long-term projects for 2012-2015

Modernization and innovation projects, implemented in 2009-

2011, at polymer cluster enterprises in the polymer

business park at LLC plastic processing plant named after

“Komsomolskaya pravda” (Saint-Petersburg, 4/2 Smolyachkova

street

Long-term projects for 2012-2015

Creation of an experimental area to arrange production of plastic items for

hydraulic systems, ducts, air purification elements, anti-icing

systems and treatments, other plastic items

LLC “Plant “KP” in accordance with the Federal target programme “Development of defense industry of the Russian Federation for 2007-2010 and for period till 2015”, approved by a Directive of the Russian Government dated November 22, 2006 № 706-32 FGUP “R&D Institute named after academician A.N.Krylov” has executed experimental and design work with the aim to work out experimentally the new technological processes to produce non-metal joints of ship systems.

LLC Plant KP has invested its own funds into equipment and creation of production areas (48% from the total project sum).

As a further project development it is envisaged to create An anticorrosion protection centre together with FGUP “R&D Institute named after academician A.N.Krylov”, NIU ITMO, by enterprises of Polymer cluster and European partners:- Belorussian academy of science,- Ticona (Germany),- Technical Research Centre of Finland (VTT, Helsinki), Lappeenranta University of Technology (LUT, Lappeenranta), Turku Science Park (Turku, Finland), University of Turku/Centrum Balticum (Turku, Finland).

Anticorrosion protection centreThe design is aimed to develop technologies and form conditions for creation and testing of new anticorrosion protection.

The technological process of development and testing of such protection will include the following processes:

computer modeling (on the basis of mathematical models and simulation calculations) of materials, received with usage of all sorts of additives to find preset properties (for example, a possibility to be used in aggressive environments);

creation of materials with usage of additives on the basis of recommendations received from computer modeling and their evaluation;

development of technologies to treat surfaces before application of anticorrosion protection;

laboratory tests of materials and optimization of surface parameters to find compliances with preset properties.

Anticorrosion protection centreThe given project envisages:

to develop mathematical models to follow changes of structure and material behaviour when additives are applied;

to develop new and adapt existing programme platforms to model material behaviour on computer after additives are applied;

to form a laboratory prototype with preset properties; to form a laboratory prototype to test materials if they comply

with preset properties; to develop requirements to arrange modeling and testing

processes with participation of Russian and Finnish companies;

to develop requirements for evaluation of quality of anticorrosion protection;

Anticorrosion protection centre

to develop requirements to quality of surfaces before anticorrosion protection is applied;

to develop mechanisms to optimize parameters of anticorrosion protection;

to develop and form consortium – a partnership network consisting of project participants and other interested sides to solve tasks for development of anticorrosion protection;

to form virtual distribution centre of anticorrosion protection to develop materials and surfaces with preset properties using the existing scientific and production infrastructure of the project partners.

Prototyping centre of items made of composition materials and surface treatment

on the basis of LLC “Plant KP”

The main task of the centre is to provide access for minor innovation enterprises from different clusters and sectors of the city to full range of modern technologies of production preparation and prototyping.

64 mln.roubles has been invested into the project (startup and promotion including R&D.

In 2010 the project received a subsidy from the Government of Saint-Petersburg for repayment of expenditures dealing with creation of prototyping centre in order to support members of minor and medium entrepreneurship, that have innovative activities :

- Federal budget – 16 mln.roubles.- Regional budget – 16 mln.roubles.

Besides, for 2010 – 2011 32 min. roubles have been spent from own funds (including banking loan of LLC VTB) Centre services for Small Innovative Enterprises are according to prime cost, expenditures for promotion and part of overheads are included into the operating budget.

Centre for development of Optical technologies and precision casting

On the basis of prototyping centre and R&D centre of “Plant KP” ENGEL Austria GmbH plans to create a Centre for development of Optical technologies and precision casting (the project budget is 70 mln.roubles). Key competencies of the Centre:

calculation of optics upon request of the Client with usage of modern software;

modeling and design of technological processes; lens computer analysis; production of lens; production of frames and parts of lamps and other

frame works.

The sum of investments for creation of Development centre of “Optical technologies and precision casting” and R&D Centre “Plant KP” ENGEL Austria GmbH in the first half of 2012 is 30 mln. roubles of own funds with attraction of the banking loan within the programme “Posttransform”.

Implementation centre for “green” energy and resource- saving technologies within the

framework of the unique technological platform on the basis of LLC “KP”.

The activity of the Centre is aimed for: complex solutions of ecological problems dealing with

deterioration of quality of potable water due to corrosion processes

a complex of measures dealing with observation of sanitary and hygiene norms in cellars, buildings and structures that are a source of bacteria

implementation of “green” energy and resource-saving technologies to reduce losses of energy resources, reduction of ice crust on roofs etc.



Full budget of the centre is 72 mln. roubles. Own means are 25 mln. roubles.In 2011 the project received a grant from the Government of Saint-Petersburg for the best innovative project implemented by the cluster in the sphere of ecology and management of natural resources in amount of 1 mln. roubles.Last year a part of expenditures was compensated at the expense of subsides of Saint-Petersburg Government dealing with research and development works (10 mln.roubles).



In 2011 in accordance with the order of LLC “KP” there was an R&D conducted for the sum of 23,7 mln.roubles. In the same year “Institute of polymers” fulfilled an R& D for GUP “Vodokanal Saint-Petersburg” for 7 mln.roublesIn 2012 LLC “KP” have concluded a contract for continuation of an R&D for 20 mln.roubles for development of technologies for application of coatings and modeling of properties of materials, items and technologies of their production.

As a further development of the project it is envisaged to create a Nanocentre for construction materials together with ROSNANO.

Fullerene production area

Nanocenter functioning diagram

Prepreg production area

TREATMENT LINE FOR BINDER MELT

NANOMODIFICATION OFBINDERS

Labo

rato

ry c

ompl

ex (

qual

ity c

ontr

ol)

PREPREG GRINDING

Production area for composite items

NANOMATERIAL PROCESSING AREA:- CASING UNDER PRESSURE;- PRESSING;- EXTRUSION; - TREATMENT PLACING.

BINDING OF PIPING ITEMS:- HOT CASTING

Area for production of Nanocontaining polymer

materials and compositions for treatment placing

Final product CLIENT

• Economy of the project:•Total amount of investments is 230 mln.roubles•Planning period is 6 years•IRR 37о%•NPV 4 576 thousand dollars under discount rate is 22%•Payback period is 4 years 8 months•Payback period with consideration of a discount is 5 years 5 months

Forecast of main financial indicators

2010 2011 2012 2013 2014 2015 2016

EBITDA, thousand roubles-45 282

8 31039

42064

52796

034149 610

207 257

Capex, thousand roubles-200 000

-14 286

-26 531

-22 741

-19 492

-16 707

-14 321

NWC, thousand roubles 0 -2 063 -1 390 -1 117 -1 462 -2 587 -2 810

Taxes, thousand roubles 0 0 0 0-12 651

-27 058

-38 996

Free monetary flow of the company, thousand roubles

-245 282

-8 03811

50040

67062

430103 258

151 130

Total monetary flow, thousand roubles

-245 282

-8 03811

50040

67062

430103 258

1 187 415

Nanocentre of structural materials

Creation of a virtual distribution Nanocentre of polymer composite

materials and surfacesInternational partners:

Babson College (the USA) Nanocentre of Saxion University Enschede (Kingdom of

the Netherlands) Vorrink (Kingdom of the Netherlands) BASF (Germany) Bayer (Germany) Alchimica (Greece) Technical Research Centre of Finland (VTT, Helsinki) Lappeenranta University of Technology (LUT,

Lappeenranta) Turku Science Park University of Turku/Centrum Balticum (Turku, Finland).


materials and surfaces

The first stage of work is to make a computer modeling of structural and behavioural change of materials received with the use of nanoadditives in different aggressive environments or working in difficult exploitation conditions and their suitability in different production processes. The second stage will include laboratory tests of the obtained materials to find their compliance with the preset properties. The third stage is “pilot” laboratory and field tests of new materials. The project will assist to form condition to transform the consortium into a fully functional network of polymer centres on the Russian and Finnish sides. In the future the given centres will provide solution of tasks not only of trans-boarder cooperation but also of broader partnership.



Scientific and technical tasks:

to develop a mathematical instrument and models for simulation how materials change their properties when different nanoadditives are applied;

to develop new and adapt the existing software to conduct computer modeling of material behaviour;

to provide knowledge to the parties about the requirements and standards existing in the EU and Russia about how to arrange the development and testing of materials to find their compliances with the preset properties and to develop proposals about their mutual registration;

to form unified information context, programme platform and requirement to verify simulation and real tests.



Arrangement tasks:

to form a consortium from Finnish and Russian institutions and companies arranging mutual actions, aimed to develop and test materials, received with usage of different sorts of nanoadditives;

to create a virtual distribution polymer centre for development and testing of materials with usage of existing scientific and laboratory infrastructure of the project partners.

Creation of a National centre for dynamic tests of transport industry

sitesCentre for dynamic tests is envisaged to conduct tests of railroad structures and railway objects, the metro, airports, highways under conditions of power loads, close to exploitation under simultaneous action of different external factors.The Client is LLC “RZD”Total project sum is 3,5 mln.roubles. 150 mln. roubles have been invested into R&D (20 mln.roubles are own funds) and preparation of project infrastructure is 54,5 mln.roubles. 14 patents have been received and five are about to be issued.

Virtual distribution centre of dynamic tests

Foreign partners: INSTRON (Germany), MTS (the USA), LDS (Britain), Angelantoni (Italy), LMS (Belgium), Turku Science Park (Turku, Finland), University of Turku/Centrum Balticum (Turku, Finland), Technical Research Centre of Finland (VTT, Helsinki), Lappeenranta University of Technology (LUT, Lappeenranta)


Effectively functioning transport infrastructure is one of the most important conditions for development of cross-boarder cooperation. Construction and implementation of high-speed railway connection between Saint-Petersburg and Helsinki- “Allegro” trains is an example of actions of Russia and Finland dealing with solution of high-speed transport problem.


Besides, the most important condition for usage of transport communication is its safety. When railway communication is considered there is a necessity to arrange and implement the following actions:

constant monitoring of railway and train status; replacement of broken structures, joints and elements; creation of scientific and production base, providing development and

creation of a new generation of structures, joints and materials that are more durable to influence of loads and climate that occurs in different regions of Russia and other countries and at the same time cheaper.

The design is aimed for development of technologies and formation of conditions dealing with arrangement and conduct of dynamic tests both of standard structures and joints and long-term including the ones developed from different polymer materials.


The technological process of tests will include the following actions: computer modeling (on the basis of mathematical dynamic models and simulation

calculations) of conduct of structures and joints under conditions of hard exploitation loads and climate conditions;

Real dynamic tests of the given structures, joints and materials of special stands when creating the adapted exploitation conditions.

The given project envisages: to develop mathematical dynamic models, allowing to conduct computer modeling

of dynamic behaviour of standard and new structures and joints including the ones created from different polymer materials under different exploitation loads and climate conditions;

to create a programme platform, providing a conduct of the modeling described above;

to develop and form a consortium – a network partnership from project participants and other interested sides dealing with solution of computer modeling tasks and production testing of new structures and joints;

to form a virtual distribution centre of dynamic tests with usage of existing scientific and production project infrastructure;

to develop proposals dealing with creation of cross-boarder network of dynamic test centres capable to solve testing of structures and joints.


The project will allow to form conditions for transformation of a consortium into a full-scale network of dynamic test centres on Russian and Finnish sides. In the future the given centres will solve tasks not only about cross-boarder cooperation but also of broad-scale partnership, on the one hand, EU countries, and on the other hand, the CIS states, Central and South-East Asia dealing with safe transport corridor, correspondently, from the shores of the Atlantic to the Pacific oceans.

www.kp-plant.ru

long-term projects for 2012-2015

Documents

computer modeling

testing processes

usage of additives

preset propertiesto

project development

new technological processes

turku science park turku

laboratory prototype