Producing its own high-pressure hoses will allow the Vinogradovsky open-pit mine to reduce reliance on external suppliers, speed up repairs to mining equipment, and generate additional cost savings. The new workshop is designed to produce up to 4,000 hoses per month, with the project’s projected economic impact estimated at tens of millions of rubles annually.A new workshop for the manufacture and repair of high-pressure hoses has been launched at the Vinogradovsky open-pit mine, a branch of JSC Kuzbasskaya Toplivnaya Company. The production facility has been set up within the engine workshop, utilizing the existing repair and installation section.
For a coal mining enterprise, high-pressure hoses are components that directly impact equipment availability. Hydraulic hoses are used in the systems of haul trucks, excavators, drilling rigs, and other machinery. Damage to these hoses necessitates immediate replacement, as even a brief repair delay can result in downtime for expensive equipment. The need to minimize such downtime was precisely what drove the decision to establish in-house production.
From Procurement to Local Production
Before the new workshop was launched, worn or damaged high-pressure hoses were ordered from third-party manufacturers. This approach not only increased repair costs but also created a dependency on production and delivery timelines.
The complete hose manufacturing cycle can now be carried out directly at the open-pit mine site. The production line comprises a cutting machine, a structural processing station, equipment for skiving and fitting swaging, a hose skiving machine for fitting preparation, and a pressure impulse testing rig.
The facility enables the production of high-pressure hoses with diameters ranging from 10 to 50 mm, including those designed for ultra-high-pressure applications of up to 700 bar. Production capacity averages up to 200 linear meters per shift, or approximately 4,000 units per month. Consequently, the enterprise is now able to rapidly manufacture hoses tailored to specific equipment specifications and operating conditions.
Direct Supplies and New Capabilities
The project places special emphasis on supply chain organization. Plans are in place to source components for high-pressure hose manufacturing directly from domestic and Chinese producers, as well as through distribution channels. Eliminating excessive intermediaries is expected to secure more favorable component pricing and, consequently, reduce the production cost of the finished goods.
At the same time, the project has enabled the development of new technical competencies within the company. Four specialists, trained by the equipment suppliers in its operation, are involved in the work shifts. Staff also receive additional consultations from engineers representing the component manufacturers.
"This is a key project for enhancing the company's competitiveness. It was implemented using lean manufacturing principles, allowing us to minimize waste and control costs. Looking ahead, once the technology is fully optimized, the high-pressure hose manufacturing workshop will be able to not only meet the needs of our own group of companies but also provide services to external organizations in the Kuzbass region," noted Evgeny Dmitriev, Managing Director and Director of the Vinogradovsky Open-Pit Mine (a branch of JSC KTK).
The economic impact goes beyond the cost of the high-pressure hose
The project's primary benefit is not limited to a reduction in the price of the component itself. For a mining enterprise, the speed at which equipment is restored to operational status plays a crucial role. In-house production eliminates the need for long waits for finished high-pressure hoses from contractors. This shortens repair times and reduces equipment downtime.
According to preliminary calculations, the cost of a hose manufactured in-house will be almost two times lower than that purchased. The total effect of reducing equipment downtime and refusing to purchase ready-made analogues, according to economists, can amount to up to 10 million rubles annually. At the same time, the expected payback period for investments in creating a workshop is about three years.
“The RVD manufacturing project makes the work of our enterprises more independent from third-party companies and generally contributes to sustainability in difficult times. Thanks to the project, our technical specialists gain new competencies that open up new opportunities and allow the company to develop,” says Dmitry Serg, Deputy Director for Equipment Repair and Operation of CPC JSC.
First result achieved on opening day
During the workshop's opening, specialists produced the first functional high-pressure hose assembly. The finished product successfully passed leak-tightness and strength tests. Moving forward, the company intends to refine the production process, enhance the expertise of its specialists, and gradually expand its manufacturing capabilities.
If the workshop achieves its planned performance targets, the infrastructure established at the open-pit mine could serve not only to support its own maintenance program but also as a potential production facility to meet the needs of other companies within the group and organizations across the Kuzbass region. This approach is particularly relevant for the mining industry: localizing the production of critical components directly at the site makes it possible to simultaneously address several challenges related to enhancing operational resilience during a historically critical period for the coal mining sector.
