Focus on import substitution

The production growth rate of 114 percent over the past year — Dobrush Paper Factory Geroy Truda [Hero of Labour] can boast increased multilayer cardboard production

Innovative, focused on import substitution and export — it is in line with this trend that Dobrush Paper Factory Geroy Truda, the branch of OJSC Management Company of Belarusian Wallpaper Holding, is actively developing. The launch of a modern complex for the production of three-layer coated and uncoated cardboard in June 2021 became the starting point for the new stage in the history of the enterprise. From then on, the factory has been developing onward and upward only. Let us peek into the production to check the company’s order portfolio, find out on what products ‘whales’ the factory stands today, and ask how the company evaluates its export potential.  

Vitaly Miskel, cutting machine operator at Dobrush Paper Factory Geroy Truda

For unique design solutions

The new complex is a full-fledged factory with several floors that features innovative production, the key element of which is a cardboard machine, which looks like a giant road train. All main technological processes around the clock hinge on it. Moreover, the equipment capacities are used more extensively every year. Thus, in addition to cardboard, the factory has already mastered the production of cellulose canvas and laminated cardboard as the basis for disposable tableware.
Three-layer coated cardboard, which was not produced in Belarus before, is now consistently on the top of demand in the segments of printing and packaging for food, confectionery, pharmaceutical, and other industries. Along with that, 80 percent of Dobrush-made innovative products are exported to 16 countries around the world. The rest goes to the domestic market for import substitution requests. The explanation lies on the surface: coated, or glossy, cardboard canvas provides an immense field of activity for the implementation of various design solutions. The interest in it is fairly high. In today’s consumer market, high-quality packaging not only ensures the safety of goods, but also serves as a marketing tool that affects sales growth.
Deputy Director of the branch Aleksandr Martynov introduced the enterprise’s results and plans in sync with the demand,

“The production growth rate amounted to 114 percent last year, with goods sold for the amount of over Br360 million. At the same time, 103 thousand tonnes of products were exported, while the growth rate exceeded 108 percent compared to 2022. In four months of 2024, more than 62.7 thousand tonnes of cardboard were produced. The export growth rate made up 106.3 percent compared to last year. Further plans are related to the increased production volume. We currently produce over 400 tonnes per day, and it is planned to raise this figure to 600 tonnes by the end of 2024.”  

Its own niche

In three years of promoting Standart class cardboard, the factory has managed to occupy its niche and gain a reputation as a reliable manufacturer in this segment, which has ensured consistent shipments, permanent partners, new sales markets. The quality of the products is confirmed by awards received at professional competitions. 
The implementation of innovative cellulose canvas, which is used in Belarus and Russia for the production of sanitary and hygienic products, such as diapers and baby linen, is also gaining momentum. By the way, the product has been recognised by professionals as a successful import substitution product despite the fact that just a little over a year ago, the enterprise started with a few tonnes as an experiment aimed to save the market of the Union State of Belarus and Russia from the shortage of cellulose canvas. Now they manufacture up to 4 thousand tonnes of high-quality in-demand products per month.
However, there is no limit to perfection. Mikhail Melnikov, Head of Cardboard Production Workshop at the factory, knows this better than anyone else, “In general, the competition in the paper production market is very tough. Therefore, work for quality is our priority. We ensure impeccable compliance with international standards at all stages. The factory can afford it, because nearly 100 percent of the products are mainly based on domestic raw materials — Belarusian timber, cellulose from OJSC Svetlogorsk Pulp and Cardboard Mill… All the links in the chain are under our control — from raw materials to the final product.”
Irina Vorobyova, a 4th grade grinder, performs the operator’s mission at the new plant. Quality control is one of her duties. There are numerous monitors which display the full picture of the technological process online. The slightest deviation from the parameters is an emergency reason to get in touch with the master and the responsible services, “I used to work on a machine that produced paper. When I was offered to train to work as an operator in a new production, I agreed. This involves other competencies, new knowledge. Undoubtedly, it is a very responsible task: during the shift, I fully track and supervise the quality of products. At the same time, it is interesting. And of course, it is very pleasant to see products made at our factory on store shelves.”  

Irina Vorobyova, operator at Dobrush Paper Factory Geroy Truda

Expanding opportunities, closing the cycle

The factory is constantly looking for new directions and opportunities. As soon as they harnessed the production of three-layer cardboard, they have gradually devised the final product in two types — rolls and sheets, having purchased a format cutting machine. Mikhail Melnikov clarified the essence of diversity, “Printing houses work mainly with sheets. When purchasing cardboard in rolls, they used to order an additional service for cutting it from other organisations. Now we can offer sheet products as well. This is good for customers and beneficial for our company, as it means a value-added product. On the one hand, we have ramped up the volume of sheet cardboard with a higher added value. On the other hand, this has become another step in order to systematically increase and leverage the capacity of the cardboard machine.” 
According to the same principle, the enterprise is developing a cardboard line — the basis for disposable tableware. In 2023, the production of single-layer and double-layer cups for cold and hot drinks was mastered at the Production Unitary Enterprise Gomeloboi [the largest wallpaper company in the Republic of Belarus and the CIS countries based in Gomel], which is also a branch of the Belarusian Wallpaper Holding. The basis is Dobrush-made cardboard, manufactured according to the game-changing formulation technology, environmentally safe, and meeting all sanitary and hygienic requirements. Unlike the conventional one, its task is to retain moisture and ensure minimal water absorption. At first, Gomeloboi used Dobrush-made cardboard, which had to be additionally laminated with the help of third-party contractors. Now, what is needed for the production of disposable cups is made at Dobrush Paper Factory, which has acquired a laminator to this end. Aleksandr Martynov shared the details to substantiate the company’s approach, “By ensuring the lamination for disposable tableware, we have closed the production cycle of cups within the holding. Besides, such products are necessary for our factory, as well. We pack cellulose canvas and coated cardboard in laminated paper so as to ensure the protection and safety of products during transportation.” 
Today, every innovative product mastered at the factory is a prospect for growth and expansion of the geography of supplies. This is confirmed by the growing demand and victories in competitions. One of the latest victories: Dobrush Paper Factory Geroy Truda has become the winner of the 2nd National Industry Competition for achievements in the field of industrial technology and management development Industry Leaders of the Republic of Belarus – 2024. By the way, a cup cardboard base, which is becoming increasingly familiar to Belarusians due to takeaway coffee from espresso to a large latte, has been recognised as the best in the Product of the Year nomination in the category Innovation.

Dobrush Paper Factory Geroy Truda, Gomel Region 

By Violetta Dralyuk

Photos by Ivan Yarivanovich