PJSC "NIZHYNSKIY ZHYRKOMBINAT" underwent a significant reconstruction and expansion project in 2020-2021, which included new construction and an increase in production capacity.
International Bank for Reconstruction and Development
International Finance Corporation - IFC
As part of the reconstruction and new construction, the following has been done:
To optimize the process of receiving raw materials, including sunflower, soybeans, and rapeseed, a new auto-weighing truck with a capacity of 80 tons and a length of 22 meters was constructed to increase the acceptance of raw materials up to 2,500 tons per day. In addition, a new raw materials laboratory was built and an automatic grain sampler was installed. The raw material acceptance department was modernized with an installation of an automatic grain sampler "COBRA 4012 Standard", including the implementation of four points of acceptance. These improvements were designed to ensure the efficient and high-quality acceptance of raw materials.
The process of cleaning and drying seeds has been modernized through the implementation of new equipment for cleaning seeds, specifically, separators SPO, BSKh-200, and LUCH. This equipment is used prior to the drying process and the feeding of the seeds to the storage silos. In addition, transport equipment was reconstructed in order to optimize the quality of raw material storage and, consequently, the quality of the finished products.
A new modern elevator, designed for the storage of seeds, was constructed on the basis of four metal silos manufactured by Variant Agro Bud LLC. The elevator has a one-time storage capacity of 100,000 m3, which is sufficient to store 40,000 tons of sunflower seeds, 65,000 tons of rapeseed, or 75,000 tons of soybean seeds.
The process of inputting raw materials into production and transporting finished products was modernized through the installation of new transport mechanisms with a total length of over one kilometer, produced by Zernovaya Stolitsa Group of Companies. In addition, existing transport galleries were modernized and new ones were constructed to improve the efficiency of these processes.
A workshop was constructed and new RVO equipment produced by PJSC "Khorolsky Mechanical Plant" was installed in the crumbling section, resulting in an increase in production capacity to 1000 tons of seeds per day;
The process of preparing seeds for pressing has been modernized by installing two new roller machines and carrying out the reconstruction of the transport elements of the press department. Also, new crushing roller machines for processing soybeans were installed.
The production capacity of the press department was increased to 1000 tons of seeds per day by modernizing the department and installing a new press and brazier produced by TAN Chernigov LLC, as well as new transport equipment;
The process of oil purification and filtration was modernized by modernizing the workshop and installing new equipment manufactured by TAN LLC and KSV-Technologies private enterprise;
A new process was introduced - hydration (purification) of oil with the installation of a lecithin drying line to improve the quality of the oil, reduce the amount of fuse in the oil and release an additional product - food phosphatide concentrate (lecithin).
The husk granulation process was modernized by installing a new line, manufactured by ICK Group, which ensures the required productivity and quality of finished products, tanks for storing granulated husk and shipment to auto and railway transport.
A new production process was introduced - meal granulation, through the construction of a new meal granulation workshop and installation of a new line, produced by ICK Group with the aim of producing an export product - granulated meal.
An elevator was built - a storage warehouse for granulated meal with a storage capacity of 5,000 tons on the basis of 4 metal cone silos produced by PJSC "Kharlovsky Machine Plant";
A new 4000m³ tank was built for storing oil, produced by LLC "AKIM", and a new pumping station to ensure the required volume of storage and shipment of oil.
The process of shipment of finished products has been modernized by building new railway tracks with a total length of more than 1 km (4 railway lines) with the installation of new railway scales.
An indoor workshop for automated loading simultaneously for 8 railway tanks for oil and for 8 railway grain carriers for meal was built to ensure prompt shipment of finished products.
The process of accounting for products in the production process has been modernized by automating accounting and installing new scales for oil, meal, husk.
The modernization of the boiler house was carried out in order to optimize its operation, reduce fuel (husk) consumption and, accordingly, reduce atmospheric emissions.
Reconstruction of power supply networks was carried out, including the construction of a new power transmission line (35 kW) with a length of 4 km, a new 35/10 kW substation for 4 MW, three new 10/04 kW substations - to ensure the reliability of power supply due to the transition from the second to the first class of energy consumption.
Reconstruction of the entire infrastructure - engineering networks, landscaping of the plant territory, laying of concrete and asphalt roads - more than 12 thousand sq. meters, construction of a storm water drain (more than 1.5 km), a fire water pipeline (more than 1.5 km) and an automatic fire extinguishing system.
The implementation of all of the above and other measures for the modernization of the "Nezhinsky Fat Plant" made it possible to reach the planned qualitative and quantitative indicators of work - processing up to 1000 tons of raw materials (sunflower seeds) per day.