Reference list for biotechnology

As part of the planned modernization of the production facilities of BRAVO PREMIUM LLC, which is part of the “RUST” group of companies, in 2021 the specialists of ZAVKOM-ENGINEERING LLC delivered a single-loop SIP washing station.

This installation ensured high quality and timely washing of the main technological equipment of the plant, which made it possible to optimize the production process and reduce production costs.

The scope of work performed included:

• Design and supply of SIP washing station,
• Implementation of installation work,
• Implementation of supervision works,
• Implementation of commissioning works.

At the beginning of 2021, the employees of ZAVKOM-ENGINEERING LLC  completed work on expanding the fermentation department of the Carlsberg brewery plant, located in Baku, Azerbaijan.

As part of this project, the following scope of work was performed:

1. Development of project documentation,
2. Supply of a set of equipment,
3. Performance of installation, installation supervision and commissioning.

In 2020, ZAVKOM-ENGINEERING LLC  carried out a technical re-equipment of the sulfuric acid storage warehouse in order to organize a site for the preparation and dosing of 30% sulfuric acid into the decalcified molasses pipeline of the desugarization production unit and the extract pipeline.

The production process is fully automated; the most modern technological equipment from leading Russian and world manufacturers has been supplied.

As part of the project, our company performed the following types of work:

1. Development of design and working documentation.
2. Development of a plan for the localization and elimination of the consequences of accidents (PMLA).
3. Development of technological regulations.
4. Complete delivery of technological Equipment.
5. Development of automated process control systems.
6. Installation work.
7. Commissioning.
8. Personnel training.
9. Putting into operation.
10. Registration of the Object in Rostekhnadzor (Federal Environmental, Industrial and Nuclear Supervision Service).

In 2020, ZAVKOM-ENGINEERING LLC  launched a distillery with a capacity of 3,000,000 decaliters per year in the Republic of Uzbekistan, Tashkent.

The production process is fully automated, the most modern technological equipment from the world's leading suppliers has been supplied.

As part of the project, our company performed the following types of work:

1. Designing part of the Production Technology and Process Automation System;
2. Complete supply of technological equipment:
• Department of water treatment;
• Alcohol storage;
• Vodka production unit;
• Compressor
• SIP washing department;
• Department of ingredients.
3. Installation work;
4. Commissioning;
5. Personnel training.

In 2020, ZAVKOM-ENGINEERING LLC  launched production area and filling of vegetable oils and fats into tanks, eurocubes and flexitanks.

The production process is fully automated, the most modern technological equipment from leading Russian and world manufacturers has been supplied.

As part of the project, our company performed the following types of work:

1. Development of working documentation for the brand Production Technology and Process Automation Systems.
2. Complete delivery of technological Equipment.
3. Development of automated process control systems, including the creation of a database of recipes.
4. Complete delivery of the refrigeration machine.
5. Design and manufacture of control cabinets.
6. Installation work.
7. Commissioning.
8. Personnel training.
9. Start-up operations.

In the first half of 2020, employees of ZAVKOM-ENGINEERING LLC  developed and implemented a project to expand the fermentation department for Pivzavod-Marksovsky OJSC.

LLC "ZAVKOM-ENGINEERING" performed the following scope of work:

1. Development of a project for piping and instrumentation for 5 CCTs (Cylindrical-Conical Tanks.).
2. Supply of a set of pipes, fittings, shut-off and safety valves, instrumentation and control cabinets.
3. Performance of installation, installation supervision and commissioning.

The reconstruction of the fermentation department made it possible to fully automate the technological process and increase the volume of production of products.

In February 2020, employees of ZAVKOM-ENGINEERING LLC successfully launched the brewing department of the Azeri brewery in Baku.

In the process of modernization, the filter tank was reconstructed and enlarged.

This allowed us to increase productivity and automate the filtration process.

On January 22, 2020, ALVIZ JSC, together with ZAVKOM-ENGINEERING LLC, successfully commissioned an aromatic alcohol production unit (Alambik).

Within the framework of this project, ZAVKOM-ENGINEERING LLC performed:

1. Design, manufacture and supply of an Alambik complete with a control cabinet and shut-off and control valves;
2. Software development;
3. Performance of the chief of installation and commissioning.

The successful start-up of the plant made it possible to provide the ALVIZ distillery with the necessary amount of aromatic spirits and improve the quality of the products.

In 2019, ZAVKOM-ENGINEERING LLC  developed project documentation under the general design agreement for a wheat deep processing plant with a capacity of 275,000 tons of grain per year, in the Serdobsky district, Penza region.

Nomenclature of finished products:

• Lemon acid;
• Gluten;
• HFSS;
• Molasses;
• High protein feed additive;
• Bran.

In 2019, within the framework of the implemented project with Gambrinus OJSC, the employees of ZAVKOM-ENGINEERING LLC  performed the following work package:

1. Turnkey delivery of the fermentation department (design, manufacture and supply of capacitive equipment, process pipelines, instrumentation and control cabinet, control cabinet; installation supervision and commissioning).
2. Turnkey delivery of the pure yeast culture department (design, manufacture and supply of capacitive equipment, process pipelines, instrumentation and control cabinet, control cabinet; installation supervision and commissioning).
3. Development and implementation of a unified automatic control system for the fermentation department, yeast department, pure yeast culture department and CIP washing department.

The reconstruction made it possible to increase the volume and improve the quality of products, as well as to increase the overall level of automation of the brewery plant.

In 2019, with the participation of ZAVKOM-ENGINEERING LLC, a plant for the production of bottled water was launched in the Republic of Tajikistan, Dushanbe for the company AVESTO GURUKH LLC.

As part of the project implementation, the following works were performed:

• Design of piping (connecting pipelines);
• Supply of piping (connecting pipelines);
• Installation works.

In 2019, ZAVKOM-ENGINEERING LLC  implemented a project for the construction of a distillery in the Republic of Tajikistan, Dushanbe for the company AVESTO-GURUKH LLC.

As part of the project implementation, the following works were performed:

• Designing a plant with a capacity of 280,000 decalitres per year;
• Complete supply of equipment;
• Installation works;
• Commissioning works.

In 2018, ZAVKOM-ENGINEERING LLC successfully implemented a project to modernize the distillery of JV LLC AFSAR COMPANY LTD in the Republic of Uzbekistan, Kibray.

The modernization included control of the filtration rate to improve the quality and organoleptic properties of vodka.

As part of the project implementation, the following works were performed:

• Design;
• Complete supply of equipment;
• Installation supervision;
• Commissioning works.

In 2018, ZAVKOM-ENGINEERING LLC  delivered a warehouse for an acceptance area, storage and dosing of improved and technical 1st. grade sulfuric acid molasses into the stream, including design, construction and installation work.

The production process is fully automated; the most modern technological equipment from leading Russian and world manufacturers has been supplied.

As part of the project, our company performed the following types of work:

1. Development of project documentation in accordance with Decree of the Government of the Russian Federation No. 87, including the examination of project documentation.
2. Development of a plan for localization and liquidation of emergency situations (PLAS).
3. Development of technological regulations.
4. Complete delivery of technological Equipment.
5. Development of automated process control systems.
6. Construction and installation works.
7. Commissioning.
8. Personnel training.
9. Putting into operation.
10. Registration of the Object in Rostekhnadzor.

In 2018, ZAVKOM-ENGINEERING LLC completed for Tatneft PJSC the Basic design of a process plant for the production of denatured bioethanol with a capacity of 25,000 tons per year.

In 2018, ZAVKOM-ENGINEERING LLC  successfully completed a project for the construction and commissioning of a new brewhouse for HANSEN BREWERY LLC, Stavropol.

This unit, with a capacity of 5 tons of wort from one brew, was developed and designed taking into account the latest design and technological solutions developed by ZAVKOM-ENGINEERING LLC. The operation of the brewing department is carried out in a fully automatic mode, which made it possible to achieve a stable mode of operation of the equipment with a minimum number of staff.

The specialists of the ZAVKOM group of companies performed a full range of services, including:

• Development of project and design documentation,
• Manufacturing of the main technological equipment,
• Assembly of control cabinets,
• Software development,
• Supply of equipment,
• Installation supervision and commissioning,
• Training,
• Warranty service.

In 2017, ZAVKOM-ENGINEERING LLC  launched a wheat deep processing plant with a complex for receiving, storing and processing wheat with a capacity of 120,000 tons of grain per year, in the city of Ishim, Tyumen Region

Nomenclature of finished products:

• Lysine;
• Gluten;
• Ethanol;
• Feed additive, Distillers' Dry Grain with Solubles (DDGS);
• Bran;
• Carbon dioxide.

The production process is fully automated; the most modern technological equipment from the world's leading suppliers has been supplied.

As part of the project, our company performed the following types of work:

1. General design;
2. Design and working documentation of the following facilities;
3. Complete supply of technological equipment;
• Mill;
• Wet process;
• Production of glucose syrup;
• Drying gluten;
• Lysine production unit;
4. Installation work;
5. Commissioning;
6. Personnel training.

In 2017, ZAVKOM-ENGINEERING LLC  upgraded the area for displacement of beet molasses, calcium carbonate from a solution by replacing it with soda ash, as well as creating a buffer zone for the accumulation of molasses treated with sulfuric acid to stop the reaction of formation of calcium carbonate particles and precipitation of sulfate calcium (gypsum) molasses desugarization unit.

The production process is fully automated, the most modern technological equipment from leading Russian and world manufacturers has been supplied.

As part of the project, our company performed the following types of work:

1. Examination of the load-bearing structures of the building at the site of the Equipment installation, with the issuance of an opinion on the strengthening and modernization of the existing building.
2. Development of design and working documentation.
3. Complete delivery of metal structures.
4. Complete delivery of technological Equipment.
5. Installation work.
6. Commissioning.
7. Personnel training.
8. Start-up operations.

As part of this project, a set of works was completed for PJSC "Vasileostrovskaya brewery" to supply a brewhouse with a capacity of 13 tons of wort from one brew. Due to the high automation of the technological process, it was possible to achieve a productivity of 12 brews / day.

The scope of delivery included:

1. Development of a technological project;
2. Equipment manufacturing;
3. Supply of a set of piping, instrumentation and control cabinets;
4. Execution of supervision and commissioning works.

In 2015, ZAVKOM-ENGINEERING LLC  launched the Usadsky distillery with a capacity of 10,000 deciliters of alcohol per day, located in the city of Usady, the Republic of Tatarstan. In this project, Zavkom Engineering LLC participated as a General Designer, as well as a supplier of process equipment for the following areas: water-heat treatment of raw materials, yeast-fermentation department, CIP station, alcohol storage.

As part of the project, our company performed the following types of work:

• General design of the facility (development of design and working documentation);
• Complete supply of technological equipment;
• Installation works;
• Commissioning works;
• Staff training.

In 2014, ZAVKOM-ENGINEERING LLC  launched a modern enterprise for the production of dry enzyme preparations for various sectors of the agricultural and food sectors. Production capacity up to 1,000 tons per year.

The production process is fully automated, the most modern technological equipment from leading Russian and world manufacturers has been supplied.

As part of the project, our company performed the following types of work:

1. General design.
2. Complete delivery of technological Equipment.
3. Installation work.
4. Commissioning.
5. Personnel training.
6. Start-up operations.

In 2014, ZAVKOM-ENGINEERING LLC  completed the reconstruction of the Mamadysh distillery with a capacity of 3,000 deciliters of alcohol per day, located in Mamadysh, the Republic of Tatarstan.

As part of the project, our company performed the following types of work:

• Development of technological sections of the project (working and design documentation for the brands of Production Technology, and Automation of Production Technology, issuing tasks for related sections of the project);
• Complete supply of technological equipment for the brewing and yeast fermentation departments and the CIP station;
• Installation works;
• Commissioning works;
• Personal training.

In 2014, the ZAVKOM-ENGINEERING LLC Company upgraded the fermenter tanks.

As part of the modernization, our company performed the following types of work:

1. Development of a model for the supply and dissolution of air and development of a model for the movement of culture fluid.
2. Making blanks.
3. Replacement of the lower mount of the agitator.
4. Replacing the lower bubbler.
5. Replacement of the lower part of the internal heat exchangers.
6. Development of technology and carrying out test fermentations.

As a result of the modernization, the process of oxygen dissolution in the culture liquid improved, which led to an increase in biomass and increased the yield of the final product.

The ZAVKOM-ENGINEERING LLC  company delivered the Equipment for the complex of deep grain processing for the production of amino acids.

As part of the project, our company performed the following types of work:

1. Development of design and technological documentation.
2. Supply of technological equipment for the following production sites:
• Isolation of starch ("wet process");
• Preparation of syrups;
• drying of gluten and fodder;
• Fermentation;
• Hazardous chemicals warehouses;
• Aspiration;
• Storage of the finished product.
3. Installation work.

In 2012, ZAVKOM-ENGINEERING LLC  developed project documentation under the general design agreement for a plant for the production of ETBE 330,000 t/year, gluten 20,000 t/year, starch and DDGS, Omsk.

In 2020, pre-design work was completed for the grain deep processing plant in 2 stages of construction:

Stage 1: grain processing 250,000 tons/year with the following product line:

• Bioethanol;
• Gluten;
• Lemon acid;
• Feed additive DDGS;

Stage 2: grain processing 860,000 tons/year with the following product line:

• Bioethanol;
• Gluten;
• Modified starch;
• Lemon acid;
• Feed additive DDGS.

In 2012, ZAVKOM-ENGINEERING LLC  successfully launched a plant for the production of alcoholic beverages in Hanoi, Vietnam.

This plant has a production capacity of 500,000 dal/year with the possibility of increasing production up to 1,000,000 dal/year.

Within the framework of this project, the following types of work were performed:

• Design;
• Complete delivery of equipment;
• Supervised installation works;
• Commissioning works.

The above works were carried out for two departments of the plant:

• Water treatment;
• Blending production unit.

ZAVKOM-ENGINEERING LLC  has reconstructed and increased the capacity of the brewery, delivered and launched new modern equipment.

The production process is fully automated; the most modern technological equipment from leading Russian and world manufacturers has been supplied.

As part of the project, our company performed the following types of work:

1. Development of working documentation for the brand Production technology, and automation of production technology.
2. Complete supply of technological Equipment:
• Department of pure yeast culture (Pure yeast culture);
• Yeast department;
• Departments of fermentation and after-fermentation (Cylindroconical vessel);
• Double-circuit SIP-washing station;
• Refrigeration unit;
• Cooling plant;
• Air coolers of the camp basement.
3. Installation work.
4. Commissioning.
5. Personnel training.
6. Start-up operations.