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Description
Established in 1994 in Sandanski, situated in the South-West Region of Bulgaria, Kristiyan-Albert Andonov-Todorka Andonova Ltd. is a compact enterprise specializing in the design, manufacturing, and assembly of bespoke cabinet furniture. Their product range encompasses a diverse array of custom-crafted furniture catering to kitchens, children''s rooms, and bedrooms. In addition to their core focus, the company also engages in the production of aluminum and PVC windows.
Presently, the company operates with equipment of limited capacity, and several operations rely on manual labor. Manual material processing proves notably time-consuming and generates a substantial volume of waste material. This project heralds an opportunity for the Project Promoter to invest in innovative, environmentally conscious equipment renowned for its enhanced productivity and cost-efficiency. The introduction of new machinery promises to significantly optimize the use of raw materials while simultaneously reducing waste production.
In a noteworthy development in May 2023, the company clinched an additional grant for innovative equipment. This addition will empower them to achieve high-precision machining, elevate material utilization (specifically chipboard and MDF), and minimize human errors throughout the production process.
Summary of project results
Complexity of Custom Furniture Production
Furniture manufacturing, particularly for custom-made pieces, is a highly complex process. Unlike mass production, where standard sizes and designs allow for streamlined operations, custom furniture requires flexibility in both materials and processes. This means handling a variety of materials, such as wood, particle boards, veneers, and edge-gluing strips, all of which need to be precisely cut, shaped, and assembled to meet the unique specifications of each customer.
Limited Equipment and Manual Operations
The company’s existing equipment has limited capacity, which has proven to be a significant obstacle to scaling its operations. Much of the production process is still carried out manually, which introduces several problems:
Slow Production Speed: Manual labor is inherently slower than automated systems. As a result, the company struggles to keep up with the growing number of customer orders. This bottleneck limits the company’s ability to meet deadlines and satisfy its clients, potentially affecting its competitiveness.
Increased Waste Generation: Manual cutting and processing of materials lead to inefficient use of resources. Each step in the process, from cutting wood panels to gluing edges, can produce a high volume of waste, including wood particles, plastics, and resin-based materials. This waste not only represents a loss of valuable resources but also presents a significant environmental challenge.
Challenges with Wood Particle Boards and Waste Management
Custom cabinet furniture, especially when designed to fit customer-specific sizes and preferences, relies heavily on wood particle boards of varying types and colors. Cutting these boards to size is a critical step in the production process, and the company uses format circular saws to handle this operation. However, the current method of cutting creates significant waste for several reasons:
Inefficient Cutting Process: The way the boards are cut leaves large offcuts and unusable scraps. This results in substantial amounts of leftover material, much of which cannot be repurposed and must be discarded.
Waste Containing Plastics and Resins: Both the wood panels and the edges used to seal them are made of composite materials that contain plastics and resins in addition to wood particles. These materials make the waste more challenging to manage, as they do not decompose easily and can pose environmental hazards.
Bulky Waste: The combination of wood, plastics, and resins produces bulky waste that is difficult to store and dispose of. Managing this waste is a significant challenge for the company, as it requires space, handling, and resources for proper disposal. Furthermore, the improper disposal of such materials can become a serious pollutant, contributing to air and soil contamination.
Environmental Impact and Pollution Concerns
The bulky waste generated during the production process poses serious environmental risks. Wood panels and their plastic-resin components do not break down naturally and can have long-term negative effects on the environment. If not properly managed, these materials can release harmful substances into the air and soil, contributing to pollution. Moreover, the high volume of waste increases the company’s environmental footprint, creating challenges for sustainability.
In summary, Kristiyan-Albert Andonov-Todorka Andonova Ltd. faces a dual challenge: improving the efficiency of its production process to meet growing customer demand, and reducing the environmental impact of its operations. The reliance on manual processes and outdated equipment is slowing production and generating excessive waste, which in turn, increases costs and poses significant environmental hazards due to the complexity of managing materials that contain both natural and synthetic components. For the company to remain competitive and environmentally responsible, modernizing its production techniques and implementing more sustainable waste management solutions are essential steps.
Kristiyan-Albert Andonov-Todorka Andonova Ltd. is a small enterprise that specialises in the design, manufacture, and assembly of a wide range of bespoke furniture. The company is committed to delivering high-quality products and services to its clients while striving to enhance production efficiency and minimise material waste.
To accomplish these objectives, the company has invested in new equipment to boost both production capacity and quality. Additionally, Kristiyan-Albert Andonov-Todorka Andonova Ltd. received extra funding within the restricted call aimed at further elevating its competitiveness and refining its production processes.
The company organised three tender procedures for acquiring two machines: an edgebander, an automatic horizontal panel saw, an automatic drilling centre, and an inverter compressor equipped with a dryer and compressed air tank. These tenders were conducted under Bulgarian law adhering to principles of transparency and fairness. The new equipment has enabled Kristiyan-Albert Andonov-Todorka Andonova Ltd. to increase production volume, reduce waste and costs, improve products quality, and enhance customer satisfaction.
The project had a significant impact on the performance and competitiveness of Kristiyan-Albert Andonov-Todorka Andonova Ltd. By acquiring the new equipment, the company was able to improve material efficiency, reduce waste, and enhanced products quality and customer satisfaction. The company also benefited from lower energy and fuel consumption, as well as lower CO2 emissions, due to the improved efficiency of the machines.
After the implementation of the project, the following outcomes were achieved:
29% increase in annual turnover compared to the baseline year 2023;
48% increase in net operational profit compared to the baseline year 2023;
Average 800 kg. annual decrease in the consumption of materials;
Reduction of 4.7 tonnes of CO2 emissions per year, thanks to the waste reduction and energy saving;
Zero-waste production process, as all the material is either used for the products or collected for re-use or recycling.