Today the plant "August-Alabuga" celebrates its 5th anniversary. This is the most modern and automated production site of the August company, a well-known Russian manufacturer of plant protection chemicals (CCPP). The enterprise is located in the SEZ "Alabuga" on the territory of the Republic of Tatarstan. The plant covers an area of 17,7 hectares, on which 45 thousand square meters are built. m of production and storage facilities according to a unique project "all under one roof." On June 28, 2019, the official opening of the enterprise took place, and today the plant has produced almost 18 million liters of CCPP, and its products are not only supplied to domestic farmers, but also exported to Kazakhstan, Belarus, Armenia, Moldova, Turkmenistan, Georgia, Colombia and Ecuador ...
The August-Alabuga enterprise was built with the expectation of the constantly growing pesticide market in Russia. The design capacity of the plant is 50 million liters of finished products per year and allows one third to cover the state's need for plant protection products. The volume of investments in the project amounted to 4,5 billion rubles, of which 4 billion rubles. - own funds of "August", and another 500 million rubles. - a loan from the Industrial Development Fund. At the same time, 233 million rubles were invested in ensuring the environmental safety of the enterprise.
The plant specializes in the manufacture of modern liquid formulations of pesticides of large-scale production. Such preparations are convenient to use: when mixed with water, they give stable solutions that allow you to achieve uniform distribution and save money when processing plants. The company produces preparations in the form of aqueous and water-glycol solutions, water-soluble concentrates, emulsion concentrates, micro- and nanoemulsions, suspension emulsions, suspension and water-suspension concentrates, as well as other liquid preparations. The plant's capacities make it possible to simultaneously produce up to 40 types of plant protection products.
“We ship to farmers only a high-quality and highly effective product, if used correctly,” says Vladimir Alin, General Director of the August-Alabuga plant. - The fact that we have the ability to produce such drugs is important both for the domestic and for the world market, where we can successfully compete with foreign counterparts of HCPP. Our products contribute to the implementation of the import substitution program, which today is a strategic task not only for business, but for the entire country. We are always sensitive to all changes in the industry in particular and in agriculture in general. We never stop developing and constantly focus only on growth. "
During the design and construction of the ultra-modern plant in Tatarstan, the long-term experience of two production sites of "Augusta" in the Chuvash Republic and in the Republic of Belarus was used. The enterprise, created on the basis of the concept of "everything under one roof", is a single huge building, you can get into any of the divisions without leaving the street. The plant is equipped with advanced equipment from manufacturing companies from Russia, Germany, Italy, Czech Republic, Portugal, Sweden, USA, Japan.
The herbicide and fungicide production areas are separate from each other and have their own separate heating systems for raw materials. Thus, material flows do not intersect anywhere - this prevents product contamination from adjacent production. The loading of ingredients is completely sealed, and the use of strain gauges and artificial intelligence ensures the maximum accuracy of dosing of raw materials and compliance with the technology for creating drugs. The automated process control system at the enterprise allows you to fully control the movement of raw materials, semi-finished products and finished products. Thanks to the centralized control of all technological lines, an increase in the productivity of equipment and labor resources of the plant is achieved. So, at the end of 2020, the production plan was fulfilled by 108% - the volume of drug production amounted to 10,7 million liters of finished products, and the total volume of drugs produced at the enterprise since its launch reached almost 2021 million liters by the end of March 18. ... The factory research center with laboratories equipped with the latest equipment with high measurement accuracy is responsible for quality control at all stages of the production cycle.
In addition to the formulation of drugs, the company produces high-quality containers - four-layer polymer canisters with an inner polyamide protective layer. The plant employs 4 co-extrusion blow molding machines capable of producing 27 thousand containers per day.
The enterprise minimizes manual labor and the influence of the human factor. So, the operator of the filling line only needs to enter a task with the selected product and the necessary container will come from the automatic warehouse, and the product itself will be received from the storage tanks or reactors. All movements are carried out on conveyors, and employees do not come into contact with the product until the moment when it is completely ready and packed. However, this does not mean that automation ends at this stage: further, KUKA palletizing robots with a carrying capacity of up to 470 kg each automatically stack boxes with products into pallets, and one such robot is able to serve 3 filling lines in turn. Also, the plant presents 2 palletizing complexes with a planned capacity of 50 pallets per hour, which perform a full cycle of work on packing finished products and delivering them to the warehouse. Each of the complexes is serviced by one operator, whose main task is to provide their work with consumables. In addition, the company has implemented an automated warehouse management system SAP EWM (Extended Warehouse Management). It allows you to make the work of the warehouse as transparent as possible, it provides a clear understanding of the number and nature of all operations carried out there, and information on the names of products and their balances is tracked in real time.
At the "August-Alabuga" enterprise, professional safety and health protection of personnel, as well as a wide social package are fully ensured. Today 234 employees work here, in the future it is planned to expand the staff to 250 people. The average salary at the plant at the end of 2020 amounted to 68 rubles, its annual indexation is envisaged - this January the salaries of all employees were increased by 150%. In addition, all employees are subject to voluntary medical insurance, free comprehensive meals are provided, and training opportunities are provided at the expense of the enterprise. For each employee who has worked at the plant for 4 years or more and has reached retirement age, a social pension is provided from the company.