Development of design documentation for a full-cycle foundry complex with a capacity of 55,000 t/year, taking into account technological processes, environmental requirements, and implementation conditions.
Integration of all engineering systems, consistency of solutions, and preparation of the project for expert review and subsequent implementation were ensured.

[00] FOR WHOM
The company operated a production line with a capacity of 800 t/day and considered expansion as part of a long-term growth strategy.

[01] CONTEXT
The client required the creation of a new full-cycle foundry production for manufacturing cast iron castings with specified quality and performance parameters.

The project implied the formation of a technologically balanced structure, taking into account environmental, engineering, and operational requirements.

[02] OBJECTIVE
To design and prepare for construction a foundry complex with a capacity of 55,000 tons of cast iron castings per year.

[03] SOLUTION
Basic engineering and design documentation for a full-cycle foundry production with integration of all technological and engineering systems were developed.

The structure of key production sections was formed:

— melting section

— raw material preparation section

— core making section

— molding mixture preparation section

— pouring and cooling section

— casting cleaning and fettling section

Additionally, the following engineering systems were implemented:

— gas cleaning system

— water treatment system

— waste management system

[04] RESULT
A technologically balanced scheme of a full-cycle foundry production was formed. Design documentation for implementation and subsequent construction of the facility was prepared. The calculated production capacity of 55,000 tons of castings per year was ensured.

A project for organizing an assembly production of armored vehicles was implemented with a full cycle of works — from preparation of production infrastructure to commissioning of the facility. Within the project, development of technological solutions, organization of welding and assembly of hulls, as well as coordination of all implementation stages with control of timelines and quality were ensured.

[00] CUSTOMER
State-owned enterprise of defense machine-building industry
Republic of the Union of Myanmar, Meiktila

[01] / CONTEXT
The customer was forming a production site for serial assembly of armored vehicles from scratch in the absence of existing infrastructure.

It was required to ensure industrial accuracy of welding of armored structures, control of geometry and strength characteristics, as well as the possibility of scaling production.

[02] OBJECTIVE
To create a welding and assembly complex with technology, equipment, and infrastructure ensuring the launch of serial production of armored hulls.

[03] SOLUTION
A technological project was developed and infrastructure was designed taking into account requirements for structural rigidity,
control of welding deformations, and industrial safety.

Within the project, the following were implemented:

— construction of a welding and assembly workshop

— preparation of sites for production expansion

— organization of zones for mechanical finishing and control

— implementation of universal assembly and welding lines

— development of a technological production scheme

[04] RESULT
A specialized production facility was created and put into operation.The possibility of scaling the production program and manufacturing several types of equipment was ensured.

Serial production of armored hulls was launched.

A project for modernization of glass production with an increase in capacity to 1600 t/day was implemented. Within the project, design and implementation of a new technological line were carried out, as well as integration of infrastructure and warehouse systems without stopping the main production.

[00] FOR WHOM
LLC “Pilkington Glass” — an operating industrial enterprise of the glass industry.
The company operated a production line with a capacity of 800 t/day and considered expansion as part of a long-term growth strategy.

[01] КОНТЕКСТ
Growth in demand for products and the company’s strategic plans required doubling the production capacity. The project was implemented at an operating enterprise, which imposed critical constraints: scaling had to be carried out without stopping production and without loss of technological stability.

The task was complex in nature and affected production, energy, logistics, and warehouse infrastructure.

[02] OBJECTIVE
To increase the total plant capacity to 1600 tons of glass per day through the construction of a new production line and creation of supporting infrastructure.

[03] SOLUTION

A comprehensive project of modernization and expansion of the enterprise was developed and implemented, taking into account requirements of industrial safety and continuity of production.

Within the project, the following were carried out:

— design and construction of a new production line with a capacity of 800 t/day

— integration of the new line into the existing production and logistics system

— construction of a finished goods warehouse

— creation of additional energy facilities

— reconstruction of the operating enterprise

[04] RESULT
The production capacity of the enterprise was increased by 100% — up to 1600 t/day.
A new production line with full engineering and energy infrastructure was created.
Stability of technological processes during scaling was ensured.

[05] STRATEGIC EFFECT
A production configuration enabling further development without structural limitations was formed.
Scaling was carried out without loss of operational stability, which is critical for capital-intensive industrial assets.
A platform for further growth and strengthening of the enterprise’s market positions was created.

[00] FOR WHOM
OOO “ZARAFSHON OYNA”, Republic of Uzbekistan, Zarafshan
JSC “AzerFloat”, Azerbaijan, Sumgait

Industrial enterprises of the glass industry focused on creating their own production base and reducing dependence on imports of flat glass.

[01] CONTEXT
Within the development of the glass industry in the region, it was required to create new production capacities from scratch.The projects implied the formation of full-fledged industrial complexes with integration of technological, engineering, and logistics systems in accordance with international standards.

[02] OBJECTIVE
To create modern float glass production plants with a capacity of 250 tons per day with full production and engineering infrastructure.

[03] SOLUTION
A comprehensive project for the construction of glass plants with the involvement of international technological expertise was implemented.

Within the project, the following were carried out:

— installation of a float glass production line

— construction of production buildings

— creation of a nitrogen and hydrogen production station

— construction of diesel fuel storage facilities

— development of railway and road infrastructure

— integration of all engineering systems into a unified production structure

[04] RESULT
Float glass production plants with a capacity of 250 t/day were commissioned.Stable and continuous operation of the technological process was ensured.

A full production and engineering infrastructure was created.

[05] STRATEGIC EFFECT
Modern centers for flat glass production were formed in Uzbekistan and Azerbaijan.
The level of dependence on imports was reduced.

A sustainable industrial base for the development of construction and processing industries of the region was created.

[00] FOR WHOM
LLP “KAZZINCMASH”, JSC “KAZZINC”, Republic of Kazakhstan, Ridder
PJSC “Novolipetsk Metallurgical Combine”

Operating metallurgical enterprises implementing programs of technological modernization and improvement of environmental efficiency.

[01] CONTEXT
Existing production capacities required renewal of melting equipment and modernization of off-gas cleaning systems.
Key tasks included increasing the reliability of the melting process, ensuring compliance with environmental requirements, and integrating new equipment into the existing workshop infrastructure without stopping production.

[02] OBJECTIVE
To increase production efficiency and environmental sustainability of steelmaking production through the installation of a new melting furnace and the creation of a modern gas cleaning system.

[03] SOLUTION
A set of technical solutions was developed and implemented, taking into account industrial safety requirements and continuity of the technological process.

Within the project, the following were carried out:

— installation of a new melting furnace with a capacity of 6 t

— integration of equipment into existing energy and technological schemes

— installation of Softplim filters, exhausters, and a gas duct system for EAF No. 4

— construction of a gas cleaning unit

— creation of a new transformer compartment

— technical modernization of the existing production workshop

[04] RESULT
The melting capacity of the enterprise was updated.
The system for removal and cleaning of off-gases was modernized. Emission reduction and compliance with environmental standards were ensured.
The reliability of the energy infrastructure was increased.


[05] STRATEGIC EFFECT
A technological basis for the sustainable development of melting production was formed.

Environmental risks were reduced and the investment attractiveness of the enterprise was increased.
Readiness for further capacity expansion without structural limitations was ensured.

[00] FOR WHOM
PJSC “Kryukovsky Railway Car Building Works”
Ukraine, Kremenchug
A large enterprise of railway engineering, focused on expanding production capacities and manufacturing freight and passenger railcars.

[01] CONTEXT
The enterprise required the creation of a modern production complex with a high level of technological equipment.
The project provided for the formation of a full production chain — from welding to painting and final preparation of rolling stock.

[02] OBJECTIVE
To create a welding and assembly complex with integrated technological lines and auxiliary infrastructure for serial production of railcars.

[03] SOLUTION
A set of engineering solutions was developed and implemented, taking into account industrial safety requirements and continuity of the production process.

Within the project, the following were carried out:

— installation of universal assembly and welding lines

— integration of auxiliary technological facilities

— installation of a washing and drying chamber for railcars and locomotives

— construction of a robotic shot blasting chamber

— creation of a painting production facility

— construction of a new welding and assembly workshop

[04] RESULT
A modern welding and assembly complex was commissioned.
An integrated production environment with a high level of automation was created.
Technological readiness for serial production of railcars was ensured.

[05] STRATEGIC EFFECT
A scalable production platform was formed, increasing the competitiveness of the enterprise.
Resilience to changes in the structure of orders and the product model range was ensured.
A basis for further development and expansion of production capacities was created.