SU-155 Company Group

Modernisation increases the output capacity of an SU-155 Group plant by 26%

On 25 October, SU-155 Group completed one of the first stages of its project to modernise its own manufacturing facilities. It held the grand opening of a new production line for manufacturing reinforced concrete panels at the Odin­tsov­­o factory "Stroyindustriya"­­. Guests at the event also had the opportunity to see the production department which manufactures sanitary cabins and ventilation units. A robotic production line made by Vollert (Germany) became the basis for the new concrete goods manufacturing line. The new equipment increased the factory's total production output by 26%, and reinforced concrete goods output alone by 24%. The group invested 932 million roubles overall in modernising these production departments.

The opening ceremony was attended by Mikhail Mien, the Minister of Construction, Housing and Utilities of the RF; Vladimir Resin, Deputy of the State Duma of the RF; Andrei Ivanov, head of the Odintsovo District Council; Mikhail Balakin, Chairman of the SU-155 Group Board of Directors; and the management of the Stroyindustriya factory. Guests at the event acquainted themselves with the details of manufacturing and triumphantly launched the core of the factory's manufacturing power – a flexible robotic circular production line made by the Vоllert company (Germany), which provides a means to manufacture internal walls, ceilings and other surfaces of various geometric sizes.

Mikhail Mien noted to the guests: "In Yekaterinburg, a large meeting was held under the direction of the Chairman of the Government to discuss modernisation and the application of newly available technologies. Today, all manufacturing sectors are tasked with creating reference books on the technologies which should be used in various manufacturing sectors, including the housing and utilities sector. Here today, we see an excellent example that can be used to show just how factories in our construction sector need to be modernised. Today's panel housing construction, made possible by the machines we see now, serves as an example of modernised manufacturing and of what it's effect will be - homes of a completely different type and quality."

The main advantage of the new production line is its ability to quickly change the shape of the product without stopping and without reconfiguration. Manufacturing reinforced concrete products using robotic form setting technology provides variety and the ability to quickly change the shape of manufactured products. It reduces the influence of human error and guarantees that the finished product will be maximally compliant with standards. The high accuracy of automatic form setting means that the manufactured parts can be used to build structures with joint widths of no more than 4 mm between plates.

"We meet today at one of the factories where parts will be made for homes which, although they are industrially manufactured, can look completely different from each other. You wouldn't think they're industrial homes to look at them. This is a great step forward." said Deputy of the State Duma of the RF Vladimir Resin.

Mikhail Balakin, Chairman of the SU-155 Group Board of Directors, listed the new production line's three main advantages: "These production lines represent a leap forward in industrial housing construction – they provide a means build unique and individual homes out of panels. The second advantage is that by launching this kind of manufacturing, we solve the problem of joints. The joints used provide a way to build quickly, cheaply, and qualitatively. Last but not least, the third advantage – this production line is eight times more efficient."

Mikhail Balakin also noted that the launch of the new production line will create many jobs for highly qualified professionals in the Moscow Region, who will receive a salary of around 60 thousand roubles.

The new Vollert manufacturing line was the first of five that SU-155 Group will install in 2014. In the near future, commissioning and start-up will be complete in two factories in Tula (Tula DSK, two production lines) and Klin (KPSK, two production lines). The products of these updated factories will supply the necessary quantity of qualitative and cost-effective building materials for the federal program "Homes for Russian Families" and for the construction of fundamentally new economy-class real estate – "City" category housing in European individual projects. The first three residential complexes in this category began their construction in Moscow and the Moscow region in 2014.

Another innovation introduced during the "Stroyindustriya" factory's modernisation was the production of sanitary cabins from gypsum concrete. These products are used in the construction of mass-produced panel houses. The production line's capacity now amounts to 60 cabins per day. The reconstruction reduced the cost of sanitary cabins by 19% on average (24.4 thousand roubles versus 30.1 thousand roubles previously).

The third technology introduced during the factory's modernisation was the production of ventilation units from gypsum concrete. The productive capacity of these products' manufacturing line now amounts to 19,800 m3 per year. This technology resulted in a 13.8% reduction of production costs (4.2 thousand roubles/m3 versus 4.7 thousand roubles/m3 previously).

In total, SU-155 Group invested around 932 million roubles in updating the factory's manufacturing processes, which included spending 210 million roubles on imported equipment and 85 million roubles on equipment of SU-155 Group's own make. The investments in reinforced concrete production are expected to pay for themselves in 5.8 years, and the investments in manufacturing equipment for sanitary cabins and ventilation units – in 3.5 years.

Developing the industrial base is a necessary measure in order to provide the market with fundamentally new panel housing construction technologies and challenge Russian preconceptions of economy-class housing. At the beginning of 2013, SU-155 Group began a programme aimed at re-equipping its industrial factories in 2013-2014. Apart from modernising and reconstructing the organisations that produce building materials and components for the building industry and engineering facilities, this programme includes relocating, merging, separating, reinforcing and regrouping several of them with a view to optimising logistical networks.