1. Technical Specification (TOR) Development
Creation of a detailed technical specification based on data provided by the client via technical questionnaires. The document includes requirements for functionality, capacity, operating conditions, and structural features of the equipment being designed.

2. TOR Approval
Coordination with the client, including technical review, clarification of performance parameters and operational requirements, and final adjustments leading to official TOR approval.

3. Engineering Calculations
In-depth mechanical and structural calculations to determine key performance metrics:

• Static, dynamic, and vibration load analysis
• Conveyor inclination angle optimization for effective material flow
• Selection of drive systems (motors, gearboxes) based on required capacity and operating conditions
• Belt type and model selection based on traction calculations, load characteristics, and material properties
• Material selection (steel grades, polymers, bearings, fasteners) according to regulatory requirements and technical criteria

4. 3D Visualization and Material Flow Simulation
Development of a 3D equipment model using specialized software (AutoCAD, SolidWorks, ANSYS). Simulation of material movement across the system, incorporating variables such as belt speed and throughput (t/h), to identify flow bottlenecks, potential blockages, and overload zones.

5. 3D Modeling and Design Documentation
Creation of precise 3D models in professional CAD systems (SolidWorks, Autodesk Inventor, Siemens NX), followed by the preparation of a complete set of design documentation (DD), including:

• Detailed part and assembly drawings
• Assembly diagrams with step-by-step installation instructions
• Bills of materials, including components and fasteners
• Mounting and operation schematics to support accurate assembly and field installation

6. Component Selection: Motors, Couplings, Gearboxes, Conveyor Belts
All equipment and material selection is based on the TOR and operating conditions:

• Electric Motors: Defined by power output, protection class, and application type (e.g., explosion-proof for hazardous environments or standard industrial use)
• Couplings: Selection of high- or low-speed couplings depending on drive system specifications, loads, and operational mode
• Gearboxes: Specification of cylindrical, worm, or planetary gear reducers in accordance with calculated torque and gear ratios
• Conveyor Belts: Choice of belt type (fabric-rubber, steel-cord, PVC) based on mechanical loads, ambient temperature, material type, and transport conditions

1. Preparation of the List of Components and Materials
Development of a complete list of required components and materials based on the design documentation (DD), including:

• Main assemblies and mechanisms: electric motors, gearboxes, couplings, bearing units, drums, conveyor belts.
• Metal products: profile pipes, sheet metal, angles, channels — suitable for manufacturing frames and supports.
• Fasteners: bolts, nuts, studs, washers, and rivets.
• Additional materials: lining covers, paint and coating materials, sealants, and gasket elements.
• Specification of consumables: welding electrodes, abrasives for treatment and cleaning.

This list becomes the basis for procurement operations and production planning in accordance with the equipment manufacturing schedule agreed with the Customer.

2. Organization of Component and Material Supply
Implementation of measures to ensure the timely delivery of all necessary components for production, including:

• Selection of verified suppliers that meet quality and reliability standards.
• Signing of supply contracts for key assemblies and materials, such as electric motors, gearboxes, bearings, conveyor belts, metal products, and fasteners.
• Control over the availability of certificates of conformity, quality passports, and other documents confirming product specifications.
• Monitoring of delivery schedules to avoid delays in the production cycle.

1. Logistics Organization for Component Transportation
Planning and execution of the transportation of procured components to the production site, taking into account the following aspects:

• Transport type selection: determining the optimal mode of transport (road, rail, sea, or multimodal), based on cargo characteristics and supplier location.
• Route planning: development of logistics routes minimizing delivery time and cost.
• Transportation condition control: ensuring component integrity during transportation, including maintaining required temperature and humidity levels for sensitive materials.
• Delivery tracking: monitoring the delivery status for synchronization with the production schedule.

2. Direct Supplies from Manufacturers
Organization of direct procurement from manufacturing plants, which ensures:

• High product quality: elimination of intermediaries allows receipt of original components that meet factory standards and specifications.
• Cost optimization: reduction of expenses by avoiding markups from intermediary organizations.
• Documentation compliance guarantee: deliveries are accompanied by factory certificates, quality passports, and other necessary documents.
• Faster delivery times: direct contracts shorten the logistics chain, minimizing time delays.

1. Incoming Inspection by the Quality Control Department (QCD)
Visual and instrumental inspection of received components at the production site to verify their condition, compliance with technical documentation, and absence of defects.

2. Verification and Approval of Component Documentation
Validation of certificates of conformity, quality passports, and other accompanying documents for received materials and components to ensure compliance with technical specifications and regulatory standards.

1. Metal Cutting Process
Mechanical processing operations including cutting of sheet, profile, and tubular metal products to produce blanks of the required shape and dimensions according to design documentation. Modern cutting methods are used, such as laser, plasma, or waterjet cutting, as well as CNC machining.

2. Metal Forming Process
Bending and profiling operations performed on specialized CNC press brakes and roll-forming machines, ensuring high geometric accuracy strictly in accordance with design documentation.

3. Application of Advanced Cutting Technologies
Use of high-precision processing methods, including laser cutting, plasma cutting, and CNC machining, to achieve maximum geometric accuracy and high productivity during the cutting process.

4. Robotic Welding Process
Execution of welding operations on automated welding stations using programmable robots to ensure high precision and repeatability of welds. Selective quality control of welded joints is performed during production, including:

• Inspection of weld geometry for compliance with design documentation
• Detection of defects such as undercuts, pores, cracks, or incomplete penetration using non-destructive testing methods (e.g., ultrasonic flaw detection)
• Evaluation of joint strength and reliability in accordance with applicable standards (GOST, ISO)

1. Control of Geometric Parameters of Blanks
Measurement of linear dimensions, angular deviations, and shape of blanks to ensure compliance with design documentation requirements.

2. Surface Condition Assessment
Detection of defects such as cracks, chips, dents, or deformations using visual-optical inspection tools and measuring instruments.

3. Weld Quality Analysis
Non-destructive testing of welds using ultrasonic flaw detection to identify internal defects such as incomplete fusion, cracks, porosity, and inclusions, as well as to assess the homogeneity of the weld structure and compliance with regulatory standards.

Identification and marking of components
Application of unique identification numbers to parts and assemblies using laser, thermal, or mechanical marking methods. This facilitates assembly, traceability, and quality control throughout all stages of production.

Abrasive cleaning of metal surfaces
Processing of components in a shot blasting chamber to effectively remove scale, corrosion deposits, and residual contaminants.

1. Technological surface preparation of components
Operations for removing fine dust and degreasing using specialized solvents or cleaning agents to eliminate oil and other production-related contaminants.

2. Surface readiness assessment
Inspection of the level of cleanliness and adhesion properties of the metal surface according to the requirements of technical documentation and paint specifications, taking into account operating conditions and customer requirements.

1. Placement of prepared components on the painting conveyor line
Positioning of cleaned and treated parts on an automated transport system for subsequent coating application in accordance with the technological process.

2. Robotic painting
Application of coatings using automated robotic systems, ensuring layer uniformity, precise application, and consistent surface quality.

3. Thermal treatment of the coating
Drying and curing of the applied coating in specialized thermal chambers with controlled temperature modes, ensuring full polymerization and the required performance characteristics.

4. Coating quality control
Visual inspection to detect coating defects (uneven coverage, skips, drips). If deficiencies are found, the coating is reapplied until the required quality is achieved.

Measurement of Coating Thickness
Measurement of the applied paint layer in microns using specialized instruments (e.g., magnetic or ultrasonic thickness gauges) to verify compliance with the design documentation and technical specifications provided by the Customer.

Verification Against Design Documentation
Inspection of geometric parameters, materials, and product characteristics for compliance with the requirements specified in drawings, specifications, and technical operating conditions of the equipment.

Inspection of Finished Assemblies and Components
Measurements and checks of product parameters using measuring tools (e.g., calipers, micrometers, thickness gauges, hardness testers, flaw detectors) to confirm compliance with design documentation and regulatory standards.

Weld Quality Analysis
Non-destructive ultrasonic testing of weld seams to detect hidden defects such as incomplete fusion, cracks, porosity, and inclusions, as well as to assess the homogeneity of the weld structure and its compliance with regulatory standards.

Functional Testing and Parameter Verification
Testing the functionality of assemblies and components, as well as measuring key performance parameters to confirm compliance with design documentation, GOST standards, and other established regulations.

Preparation and Transfer of Documentation to the Customer
Preparation of a complete documentation package, including certificates of conformity, equipment quality passports, operation, installation, and maintenance manuals, and other required documents as specified by technical conditions and Customer requirements.

Transportation of Finished Components to the Packaging Area
Movement of completed parts and assemblies to the packaging section using specialized handling equipment to ensure product integrity and compliance with logistics requirements.

Fabrication of Custom Metal Crating
Assembly of a rigid structure made of profile steel for each item, based on its dimensions and weight, to protect against mechanical damage during transportation and handling.

Fastening of Elements with Bolted Connections
Fixing components within the metal crate using bolted connections to prevent shifting, friction, impacts, and mechanical damage during transportation and loading/unloading operations.

Placement of Equipment into Transport Containers
Positioning of finished equipment into standard-size marine or rail containers (20- and 40-foot), in accordance with loading regulations to ensure efficient use of space and protection from damage during transportation.

Securing Equipment Inside Containers
Rigid fixation of transported items using tie-downs, braces, tension straps, and other fastening elements to prevent shifting, impacts, and damage during transit and multiple loading/unloading operations.

1. Logistics Delivery of Containers
Arrangement of container transportation by road, rail, or multimodal transport to seaports, railway terminals, or customs facilities, considering route planning, timelines, and transport safety requirements.

2. Customs Clearance of Goods
Execution of all procedures necessary for lawful border crossing, including:

3. Obtaining Certificates of Conformity
Preparation and submission of documents confirming that the equipment complies with technical and legal requirements of the importing country.

4. Completion of Customs Documentation
Filling out declarations, invoices, packing lists, and other accompanying documents in accordance with customs legislation.

5. Product Classification
Determination of the customs code in accordance with the HS (Harmonized System) and obtaining a classification decision for duty and tax calculation.

Delivery of Equipment to the Customer
Transportation of customs-cleared equipment to the customer’s warehouse using road, rail, or sea transport, depending on logistical requirements and the location of the final destination.

Supervised Installation
Includes technical supervision of equipment installation at the customer’s site, verification of compliance of the installation works with design and as-built documentation, including analysis of geodetic measurements, and assessment of assembly, mounting quality, and connection integrity.

Commissioning Activities
Verification of correct electrical and control system connections, configuration of frequency converters, drive systems, automation, and protection systems.

A trial run of the equipment is conducted in idle and operating modes with logging of key performance parameters. The stage concludes with a training session for the customer’s maintenance personnel and transfer of the complete commissioning documentation package, along with signing of the industrial commissioning certificate.

Warranty Period Support
Technical support from the manufacturer’s design department, including initial consultations via audio and video communication and remote diagnostics.

In the event of malfunctions during the warranty period, a specialist is dispatched to the site for diagnostics and resolution. The faulty unit is identified along with the root cause of the failure. After addressing the issue, the faulty components are replaced if necessary.

Post-Warranty Service Program
Upon expiration of the warranty, the customer is offered a post-warranty support program that includes equipment modernization, supply of original spare parts (with the option of setting up a consignment stock, subject to agreement), and ongoing technical consultations. Support is provided throughout the entire life cycle of the equipment — from commissioning to potential reconstruction.