Lyudinovo 2012
TYPES OF PRODUCTS
Production facilities The Company has two main foundries: Foundry No. 2 produces grinding bodies of 40 and 60 mm diameters for GOK (Ore Mining and Processing Enterprises), shaped pieces for sewage systems in accordance with GOST 6942-98 and cast iron hatches against order of NORDIC CAST SOURCING LTD (Finland). Foundry design capacity is 57 000 tons of cast-iron per year.
The Pipe casting plant produces cast-iron drain pipe according to GOST6942-98 of 50, 100 and 150 mm diameter, wash basin brackets, sinks, radiators, storm water drainage products in accordance with BS460 against order of Hargreaves Foundry (UK), drains and manways, drain covers, including hatches against order of Fa. Schachtguss GmbH (Germany) and counterweights against order of JONH DEERE (USA). Currently the pipe casting plant design capacity is 34 000 tons of cast-iron per year. Foundries are equipped with all necessary amenities. The Company has a number of service shops to ensure the smooth operation of the line working.
Engineering Solutions The following modern engineering methods are implemented by the Company: - production design and tools with 3D modeling systems; - engineering analysis of possible casting defects by computer modeling of casting processes;
Quality assurance In 2009, the Central Laboratory of the Company (CLC) was equipped with an optical emission spectrometer SPECTROMAXx F (Germany), and established metallographic laboratory based on metallographic microscope Altami MET 1M and hardware and software complex ImageExpert Pro 3. It allows in a short period of time to make all the necessary analysis to a high precision for manufacturing process and work upon it in a timely manner thus delivering the highest standards of quality.
Foundry No. 2 Step by step modernization of the molding area in foundry equipped with a help of our own resources based on the existing jolt-squeeze molding machine made in the 50s working on the principle of jolting with pre-molding enables at the first stage: to increase the working length of casting conveyor (it has a positive impact on the capability), replace one of the mixers (1973 year of manufacture) to the modern mixture complex of vortex type made by VMZ OJSC (that allow to improve the quality of molding sand and reduce the number of emergency downtimes). At the second phase the replacement of the morally obsolete mold equipment to the automatic molding machine type HSP 3D made by HWS was carried out. At the present time the development of flask molding and attainment of production capacity of working area is under way. Solving of these problems enabled to approach the third phase of the foundry modernization without significant interruptions of production process.
Core shooter Compact 5, production of company Omega Foundry Machinery (on the left) and chemical composition rapid tester, production of company Omega Spectromax (on the right)
The following third stage of foundry development involves the purchase of transportation systems, automation equipment and knock-out machines and their integration to the existing molding machine HSP 3D and automatic molding setting up line with scheduled capacity up to 50 complete forms per hour. At the same time sand preparation department will be modernized. The total project cost is 86.5 million rubles. Molding line: Molding line:
The implementation of this project will enable to develop new types of castings for Holding Companies that produce flask moldings with clear dimensions equal to 1000.800.300/300 mm the next target of this area will be the production of cast iron hatches according to standard EN 124 for consumers in western and northern Europe. Recent talks with NORDIC CAST SOURCING LTD (Finland) have demonstrated that this Company is ready to increase the volume of purchases on the existing nomenclature up to 60% (up to 110 tons per month). Besides, it will enable to place orders for new types of products in the amount of up to 40 tons per month. In addition, our other partner Fa. Schachtguss GmbH (Germany) has repeatedly expressed his desire to place additional orders with our Company (up to 170 tons per month) for casting iron hatches. There is a preliminary agreement with Big Dutchman (Belgium) to supply grids for storm water runoff. However, at present the lack of available facilities of molding does not allow to implement these orders. But the main objective of the project is the entry into the fundamentally new markets of high level casting, such as the production of electric motors and automotive castings. After all, this technology permits casting of: 4-5th complexity groups, up to 7th grade of accuracy, up to 9th surface accuracy degree, up to 7 tons of mass precision, roughness of up to 16 units in Ra values.
Foundry conveyor No. 9 on the basis of automatic molding line HSP3D production of German Company Heinrich Wagner Sinto
Pipe casting plant The purchase of continuous mixer Q that produces 3-6 tons per hour of molding sand on Cold Hardening Mixtures of OMEGA in 2011, as well as molding sand pneumatic conveying system to it enabled to master this technology by now. Also it enabled to learn how to make model kits, train staff and prepare the ground for further development of the plant in the selected direction. Besides to implement the project into the pipe casting plant there were created areas shot- blast cleaning based on the shot-blast unit GOSTOL-TST (January 2012) and heat treatment cell of castings based on furnace SNOL (April 2012 year.) The next stage of plant development focused on castings production growth in nomenclature, developed during the first phase. Taking into account the generality of technology and interest of the Company’s owners, the basis for the production program should be the orders from Holding Companies.
For implementation of this phase AFL unit produced by OMEGA FOUNDRY MACHINERY LTD (UK) on Cold Hardening Mixtures in the territory of Pipe casting plant is planned along with the solution of issues related to the organization of mobile production. This equipment will enable to make forms of molding plate with dimensions of 1600x1200 mm and 475 mm of maximum height, with a capacity of up to 8 complete forms per hour. This equipment has been purchased and delivered to the Company. At present the completion of design works is under way and construction and installation works and non-standard equipment production that not included in delivery (bunkers, pneumatic transport lines and intermediate conveyers etc.) are started in parallel. Commissioning of the line is scheduled for the second quarter of 2013. On this line will be possible to have castings of: 4-5th complexity groups, up to 6th grade of accuracy, up to 8th surface accuracy degree, up to 7 tons of mass precision, with roughness of up to 10 units in Ra values.
To implement all the production capacity of purchased equipment for the Pipe casting plant the issue of providing the area with hot-metal by organizing of induction melting area is to be settled. For this purpose the reconstruction of high- voltage cable line and purchase of two induction melting furnace with 3 tons crucible capacity is planned in 2013. The total cost of the project is 58 million rubles. In future, in case of necessity to increase the metallurgical capacity of the plant the possibility to install another melting unit under the modular approach is provided.
Our Company is situated in Lyudinovo, 330 km south-west from Moscow. The facility covers the area of 17,000 m2. Our highly qualified personnel is ready for further work in a very demanding, but growing market.
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