Where metal moves

Lida Foundry and Mechanical Plant increases production volumes, invests in the environment and introduces innovations

Lida Foundry and Mechanical Plant is a truly unique production. For almost 50 years of its existence, the enterprise has gone through different stages of development, but all this time hundreds of Lida residents who worked on it have made a worthy contribution to the socio-economic growth of the city and the country. Today, Lida metallurgists are proud of the quality and demand for their products, which are known and expected in Belarus and abroad. In 2022, exports increased by 21 percent compared to 2021. How do they manage to invest in the renewal of production, develop know-how, and raise wages for employees today?

Caster Artem Narbut came to the plant seven years ago, having mastered the profession from scratch

In conjunction with science

Lida Foundry and Mechanical Plant Director Roman Trubitsky described the current situation in production, “We specialise in the production of castings and blanks from grey and alloy cast iron using various technologies for machine-building enterprises. In particular, for automobile and tractor internal combustion engines, agricultural machinery produced in Belarus and Russia. The enterprise produces about 700 tonnes of products monthly. The main types of cast iron castings are made by casting in a lined mould. When using this technology, the metal solidifies evenly, but the main advantage is the accuracy of the casting. Part surface needs minimal machining.”
The plant employs almost 350 people. Revenue from product sales per person increased by 37 percent.
Now the plant is participating in the implementation of the ‘Casting Technologies’ state scientific and technical programme together with the Physical-Technical Institute of the National Academy of Sciences.
“We are talking about an investment project for the modernisation of the smelting complex, which consists of two smelting furnaces. The new equipment has already been practically manufactured, for which Br1.7 million have been spent. The total cost of the project is more than Br3 million. This amount includes the company’s own funds, money from the republican budget and extra-budgetary investments. It is planned to invest almost Br1.3 million to complete the project this year,” Director explains. 
Thanks to the development and implementation of the project, the production of castings will increase to 8,500 tonnes per year, the duration of melting will be reduced, the unit costs for electricity will be reduced by 20 percent, and emissions of pollutants into the atmosphere will remain almost the same.
Roman Trubitsky continues, “In general, the enterprise is actively engaged in the modernisation of treatment systems. At the moment, a part of the equipment for cleaning exhaust gases from shot blasting drums has been installed. And already in 2023, an aspiration system will be installed, which will reduce particulate emissions by 25-30 percent. We continue to co-operate with the Belarusian National Technical University, the Belarusian Research Institute of Foundry (BELNIILIT) and the Physical-Technical Institute of the National Academy of Sciences on the development and implementation of innovative technologies.”

With a steel character

The enterprise has introduced a technology for manufacturing models and moulds by 3D printing, which allows obtaining results that are unattainable by means of classical technological processes. An important advantage also lies in the significant time savings for the production of pattern equipment.

Head of the foundry shop at Lida Foundry and Mechanical Plant Denis Kulikov

Recently, the plant received an order for casting and die-casting of a new innovative product for the Russian Railways. In addition, a pilot batch has already been delivered to the customer. The casting is complex; several rods are used to obtain it. Special requirements are imposed on all surfaces, since the casting is not subjected to machining, but is immediately installed in the unit. The project is large-scale, the whole enterprise is engaged in it.
Usually the customer sends a drawing of the part and asks to consider the possibility of production, then the technology is developed with process engineers. Then comes the creation of 3D tooling and drawing up of drawings, according to which the model shop creates model mould tooling. And only after that it is transferred to the foundry.

Male endurance

Working in a foundry is a fascinating sight. People in protective helmets move easily and naturally, without interfering with each other in their work duties amid the fire and heat. Caster of Metals and Alloys Artem Narbut tells us with a smile, “A good foundry worker must understand the metallurgical industry and be able to operate the machine. It is important to be careful: any flaw on the surface of the lining, violation of the heating mode of the tooling can lead to defect. You need to be strong and hardy: some operations have to be done manually. This is a real male profession, which not everyone can master.”

It’s always hot in the foundry

Head of the Foundry Shop Denis Kulikov is pleased with his team, “Our team is good. There are 130 people in my subordination, there are both young guys and old-timers. We are constantly developing new types of products, achieving excellent quality, so we feel like a single mechanism. Each casting is a separate chemical composition. The smelter, like a skilled cook, must add certain materials to the melt in the right amount in order to obtain a given alloy and provide the required properties. I myself have worked for 15 years here — and I cannot imagine a more courageous profession.”

It’s good to have work

Leading Marketing Specialist Zhanna Ovsyannikova is sure that the activity of the entire enterprise directly depends on the work of its service, “It is very important to properly build work with the consumer — from the analysis of product requirements to the conclusion of a contract and access to serial deliveries. Last year, 7,894 tonnes of products worth Br25.4 million were sold. In general, the volume of exports for 2022 amounted to almost Br14 million ($5.3 million in equivalent), or 121 percent of the 2021 level. The main share in export deliveries is castings for the assembly of agricultural units of Avtotekhnologii Plant LLC in the Volgograd Region — 53.5 percent. Shipments to the Zavolzhsky branch of UAZ LLC in the Nizhny Novgorod Region are in second place. The main share in the structure of sales to the domestic market is occupied by Minsk Motor Plant Holding Management Company.”

By Tatiana Vrublevskaya
Photos by Aleksey Bibikov