Walltopia has two manufacturing facilities with a total footprint of over 26 000 m2 factory ground which makes it the biggest production faclity within the climbing industry.
The main factory is located in Letnitza, Bulgaria - a two-hour drive from the company’s headquarters in Sofia. It is focused on the production of climbing walls and volumes. The second factory is located closer to Sofia and is dedicated to R&D, adventure products and flooring.
The main plant opened in 2010 and today it has the capacity to produce up to 100,000 m2/year of plywood panels. Walltopia also has posession of the land surrounding the facility which allows for further extension to meet increased demand levels.
Depending on the work load, there are around 300 full-time emloyees working at the factory.
The climbing walls facility is organized into three main areas:
Iron Shop – construction and assembly of steel frames for the walls with the capacity to process 800 tons of steel per year.
Plywood Panels Shop – this is where the plywood is cut, painted and textured with a capacity to process 100,000 m2 per year. This workshop uses CNC Machines to cut the plywood with laser precision. It also has the latest texturing and painting equipment.
GRP Panels Production –the production center for GRP walls has an annual capacity of 10,000 m2 per year. GRP panels walls offer great durability in all-weather conditions and also allow the shaping of panels in various 3D forms, such as for the Deep Space and Rocktopia wall designs.
As well as these three main areas, there are also several smaller departments: plaster and mold casting, grinding, molding, cutting and volume production.
Depending on order flow the factory works on 2 or 3 shifts to meet the demand of all our clients.