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“Balkancar-Zarya” AD launches a project aimed at developing an innovative process for the production of rims — a key component of steel disc wheels for industrial vehicles. Project BG16RFPR001-1.001-0060-C01 is financed under the “Competitiveness and Innovation in Enterprises” Program 2021–2027 and will be implemented over 18 months at the company’s production site in Pavlikeni.
The project falls under the thematic area “Clean Technologies, Circular and Low-Carbon Economy” of Smart Specialization and represents a national innovation. The innovation involves the development of a new manufacturing process based on plastic deformation of thin-walled welded steel tubes using the direct extrusion method to obtain high-precision blanks for the rims.
The overall goal of the project is to increase the company’s innovation capacity through the implementation of a production process with higher efficiency and technological maturity. In line with European policies for a smarter and circular economy, the project supports industrial transformation, modernization, and digitalization in mechanical engineering.
The expected outcome is to reach TRL 7 — a prototype demonstrated in a real production environment, creating conditions for future serial production and improved market positions for the company in both national and international markets.
The development of the production process includes experimental development, which is an integral part of industrial innovations. The project foresees:
Design and fabrication of a prototype tooling set — die with matrix and punch
Analytical and engineering modeling of key technological parameters
Creation of a pilot line for test production
Multi-stage testing, measurement, and optimization of obtained results
Production of trial series with control of repeatability and compliance with standards
The process is supported by qualified specialists, the use of the company’s own equipment and materials, as well as the engagement of external experts for specialized activities.
The implementation of the project will result in a new production process developed to an operationally applicable level (TRL 7), as well as improved resource efficiency and waste reduction in line with circular economy principles, and last but not least — an increased innovation capacity and higher competitiveness for “Balkancar-Zarya” AD.