"Metalik" AD starts a project for energy efficiency of industrial processes with the support of the EEA Financial Mechanism

In May 2023, "Metalik" AD started the implementation of a project, realized with the financial support of the Financial Mechanism (FM) of the European Economic Area (EEA) 2014-2021 under the Memorandum between the Republic of Bulgaria and the Republic of Iceland, the Principality of Liechtenstein and the Kingdom of Norway, under the Operational Programme "Renewable Energy, Energy Efficiency, Energy Security", Priority Axis "Improved Energy Efficiency in Buildings, Industry and Municipalities", Procedure BGENERGY-2.003 "Energy Efficiency in Industry".

The Financial Mechanism provides a grant of BGN 389 760, representing 58% of the total project cost of BGN 672 000. 

The period for the implementation of the project is from 19.05.2023 to 30.04.2024.

With the project funds a new beveling and seam preparation machine for welding, as well as an automated energy monitoring system will be purchased and commissioned. The machine will replace two obsolete machines – an edge milling machine model - MC 7820, manufactured in 1993 with an installed power of 34.5 kW, and a horizontal milling machine (Russian milling machine) model - 6М610Ф1, which is used to make bevels (preparing the edges of workpieces for welding), which was manufactured in 1976 and operates with an installed power of 45 kW.

The implementation of the project will result in at least 3 times energy savings for the industrial process activity. The cost per product unit will be reduced, and the production capacity for these activities will increase by a factor of about 6, from 2,800 t/y of metal structures now to 12,600 t after the completion of the project.

All this will be achieved in a sustainable way, with a reduction of the energy used and the CO2 emissions generated, in line with the objectives of the Programme and the Financial Mechanism. Existing positions will be preserved and new ones will be created, while also improving working conditions.

The current limited production capabilities are impacting the company's ability to accept a significantly larger volume of orders, as well as meet the ongoing customer-required timelines. For this reason, the company cannot offer competitive prices for its products.

Preparatory operations require higher productivity and precision, whereas currently part of the operations are carried out on machine tools and CNC machines, others on an edge milling machine. A significant part of them also by hand - with hand-held angle grinders. This makes difficult and delays the production of the final products.

The edge milling machine and the horizontal milling machine (Russian milling machine) are obsolete and their work is accompanied by a lower quality of the processed surfaces and frequent breakdowns leading to long downtimes. With the available technology, a machining throughput of 150 kg/h is achieved.

The existing machines used to perform manufacturing operations have very high specific energy consumption and low productivity. The equipment is very old, limited in capability, depreciated, energy inefficient and operating at a low accuracy level, requiring replacement.

To overcome the above problems, the energy audit recommends replacing the machines with a universal machine for bevel grinding and seam preparation for welding.

It is recommended to install the latest generation of metalworking machine, high-tech, high-performance and with improved energy efficiency, leading to lower specific energy consumption. All this will increase the functionality and overall manufacturing efficiency of the industrial process. Accordingly, the CO2 emissions generated will also be significantly reduced.

Download documentation for participation in the auction /in Bulgarian/ from here