a transition was crucial not only for regulatory compliance but also for improving the company''s market image and appeal to environmentally conscious consumers.
- Cost Efficiency: The need to find cost-effective solutions and technological modernization to remain competitive in the pricing war with Asian competitors. In a highly competitive market, particularly against Asian manufacturers known for their cost-effective production, the company needed to innovate continuously. This meant adopting new technologies that could streamline operations, reduce manual intervention, and cut down on unnecessary expenses. Investing in automation and optimizing supply chains were key strategies employed to bring down costs without compromising on quality.
- Energy Costs: High electricity costs necessitated the implementation of energy-efficient equipment. The significant expenditure on energy was a critical area of concern. To mitigate this, the company explored renewable energy options, such as solar or wind power, and invested in state-of-the-art energy-efficient equipment. These measures were designed to reduce dependency on traditional energy sources, thus lowering overall electricity costs and contributing to environmental sustainability.
- Material Waste: The production process had too high a ratio of waste from embedded materials, increasing production costs. The production process was plagued by a high level of material waste, which not only escalated costs but also posed environmental challenges. The company undertook rigorous process audits to identify wastage points and implemented recycling and reusage protocols. Adopting lean manufacturing principles, they aimed to minimize waste generation, thereby enhancing both cost-efficiency and environmental stewardship.
Collectively, these measures were designed to position the company at the forefront of the industry, capable of meeting contemporary challenges while paving the way for sustainable and profitable growth.
The project "Don’t lose it, reuse it!", involved the purchase and installation of an innovative electric injection moulding machine of hybrid technology for plastic elements.
This state-of-the-art machinery represents a significant advancement in the company''s production capabilities, allowing for greater precision in the manufacturing process while reducing energy consumption. By integrating hybrid technology, the machine combines the benefits of electric and hydraulic systems, ensuring both speed and efficiency. The project''s objective is not only to enhance production but also to align with environmental sustainability goals.
The new machine enabled the reuse of plastic materials that would otherwise be discarded, thereby significantly reducing waste. The initiative aimed to set a benchmark in the industry for sustainable practices and innovation. As part of the company''s commitment to continuous improvement, the Promoter monitors the machine''s performance closely and makes necessary adjustments to optimize its functionality and impact.
This project is in harmony with the company''s broader strategy to foster an eco-friendly manufacturing environment, reduce carbon footprint, and drive sustainable growth. The implementation of this innovative solution is expected to open new markets and opportunities, reinforcing company''s position as a leader in environmentally responsible manufacturing.
Outcomes
- Increased competitiveness of Ansa Borima Ltd.
- Estimated annual growth in turnover.
- Estimated annual growth in net operational profit.
- Creation of two new jobs.
- Reduction of CO2 emissions by at least 47.4 tonnes annually.
- Introduction of one innovative technological solution into operation.
- Implementation of one measure to decrease CO2 emissions.
- Implementation of one measure to increase energy efficiency.
- Implementation of one measure to improve material efficiency.
- Enhanced production capacity and energy efficiency for Ansa Borima Ltd.
- Better quality products and improved competitiveness on the international market.
- Contribution to the local economy by creating job opportunities in a region with limited employment prospects.
- Environmental benefits through reduced energy consumption and CO2 emissions.
- Primary beneficiary: Ansa Borima Ltd., which gains increased competitiveness, production capacity, and profitability.
- Secondary beneficiaries: Local community in Borima and Lovech, benefiting from job creation and economic development.
- Environment, benefiting from reduced CO2 emissions and increased use of recycled materials.