SUPPLIER OF POWER HYDRAULIC EQUIPMENT FOR GENERAL, MINING AND SPECIAL APPLICATIONS

www.agregat-pro.ru

Total area – 32,0 hectares

Total area of the main building – 80,0 thou. m2

including production shops area – 75,0 thou. m2

Amount of machines – 1120 units

General Director

Yevgeny Yegorovich Vainmaer

Year of birth – 1966.

Education – higher.

Started working at JSC Agregatny Zavod in 1984.

In 1999 takes office of Deputy Commercial Director.

In 2002 is appointed Commercial Director.

Since 2008 – General Director of the plant.

“We managed to reequip back in the day and retained our staff. Today it is our best trump card.”

Yevgeny Yegorovich Vainmaer.

Company’s history

• 1967 – on the 5th of April, in accordance with an Order of Machine-tool Construction and Cutting Tool Industry Minister, A. Kostousov, the management of the plant is created.

• 1974 – first production facilities of the main production building are put into operation.

• 1983 – by order of the Machine-tool Construction Industry Ministry, Yegor Yegorovich Vainmaer is appointed director of the plant.

• 1992 – By President’s Decree No. 721 dd. 1.07.1992, Production Association Agregatny Zavod is reorganized into a Joint-Stock Company Agregatny Zavod.

• 1998 – The plant becomes a member of Russian Miner Union.

• 2001– One of a kind powered support КМЛ 220/480 for mine complexes is designed and manufactured at the plant.

• 2004 – The aggregate plant becomes the official supplier of OJSC SUEK.

• 2005 – European Integration Institute proclaims JSC Agregatny Zavod a winner of an international prize European Quality Standard.

• 2012 – several major projects on thorough modernization of production system and reorganization of management system are started at the plant

1967 2012 1983 1998 2004 1992 2001 2005 1974

About our company

JSC Agregatny zavod is one of the leading companies in Russia and neighboring countries specializing in manufacture of power hydraulics for many industry branches and also the largest supplier of hydraulic equipment for general, special and mining applications.

Today, Agregatny zavod is a fast developing company. The level of production organization and techniques used allow us to successfully compete with leading foreign companies.

Machinery equipment of the plant that includes modern machining centers produced by international concerns in Germany, Japan and the USA allows to manufacture parts of different dimension types in shortest time possible and with guaranteed high precision. Company resources include the entire manufacturing cycle, from creation of design solution to output of the finished product.

The company has extensive experience in product manufacture according to customer’s drawings with the use of machine working, welding works, heat treatment and electroplating.

Production processing capabilities

Processing type Maximum dimension types

1. Turning 900 mm, L=4000 mm

2. Milling В=1000 mm, L=3000 mm

3.

Grinding of surfaces:

outside

inside

350 mm, L=3000 mm

360 mm, L=360 mm

4. Boring, rolling of liner type parts 40÷380 mm

L=1000÷3500 mm

5. Thermal cutting (B×L×h) 2500х6000×200 mm

6. Bandsaw machines 510 mm, □500×800 mm

7.

Heat treatment:

- volume: annealing, quenching, refinement, etc.

- surface: carbonization, HFC quenching

1000 mm, L=3000 mm

260 mm, L=2000 mm

8.

Electroplating:

- hard and decorative chrome (rods)

- cadmium plating, galvanizing

- inside chrome plating of liners

L=3000 mm

80÷220mm, L=1000 mm

9.

Plant’s machinery equipment (1200 units of equipment including machines with CNC –

180 units) allows to manufacture parts of different dimension types in shortest time

possible.

Blank preparation shop and assembly-welding production

• Installed equipment allows to machine blanks up to 500 mm including bandsaw machines up to 510 mm and □500×800 mm, straightening and polishing machine up to 90 mm.

• A thermal cutting machine Messer is equipped with a state-of-the-art CNC system GLOBAL CONTROL S which allows shape cutting of plates with the thickness from 1,5 to 160 mm with high accuracy of linear dimensions, any curves and coordinates up to ±0,1 mm.

• Guillotine-shears with cutting thickness up to 32 mm. Plate-bending machines of 100 ton-force. Sheet stamping presses of 250 ton-force.

• Hoisting-and-conveying equipment (up to 15 tn), industrial approach railways are in place.

• Processing capacity of the shop is up to 1200 tn of rolled products per month.

MultiTherm 4000 Messer

Meba

Cylinder production Spinner Romi Mori Seiki DMG

Process capability allows to manufacture hydraulic cylinders with the inside diameter of a liner from 40 to 390 mm and the stroke of up to 2600 mm. For such purposes, there are special boring, turning and cylindrical grinding machines with machining length of up to 4000 mm, as well as high-precision lathe machining centers. Welding of submerged hydraulic elements is carried out with the help of Migatronic welding machines FLEX 4000. Automatic submerged-arc welding is widely used.

Motor production

Process capacity of the shop and workers qualification make it possible to manufacture complex parts with cylindrical and spherical surfaces and to carry out necessary works for the entire production chain of pumping stations, pump units, hydraulic motors, hydraulic couples, hydraulic drives. The shop is equipped with a wide range of universal equipment for precision working of prismatic parts and includes sections of high-precision hydraulics and finishing.

• Thermal plating shop is equipped with shaft and chamber furnaces, as well as other necessary equipment, for quenching and straightening of liners and rods with the length of up to 3000 mm, two-layer (“decorative” and “hard” chrome – 24 µm) chrome plating of rods and inside chrome plating of liners with the length of up to 3000 mm, and also for cadmium plating, galvanizing, phosphatizing, etching and carbonization of part surfaces.

• The plant has adopted an absolute rule that there should be 100% control of all manufactured products at the control and test station.

• Additional production facilities include finishing-paint shop, tool shop and mechanical repair shop.

• Company’s laboratories have equipment for carrying out of inspection tests, compliance checks of process operations, air, drain, discharge monitoring, etc.

Additional process capacities

Products for mining applications

Powered supports, hydraulic props and hydraulic jacks for powered supports, bottom-hole hydraulic props, pumping stations, emulsion preparation stations, pumping installations for water injection into a coal bed, high-pressure spraying stations, radial piston pumps, hydraulic couples for shearer-loaders, hydraulic motors, gateway pipelines, hydraulic drives for mine transport systems, accumulator banks, compressor line filters, pressure relays, hydraulic valves.

General machine-building products

During 45 years, the company has been involved in engineering and production of hydraulic and pneumatic cylinders for different types of machinery including: • hydraulic cylinders for general machine-building applications;

• hydraulic cylinders for truck-mounted cranes, arms, waste trucks; • hydraulic cylinders for special equipment, machine-tool hydraulic

cylinders according to Industrial Standards; • hydraulic and pneumatic cylinders for railway machinery.

Production and process capabilities of the plant allow to manufacture 15 thou. cylinders per month with piston inside diameter from 40 to 380 mm, stroke up to 2600 mm, operating pressure up to 70 MPa.

Seals of European production are used: BUSAK, Shamban (Sweden), Polypac (Italy), Simrit (Germany), Merkel (Germany).

General machine-building products

Hydraulic high-torque radial piston motors: МРФ and 1МР16С; pneumatic hydraulic accumulators АРХ, АРФ, АПГ-Т and chargers АР-04/320.040А; pumping installations: УН, УНМ, 1УНМ (designed for charging operating fluid flow of constant force and direction into hydraulic systems and machines and for feeding them); multiphase pumping installations; hydraulic drive stations.

Special products

For over 15 years JSC Agregatny zavod has been a leading Russian company in production of round section anchor ties designed for anchoring face walls of berthing facilities at sea and river ports, dams, levees and other hydraulic engineering constructions.

Production capacities of the company allow to monthly produce up to 1200 t. of complete anchor ties in accordance with ТУ6411-008-00221058-98 designed and agreed together with OJSC LENMORNIIPROEKT, St. Petersburg.

Location and infrastructure

• The company is situated in a large industrial center of Kaluga Region – town of Lyudinovo

• In 80 km from the nearest regional center – city of Bryansk

• In 30 km from federal significance highway “Moscow-Kiev” (М3)

• Private railways leading to Lyudinovo-1 station are in place. Existing freight turnover: 1-2 carriages per day

• Height of industrial buildings in front of the crane runway 8,2 m.

• Height of gates in production and storage rooms is fit for trucks

Possible use of production capacities and facilities. Address of free spaces 13, Chernyakhovskogo St., 249400 Lyudinovo, Kaluga Region

Area of production (including storage)/office rooms

(m2) 30000/11000

Bay (m) 6

Floor load (ton/m2) 3,5-4,0

Hoisting machines: Bridge cranes (max. carrying capacity 15 tn)

Power supply:

(mW) fed/reserve 50/30

Gas supply:

(m3/year) 246000

Pressure (bar) 4

Water supply/drain

total (m3/day) 880,9

Drinking water (m3/day) 97,3

Possible increase of drinking water, reserve (thou.

m3) 70

Process water (m3/day) 783,6

Possible increase of process water through use of

storm discharge (thou. m3) 29

Drainage of utility fluids (m3/day) 787,7; limitless drainage

Possible joint development of the company Preferable production types:

automated production lines with around-the-clock work mode and minimum of service personnel

Undesirable production types:

hazardous industry, production similar to that of the plant

Possible forms of relationship with potential partners:

joint venture

rent of space

other forms depending on particular activity of potential partners

We invite you to mutually beneficial and long-term cooperation!

www.agregat-pro.ru