BMZ machines and updated production
13.11.2017BMZ is proceeding on the modernization of the CNC machinery equipment. Company also mastered new technology to produce structural composites that was up until recently reserved for aerospace use only.
Among the new high-tech machines recently put into operation, BMZ out into operation new milling machining center GRATA made by Czech company TOS VARNSDORF. The machine is unique in its kind and has no analogues in the Perm region.
This 25-ton machine allows processing of large-sized products up to 8 meters in length and 3 meters in height in several planes. Automatically controlled GRATA equipment is a combination of wide range of operations: milling, drilling, threading and boring to micron close precision. First, the operator put the piece on a special rotating table, sets the relevant computer program and starts processing. GRATA is already being used for processing of frames and housings for mining equipment.
- It’s a pleasure to work on such equipment. Previously product processing took approximately 3 days using several machine alternately, right now, it takes just a few hours to finish the operation on one single hi-tech equipment. I am glad that technological process is being improved, we receive new orders and specialists improve their skills and professionalism, - said Anton Syromolotov, operator of CNC machine, BMZ mechanical workshop.
New heavy-duty lathe made by Italian company MCM srl. was put into operation in mechanical workshop. Machine processes rotary parts, i.e. shafts, pulleys, hubs and housings up to 5 meters in length and 1 meter in dia. Equipment has Digital readout or DRO unit to achieve high machining accuracy. This lathe significantly improve the manufacturing process, increase performance and therefore reduce final labor costs. BMZ specialists were trained by engineers from manufacturing plant to work on such hi-tech equipment.
For the past two years BMZ had been substantially modernized. 15 multifunctional hi-tech equipment were assembled and put into operation.
Modernization of machinery equipment is continuing under the massive MCC EuroChem invest program.
Modernization of machinery equipment is continuing under the massive MCC EuroChem invest program.
Implementation of industrial technology for composites manufacturing based on newly established workshop is quite significant for Berezniki mechanical works. Pultrusion line is automated continuous production of long profiles: channels, H-beams, angle bars and other complex profiles max. 400mm in width and 450mm in height, profile length is not defined.
Production technology allows producing profiles of fiberglass, basalt fiber and carbon fiber reinforced polymers of different configuration. Finished products, such as stairs, platforms, rail and wire mesh fencing and other auxiliary facilities have a comparatively light weight, high chemical and corrosion resistance, and improved lifetime.
- Pultrusion line ensures continuous production of high quality products. This procedure is carried out after fiberglass preliminary configuration. Fibers are pulled through a special bath with polymer composition. After that a stream of polymeric material is forced through a die to manufacture the proper sample geometry. The whole manufacturing procedure is totally automated and controlled by integrated electronic control system. Russian manufacturers are barely familiar with this technology; however, it is our future, - said Semen Gladkikh, BMZ design engineer.
Total value of new production line is 19 million rubles. The line productivity is 20 meters of fiberglass profile per hour. The company has already produced a trial batch of products: angle of equal legs, square and shaped pipes. Moreover, BMZ has already received its first order for the wire mesh fencing assembly.
According to experts, this production line will be constantly improved. In addition, BMZ is going to organize personnel training to increase the production capacity of composites and finished products. This allows the Berezniki mechanical works to expand the range of its products and enter new markets in chemical, energy, gas and oil industries.
Corporate Newsletter JSC Mineral and chemical company EuroChem 22 edition from November 13th, 2017.