Ukrainian Casting Company 

History

Ukrainian Casting Company is the youngest enterprise of UPEC Industrial Group. Ukrainian Casting Company, a specialized complex to produce iron and steel castings, was founded in 2004 on the basis of the foundry shop and pattern shop of Kharkov Machine-Tool Building Plant. 

IMG_5363.jpgSpecialization

The production facilities of Ukrainian Casting Company, LLC comprise a specialized complex to produce iron and steel castings. A competitive feature of the company is the ability of producing castings of any complexity of between 500 grams and 20 MT of grey iron and between 500 grams and one ton of high-strength cast iron and steel owing to the existing sets of process equipment.
A unique feature of the casting complex is the personnel and productive potential of the enterprise which has managed to preserve multiyear traditions of machine-tool building.

Production Facilities and Technologies

The casting complex includes several sections and lines: Small Casting Section where sand-clay mixtures are used to produce castings of between 0.5 kg and 25 kg in weight; Medium Casting Section where molds based on liquid glass mixtures are prepared to produce castings of between 25 kg and 2 MT in weight.
P1014287.JPGHeavy Casting Section produces 2-MT to 20-MT castings. The section is equipped with a sand slinger which makes it possible to produce castings by both floor molding and flask molding. The molds are made of sand-clay mixtures with following drying and painting. Mold cores are made of cold-hardening mixtures cold hardening mixtures.
The molding line for cold hardening mixtures is designed to produce casting molds and mold cores of up to 2 MT in weight of cold hardening mixtures using the Alpha Set Process. This line was created by the company’s specialists through the reconstruction of the L100X mold core line. The line output is between 15 and 20 molds/hr.
DSC04944.JPGGasified Pattern Casting Section is intended to produce complicated configuration castings of up to 20 kg in weight of high-strength grey cast iron and steel. This method of casting makes it possible to produce high accuracy castings, i.e., by 4 to 5 classes of accuracy higher than castings made in a sand-clay mold. Surface roughness approaches the investment casting indicators, namely, Rz of between 60 and 80.
Melding Department consists of the set of cupola furnaces of three MT per hour and ten MT per hour in capacity.
Currently, Ukrainian Foundry Company has installed and put into operation two induction melting furnaces from EGES, Turkey, of 1 MT per hour in capacity each. The furnaces are configured to melt grey, high-strength grey cast iron and steel.
Furthermore, the production complex includes Chipping Department and Finishing Operation Department, Core Sand and Molding Sand Mixture Laboratory, Mechanical Testing Laboratory, and Metal Chemical Composition Express Analysis Laboratory.
Pattern Shop specializes in making wooden and metal patterns for own production needs.

Complex Automation System

IMG_5404.jpgDuring 2008-10, at ULC LLC like at all the enterprises of UPEC Industrial Group, a Combined System of the Automation of the Design and Process Preparation and Computer-Aided Support of Mechanical Engineering Production (CSA) was implemented.
The CSA Project has been implemented based on integrated CAD/CAM/PLM solutions and program products of Pro/ENGINEER—Windchill platform from PTC (the United States). Also, a unique process engineering and production tooling complex based on Windchill MPMLink system and VERTICAL system from ASCON (Russia) has started to operate.
As the basic advantages of CSA implementation, the following may be noted: increase in the accuracy and quality of products owing to operation in the unified environment — from a design 3D model through a manufacturing process; reduction in manufacturing process time; the improvement of effectiveness of preparing design and process documentation; a substantial reduction in the costs of design and process preparation of production as a whole.

Recognition of Quality

In 2008, the enterprise implemented and maintains currently a Quality Management System complying with ISO 9001:2000. In March 2009, Ukrainian Casting Company passed successfully a supervisory audit to switch over to the 2008 version.
In July 2009, Main Laboratory obtained an Attestation Certificate of the Ministry of Industrial Policy of Ukraine. In September 2010, as a result of a supervisory audit, it confirmed successfully the same.
Activity Figures
In 2010, net income of Ukrainian Foundry Company LLC was UAH114.027 million this being more than 4 times as much the figure for the prior year. The company refocused on the production of products for rail transport (heretofore, the agricultural machine-building sector was the key line of sales).
As a result of 2010, the company recorded loss of UAH4.284 million (2009 was ended by the company with loss of UAH11.389 million).


Key Partners in the CIS Countries

Ukraine:

  •  Lozovsky Forging-Mechanical Plant, Ltd 
  • JSC "Kharkov Machine-Tool Building Plant"
  • Kryukov Railcar
  • Azovmash JSC
  • Dniprovagonmach JSC
  • Verkhnoydniprovsk Railcar Repair Works JSC
  • Lugansktsentrokuz JSC

Russia:

  • OOO Bryansk Cushioning Devices Works
  • Uralvagonzavod PLC


Contacts

277 Moskovskyi Ave., Kharkov 61055, Ukraine
Tel.: 38 (057) 703-34-85
E-mail: info@ucco.com.ua