About us

Togliatti foundry and mechanical plant «RUSKAT» specializes in manufacturing of copper wire rod which is meeting the requirements of GOST R 53803-2010. The high quality of products in accordance with international standards is achieved by creating highly skilled staff, the unique technology of production, environmentally friendly raw material and the use of the modern European equipment provided by Italian company Continuus Properzi – a global leader in this field. At every production stage all products pass through quality control and acceptance. The factory is equipped with a modern laboratory for this purpose. Copper wire rod manufacturing process is environmentally-friendly and absolutely safe thanks to the modern filtration system and gas cleaning system.

Our plant’s production capacity in copper wire rod production is 24 000 tons per year.

“NEW PLANT – NEW OPPORTUNITY”

Director of LLC RUSKAT
Valery Shalaev

The idea of building a modern plant for copper rod production and other products made from copper in the Samara region was born some years ago. Metallurgical industry is well-developed in the region. There are someone who sells raw material and who is ready to consume finished-products. In addition to, there is a general need for copper products throughout the country. Business-project RUSKAT started in 2017, when an industrial site of the former plant “KuibyshevPhosphor” was acquired. RUSKAT was built on its base.

 

— Valery, tell us about the production capacity of the plant?

RUSKAT produces about 20 000 tons of copper rod per year. But that was until 2019, as when we had only one fire refining furnace. In 2018 the active construction of the second furnace was going on. It will enable us to achieve the double capacity of production. Our plant makes copper rod with 5 different cross-sections. We also produce wire with a huge number of sections on demand. Thus, we reduce our risks and provide a wide product range.

 

— How do you ensure good quality of your products? What equipment will be used?

We have decided on the Italian brand “Properzi”. It is a well-known company on the market supplying its equipment to every country of the world. We bought ready-made equipment, and thus reduced the duration of our project. The equipment is new, produced in 2007. The quality of each molded products batch is monitored by laboratory specialists. Such close control allows us to maintain the quality of products at a consistently high level.

 

— What level of skills and competence do have you specialists, which will be involved in the project?

On the plant work the best professionals and specialists of the industry form all over the country. Professional skills of both management and line personnel allow reducing time costs for production start-up and setup. Our team is not just professionals, they are people who love and deeply understand their work. Thanks to combination of interest and competence, the actions of the team look like a well-coordinated play of the orchestra. For example, we have employed the chief engineer from Ukraine (Artemovsky plant ). He is engaged in the wire rod production from the 80s, took part in the building of our plant and knows it from the inside. The head of production is the employee who took share in building and developments of operating plants of copper rod production in Kamensk-Uralsk, Nalchik, cooperated with the plant in Rostov. He also has experience with the equipment «Properzi». In addition, we train employees by inviting professionals from Europe. All this allows us not to stand still and constantly improve together with our employees.

 

— Is the plant working on the full capacity now? What are your development plans?

Nowadays we own 4 000 m² of production space and 1350 m² of office space. We have already built 2 factory floors. The first furnace and the first office were launched in the first half of 2018. So began our active production. In the second factory floor we are doing commissioning and start-up works now. The factory floor was fully built in record 9 month. We not only opened the plant from scratch in two years, but also doubled production capacity. There is still a lot of work ahead, but we are in the homestretch, and it makes us happy.

 

— Why is your plant such important for your city and for Russia?

Of course, the city needs strong, stable plants, such as RUSKAT, because it means tax payments to the region, job creation and regional market saturation with finished products at a competitive price. We can provide the entire Samara region with wire and copper rod. Without logistics leg regional plants can purchase copper rod at a lower price in comparison with remote suppliers. In my opinion, it is very significant indicator for our region.

 

— Why did personally you decide to take on this project?

I have always been close to the processing, production: when you produce something, create, you get much more pleasure. I like to manage, to be a «driver-mechanic» in production industry. Why «driver-mechanic», and not the driver? Тhe driver-mechanic repairs the car, he perfectly understands system and principles of work. And when you understand the plant from the inside, there are many opportunities to develop it more in terms of obtaining benefits, both for the plant and for the state.

 

— What inspires you in your work? What brings success to you, your employees?

As for employees, it is important for me to “send them the message” about our goal and explain why it is so important for our plant and for this employee individual. When you see how every day, every minute, every moment you are approaching your goal, it inspires to go forward and in any case not to stop. And if something does not work, the inspiration is even more. You want to understand the problem and to move on. Today when the work is going swimmingly at our site, I see this moving. It means that we are succeeding, we are not standing still, we are moving forward.

DEVELOPMENT
Beginning
VIDEO PRESENTATION OF RUSKAT BUILDING STAGES

2017
LAUNCHING OF COPPER ROD OWN PRODUCTION

In April 2017 we bought the production site of “KuibyshevPhosphor” in Togliatti. The key task is to build a new plant in a short time. After reconstruction we have started to prepare to equipment installation.

  • floor demolition;
  • digging of foundation pits;
  • construction of formwork and concrete casting of foundation using a special process.
MAY-OCTOBER
BUILDING AND CONSTRUCTION WORKS IN THE INDUSTRIAL SPACE:
  • furnace structural construction and lining;
  • exterior finish and mounting of ventilated fronts;
  • interior finish;
  • toping floor pouring, replanning and renovation improvement of the office space.
NOVEMBER – DECEMBER
EQUIPMENT INSTALLATION

Mounted overhead cranes, chimney neck, completed modernization and wiring.

2018
JANUARY - FEBRUARY
FINAL STAGE OF THE FIRST FACTORY FLOOR BUILDING. ACTIVE PREPARATION FOR COMMISSIONING
  • Office finishing works and wiring of continuous casting and rolling line.
  • February new plant inauguration. Objective has been attained!
PHOTO PRESENTATION OF CEREMONIAL OPPENING OF RUSKAT PLANT


PRODUCTION STARTUP AND FIRST PRODUCTS
  • March. Laboratory commissioning, furnace warm start
  • April First furnace loading-was produced a liquid metal in accordance with specifications.
  • May. Was produced the first rod coil. Concrete pouring for second furnace foundation pit.
  • June-November. Subflooring arrangement, the gas chamber and chimney installation, loading door preparation and second furnace lining.
BUILDING OF RUSKAT SECOND FACTORY FLOOR

NOVEMBER - DECEMBER

Scrap yard building

  • November. Cold start of the second factory floor furnace.
  • December. Warm start of the furnace.
NOW
PRODUCTION RAMP-UP AND GEOGRAPHIC GROWTH

Ramp up and supplying geographic growth.

RUSKAT LABORATORY

There is an own new all-equipped laboratory based on RUSKAT plant. High trained laboratory specialists accompany the copper rod production process at all stages and strictly monitor finished products quality. Internal quality control of copper wire rod is built on testing in accordance with the requirements of the National standard of the Russian Federation GOST r53803-2010 "copper wire Rod for electrical purposes."

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Spectrometer SPECTROLAB LAV M12.
Designed for finger tests and finished products analysis.

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Analyzer ELTRA ONp.
Determines copper oxygen content

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Digital resistance meter RESISTOMAT 2316.
Designed for fast and accurate determination of electrical resistivity.

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Refractometer N-8α.
Designed to control the concentration of cutting lubricant

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Refractometer 34s.
Measures the mass fraction of iso-propanol.

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Universal testing machine ИР 5082-100.
Designed to determine tensile strength and elongation of samples.

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Torsion testing machine МСК-500/20.
Twists sample in one direction to its destruction and makes twisting followed by untwisting.

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pH-tester – millivoltmeter рН-410.
Allows you to determine the acid-base index, conductivity and temperature of process liquids.

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Turning and drilling machines.
They are designed for samples preparation.
Laboratory specialists monitor the condition of the equipment, timely provision of consumables and maintenance.
All studies shall be recorded.

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