Horizons of ‘northern silk’

Increased production and enhanced product quality — how modernisation has affected the economy of Dvorets Flax Factory

JSC Dvorets Flax Factory is one of the enterprises that make the difference in the structure of industrial production in Dyatlovo District. A new stage in the life of the enterprise began in 2009 when a new modern line was put into operation thanks to government support. The operation of imported equipment requires not only the specific amount of retted straw but also a certain quality. That is why so much attention is paid to working in the fields and reaping a good harvest, which affects the revenue and profitability of the factory as well as increased export positions.

Long fibre line operator Yevgeny Isachenko

Reconstruction gave it a second wind   

The territory of the flax factory impresses with cleanliness and bright new buildings. Rolls neatly placed under canopies are sent for processing with the help of a loader. Oleg Zhidko, Chief Engineer at Dvorets Flax Factory, offered a tour around the workshops. “Here it is, our new Van Dommele line for the production of long flax fibre with a capacity of 200 tonnes per shift,” the interlocutor pointed to the high-performance equipment. “It was launched in 2009, and an additional short fibre production line was installed in 2013. The reconstruction made it possible to automate a lot of production processes, improve product quality, and boost labour productivity. The factory seemed to get a second wind. This year, it is planned to commission a cottonisation line at the Slonim site. This will enable deeper processing of raw materials as well as exporting more products.”  
The content of flax fibre in hemp straw constitutes only 30 percent. That is, 70 percent of flax shive remains for every thousand tonne. According to the company, “Waste is primarily used for heating the factory. Two Italian boilers of 4 MWt each are installed in our own boiler house. We provide heat not only for our factory, but also for half of the village.” 
The chief engineer offered to assess the retted straw quality by touch, “Do you feel it? It differs by touch. Here is number nine — it is dark grey and coarse. This one, number twelve, is much softer and lighter. The highest retted straw number we have this year is twelve. The higher the retted straw number is, the more expensive the fibre is. The number is composed of many indicators. It depends on the length, flexibility, and colour. First of all, the fibre colour is influenced by weather conditions. Thus, we received fibre number fifteen in 2015. It was a great harvest!” 

A close-knit team is the key

A new workshop is bright and warm. The flax fibre of the new harvest is being sorted at large tables, and next to them is an energetic young man, Yevgeny Isachenko, deftly serving rolls to the line. “It is impossible to do without manual labour here since no machine is able to capture all shades of grey,” the long fibre line operator clarified the details of the labour-intensive process. “I throw a roll in, and my assistant distributes it evenly along the conveyor line. Only retted straw with a number above one is suitable for this line. The higher the retted straw number is, the greater the fibre output is — both long and short.”  
The enterprise, which has become truly advanced and competitive over the past few years, employs almost 280 people. The Head of Production, Svetlana Gerasimovich, is constantly in touch with her team. “The factory works in three shifts,” the interlocutor spoke about the everyday working life. “The process is complex and time-consuming. My production site is responsible for the harvesting and processing of retted straw that enters the factory. However, the workflow begins from the moment when flax is pulled out of the ground and left in the open air. We go to the fields in order to assess the quality of flax retting, take samples, and determine the number. As soon as we see the shade of grey we need, we immediately give the command to bring it in from the fields. We accept the flax, stack and place it in special warehouses [large open-sided canopies made of precast reinforced concrete], sorting by numbers — from 0.5 to 2. There are six ‘nominations’ in total.”
Head of production Svetlana Gerasimovich and long fibre remover Natalya Levshuk

Seamless operation guaranteed 

The successful operation of JSC Dvorets Flax Factory directly depends on the availability of raw materials for processing. Last year, the farmers harvested a sufficient amount of retted straw for seamless operation of the enterprise. The raw material zone of flax cultivation is 3,276 hectares and is located on the lands of Dyatlovo, Novogrudok and Slonim districts. 
In order to ensure uninterrupted supply of raw materials to the enterprise, a mechanised subdivision for growing and harvesting flax was created at the flax factory back in 2003.  
The Head of Mechanised Subdivision, Renat Grankovsky, demonstrated the equipment pleasing to the eye, “We have 360 units of diverse machinery, including self-propelled machinery, as well as trailing and mounted equipment. In total, we have 44 tractors, five of which are energy-saturated. At present, the mechanised subdivision is equipped with the latest mechanical means of both domestic and imported production. We are very pleased with the flax pullers assembled on the basis of JSC Shchuchin Repair Plant. We have 11 of them. In general, ploughs, flax strip turners, cultivators, and sowing units are always cleaned, repaired, and ready to work. The availability of a highly equipped material and technical base allows for timely and high-quality implementation of all the measures for flax cultivation and harvesting, and the creation of necessary stocks of raw materials for production needs. At the same time, we buy several pieces of equipment every year, realising that upgrading is the key to progress.”  
Renat Grankovsky admitted that flax culture is capricious and very demanding. “Our major task is to ensure a sufficient amount of raw materials. We manage to achieve this goal every year due to strict compliance with technological regulations. More than 50 tractor drivers work in two subdivisions on a permanent basis. We carry out the flax sowing campaign on our own, but for harvesting we attract farmers who have machinery available, from all over the region. Meeting the deadlines is a crucial aspect in this case. We have as many as 31 self-propelled balers at the Dvorets site, and we contract approximately ten more from the outside.” 

Keeping up with best practices  

Inna Kanus, Chief Economist of JSC Dvorets Flax Factory, confirmed the above with figures, “Over the past year, the enterprise processed slightly more than 10,140 tonnes of retted straw, which is higher compared to the level of 2022. The long fibre output also increased and made up about 25 percent. A total of 2,819 tonnes of flax fibre were produced, of which 765 tonnes were long flax fibre, and 2,503 tonnes — short flax fibre. This is 27.8 percent higher than in 2022.”  
In 2023, the enterprise fulfilled a government order for long and short flax fibre for Orsha Linen Mill and Grodno-based textile enterprise Gronitex OJSC. “2,970 tonnes were sold, including 794 tonnes of long flax fibre, and 2,176 tonnes of short flax fibre,” the chief economist shared the details. “1,280 tonnes were supplied to Orsha Linen Mill, and 680 tonnes — to Gronitex. The rest of the products were sold at free prices. The export revenue amounted to $1,039,000. Over 80 percent of the products were shipped to the Russian Federation, and a small part to the People’s Republic of China. 
In total, the company received Br18.1m of revenue, which is 26.4 percent higher than the last year’s level. This indicates production efficiency. Along with that, net profit amounted to Br965,000. This allows the factory to look confidently to the future.   

By Tatiana Vrublevskaya

Photos by Aleksei Bibikov