Client: BAKELITE-SHCHEKINOAZOT LLC, Russia
Industry: Chemical Manufacturing — Phenolic & UMF Resin Production
System Type: Bulk Material Receiving, Storage, Conveying & Batching — Turnkey
Russia’s largest phenolic resin producer needed a complete replacement of an existing Austrian-engineered bulk material handling system — under active construction schedule pressure. Wijay delivered a fully integrated pneumatic conveying solution from design through commissioning, meeting all technical specifications without delay.
Industry Challenge: Replacing an In-Progress System Without Losing Schedule
BAKELITE-SHCHEKINOAZOT LLC is Russia’s largest producer of phenolic resins and a leading European manufacturer in the sector. Its production lines for urea-melamine-formaldehyde (UMF) resins operate under stringent requirements for system reliability, measurement precision, and process integration.
During construction of a new production line, the originally specified Austrian technical solution encountered engineering bottlenecks across four core process stages: raw material receiving, storage, pneumatic conveying, and batching. With the construction timeline already committed, the client required an urgent, full-scope technical replacement — one that could match or exceed the original specifications while maintaining project momentum.
Solution Overview: Turnkey Pneumatic Conveying Architecture
Wijay engineered and delivered a complete bulk material handling system covering the full process chain:
- Receiving — structured material intake from bulk delivery
- Storage — silo and hopper configuration matched to UMF resin material properties
- Pneumatic Conveying — positive pressure system designed for resin powder characteristics
- Batching — high-precision metering and dosing integrated with the conveying line
- Control System — full PLC programming and commissioning delivered as part of the scope
The project was executed under a turnkey model: Wijay handled system design, equipment manufacturing, software programming, and on-site commissioning as a single integrated scope — eliminating coordination gaps between disciplines.
Key Technical Highlights
Seamless technical replacement under schedule pressure The Wijay engineering team completed system design, manufacturing, and programming within a compressed timeline, achieving full commissioning without disrupting the client’s construction schedule.
Material-specific conveying design UMF resin powder presents specific handling challenges including moisture sensitivity and particle fragility. The conveying system was engineered around the material’s actual bulk properties — not a generic configuration.
Full process integration The system addressed receiving, storage, conveying, and batching as a unified architecture. This avoided the common failure mode of sourcing separate subsystems that require field-level integration work.
Control system delivered in-scope PLC programming was completed by Wijay’s own engineering team, ensuring that control logic, conveying parameters, and batching sequences were aligned from the start — not retrofitted after mechanical installation.
Operational Results
- Complete replacement of the original Austrian system across all four process stages
- Full compliance with the client’s technical specifications on first commissioning
- No schedule impact to the new production line construction timeline
- Formal letter of recommendation issued by BAKELITE-SHCHEKINOAZOT LLC upon project completion
The client stated in their written recommendation:
“Wijay is a competitive and reliable partner. The strengths of its professional team make it the preferred collaborator for projects.”
BAKELITE-SHCHEKINOAZOT LLC
The letter specifically recognized Wijay for “breaking through technical bottlenecks with professional capability” and “reshaping project efficiency with exceptional responsiveness.”
The client also noted the team’s “proactive attitude, deep understanding of requirements, and commitment to quality and transparency” as distinguishing factors throughout the engagement.
Why Wijay for Chemical Industry Bulk Material Handling
Direct management involvement President Mr. Liqun Zeng and Vice President Mr. Tarik Muminović were directly engaged in this project. For technically complex replacements with compressed timelines, direct access to senior engineering decision-makers removes the response latency common in larger organizations.
Turnkey execution capability Wijay designs, manufactures, programs, and commissions as a single team. This matters when replacing an existing system under an active construction schedule — there is no handoff risk between mechanical, electrical, and controls disciplines.
Chemical industry experience Wijay has delivered bulk material handling systems across chemical, food, plastics, and new energy industries. UMF resin production requires a team that understands powder behavior, process containment, and precision batching — not a generalist conveying contractor.
Cross-border project delivery This project was delivered to a Russian facility operating under European manufacturing standards (the client is a subsidiary of the German Bakelite Group). Wijay’s ability to meet European-standard technical documentation, commissioning protocols, and quality requirements was a prerequisite for project approval.
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