WHAT WE DO / OUR
OPERATIONS / PACKAGING
DIVISION / SAYANAL
SAYANAL
 SAYANAL (the Republic of
Khakasia) was commissioned in 1993. It is now the largest producer of foil and
foil-based packaging materials in Russia.
The mill utilises a complete process cycle, from preparation of the melt to
production of foil and foil-based packaging materials.
The mill was built under agreement between the Sayanogorsk aluminium smelter,
an Italian engineering company FATA and the US-based Reynolds Metals Company,
one of the world’s leaders in production of aluminium-based packaging
materials.
The annual capacity of SAYANAL is about 40,000 tonnes of foil and foil-based
packaging materials. The mill employing 700 people delivers products to 5
continents, 46 countries and 40 regions of the Russian Federation.
| Geography |
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SAYANAL is located in the city of
Sayanogorsk in the Russian Republic of Khakassia. The city has a population of
55,100 people and sits on the banks of the river Yenisey. Its main production
facilities include the Sayanogorsk aluminium smelter, the Khakas aluminium
smelter, a stone works and a residential property construction facility. Two
hydropower plants – Sayano-Shushenskaya and Mainskaya - are located to the
south of Sayanogorsk.
The Republic of Khakassia occupies 61,900 square kilometres with the population
of 580,100 people and a capital in the town of Abakan. The Republic’s main
industries include mining, mechanical engineering and non-ferrous metallurgy,
as well as forestry and woodworking. The Republic of Kakassia is part of the
Siberian Federal District of Russia.
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Technology
SAYANAL uses molten aluminium supplied by the Sayanogorsk aluminium smelter and
in-house production waste as raw materials for foil production. The melt is
prepared in the smelting furnace. It is then degassed and a modifier is added
to mill grains and improve the cast section structure.
Following, the melt is sent to the Super Caster continuous casting line where
cast section rolls 6-10 mm thick and 1,200-1,650 mm wide are produced and used
for rolling of aluminium tape and foil. Cooled rolls are rolled in mills down
to 0.6-0.006 mm thick. Readymade foil is cut, annealed in electric furnaces and
sent to the packaging area, while the other part that needs further processing
is sent to the conversion area, where foil and foil-based packaging materials
get laminated to plastics or paper, gravure printed, lacquered, painted and
embossed.
New products
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Foil made from alloy 8006 and used for aluminium flexible ducting of high
quality and required mechanical properties.
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Foil made from alloy 8011 is used to produce composite piping.
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Radiator foil from A5 grade aluminium.
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6.35µm-thick foil.
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Cigarette pack applications painted in brand colours.
Certificates
A quality management system compliant with ISO 9001:1994 was developed and
implemented at SAYANAL in 2000. In 2002 SAYANAL became the first production
facility in Siberia and the Far East to be certified under the ISO 14001:1996
environmental management standard.
Recertification audits in 2003 and 2005 confirmed SAYANAL’s compliance to ISO
9001:2000 quality management and ISO 14001:2004 environmental management
standards.
Investment
The areas modernised within the 2007 investment programme include the foil
separator and cutting C4 machine, Super Caster control system No.2, the
equipment for printing roller production, as well the mill’s electronic and
computer system. The assembly of a new roll polisher was initiated and another
stage in the technical upgrade of main equipment has been completed.
The company’s investment programme for 2008 includes allocating USD 4 mln to
upgrade the main equipment, ensure a better product quality, improve labour
safety and purchase a waste recycling plant.
Environment
SAYANAL is equipped with modern gas collection and treatment mechanisms that
eliminate emission of hazardous substances used in the process and secure a
sufficient degree of gas treatment.
In recent years, environmental safety projects have included:
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The purchase and commission of ALTEK, a hot mud press that can recover up to
100 tonnes of aluminium annually;
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The equipping of air sample collection points for environmental emissions;
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The modernisation of equipment at the sanitary group at the mill’s central
laboratory;
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The introduction of a closed technical water cycle with an internal treatment
system.
Management
Managing Director – Gennady Gamanovich
Contacts
Tel.: +7103904273375
E-mail: chamber@sayanal.rusal.ru
Please visit http://www.aluminiumleader.com/en/
for a unique insight into aluminium.
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