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БАЛКАНКАР-ЗАРЯ АД

Balkancar Zarya
A Remarkable History and an Important Role In the Forklift Manufacturing Sector

60 + Years of Balkancar ZARYA

We present a concise and chronological overview of the history of Bulgaria’s single enterprise specialized in steel wheels and rims manufacturing, outlining the key milestones and achievements of the company throughout its development. The history of Balkancar ZARYA is a story of perseverance, proven professional experience, and continuous improvement. Today, the company remains a leader in its sector, providing high-quality solutions to clients worldwide.

Thank you for being part of this journey!

Founding and Early Years (1961–1970):

Founding and Early Years (1961–1970):

Balkancar ZARYA began operations in Pavlikeni with state support and Soviet technology. The plant was established to meet the national demand for wheels and rims for all types of vehicles. The first rim was produced in the autumn of 1966.

  • October 28, 1963: The Council of Ministers issues Decree No. 787 for the construction of a State Forge-Press Plant for Rims.
  • February 28, 1964: Decree No. 49 of February 21 is published in State Gazette No. 17, establishing 14 enterprises under the Committee for Mechanical Engineering, including the State Forge-Press Plant for Rim Manufacturing in Pavlikeni.
  • March 1, 1964: The company “State Forge-Press Plant” – Pavlikeni is formed, marking the beginning of today’s “Balkancar ZARYA” JSC.
  • August 1966: First rim model 59-74 (4.00E-9) is produced for a 2-ton electric truck.
  • March 15, 1967: Renamed to Machine-Building Plant “ZARYA.” 113 people are employed. The first batch-type automotive rims (3.75R-13) enter serial production.
  • February 17, 1967: A contract is signed with French company OLLIER for comprehensive equipment for 9 production lines.
  • July 29, 1968: Groundbreaking for a new plant building. Production of rim models 6010-1 and 6012-2 (5.00S-12) begins, crucial for Bulgarian electric and forklift truck production.
  • 1970: Business relations are established with the Kremenchug plant (Ukraine), developing into productive cooperation and technology transfer.

The Golden Years (1971–1989):

The Golden Years (1971–1989):

During this period, the Machine-Building Plant “ZARYA” became integrated with the electric truck plants of the “Balkancar” State Industrial Enterprise, which peaked as one of the largest producers of lifting and transport equipment in the Eastern Bloc. In 1988, Bulgaria produced one-fifth of the world’s electric and forklift trucks, ranking first globally in per capita production (82,500 units annually).

Machine-Building Plant “ZARYA” was the sole producer and supplier of rims for all "Balkancar" branded vehicles.

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  • April 2, 1971: The new building of Machine-Building Plant ZARYA is officially opened.
  • 1977–1980: R&D activities lead to the development and mastering of new wheel sizes ranging from 8 to 15 inches, along with new production lines for wheel rims.
  • 1981: Annual production capacity reaches 485,000 wheels.
  • June 1981: A department is established at the Engines and Automobiles Laboratory in Sofia (LADA), to legally certify and test the wheels produced by the plant.
  • 1981: Completion and commissioning of an expanded compressor station. Pilot operation of a powder coating facility for wheels using epoxy paint begins. New CNC lathes are installed. A water treatment plant is built.
  • April 1983: A mechanical maintenance workshop is established, with specialized teams for emergency, routine, and major repairs.
  • 1984: In its 20th anniversary year, the plant employs 23 engineers, 76 technicians, 12 specialists with higher education, and 184 professionals with mid-level education.
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Transition and Challenges (1990–2000):

Transition and Challenges (1990–2000):

With the onset of the transition to a market economy, the company faced numerous challenges and changes. Despite the difficulties, Balkancar ZARYA managed to maintain its position in the market due to the high quality of its products.

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  • November 25, 1993: By Order No. 125/25.11.1993 of the Council of Ministers, a sole-owner limited liability company named “Balkancar ZARYA” is established—this is the name under which it continues to operate today.
  • January 21, 1994: The company, with the state-owned “Balkancar Holding” JSC as its sole owner, is registered in court under file number 171/1994.
  • June 26, 1996: The company is transformed into a joint-stock company and registered with the Veliko Tarnovo Regional Court under file number 1029. Over 1,000 individuals become shareholders.
  • May 19, 1998: “Balkancar ZARYA,” now a joint-stock company, is listed on the Bulgarian Stock Exchange–Sofia, beginning public trading of its shares.
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Modern Era and Future (2000–Present):

Modern Era and Future (2000–Present):

At the beginning of the 21st century, Balkancar ZARYA continues expanding its presence in international markets. Over the years, the company undergoes restructuring and modernization, implementing new technologies and standards. Balkancar ZARYA commits to sustainable development and corporate social responsibility, adopting eco-friendly and energy-efficient technologies while supporting local initiatives.

  • May 2005: The factory is successfully privatized, with 100% of the company’s capital now privately owned. The 2010+ strategy “Moving Forward” is introduced, aiming to position the company as a premium supplier of wheels and rims to leading forklift and tire manufacturers, enjoying an excellent international reputation.
  • November 2005: The company's own trademark “ZARYA” is filed for registration, along with the verbal mark “Moving Forward.”
  • August 2006: The company receives the DIN EN 729-2 (now EN 3834-2) certification, proving the implementation of a quality control system and qualified personnel for welding and related operations.
  • March 2007:–Together with the UK-based Watts Tyres Group, the company establishes WattsZarya—targeting the market with a complete solution of wheel and tire assemblies for OEM deliveries.
  • June 2007: Launch of a project to implement an integrated business management system—SAP “All-in-One” project.
  • September 2007: Acquisition of a majority stake in Balkancar RUEN AD, a company within the structure of “Balkancar Holding.”
  • June 2009: Finalization of the ERP system implementation with the “Go Live” stage of the SAP project.
  • October 2009: Acquisition of an additional stake in Balkancar RUEN, raising direct and indirect ownership above 96%.
  • October 2010: New capital is subscribed and fully paid through a public offering of 1,081,900 new shares in the capital increase of Balkancar ZARYA.
  • February 2018: Project launch to enhance Balkancar ZARYA’s competitive advantages and sustainability through investment in energy-efficient technologies. New energy-saving production equipment and heat recovery systems are acquired. An automated energy consumption monitoring system is introduced.
  • December 2018: Start of a project for implementing a pilot resource-efficient production method and product innovation at Balkancar ZARYA AD. Equipment is introduced to reduce raw material use and improve waste management in existing production.
  • August 2020: The company holds a press conference to disseminate the results of the pilot project on resource-efficient production and product innovation at Balkancar ZARYA AD.
  • May 2023:Balkancar ZARYA AD begins implementing the project “Technological Modernization in the Enterprise” under financing agreement No. BG-RRP-3.004-1483-C01, within the BG-RRP-3.004 “Technological Modernization” procedure, supported by the EU through the National Recovery and Resilience Plan and Next Generation EU.
  • March 2024: The factory celebrates its 60th anniversary as a recognized supplier of high-quality, reliable OEM products. It offers a complete production range from a single trusted source, with unmatched flexibility and seamless communication. Customer-oriented solutions in chassis manufacturing help OEMs tackle growing challenges and achieve their sustainability goals with confidence.