Advanced IT Solutions: A Key to Long-Term Growth and Industrial Sustainability

Digital initiatives at Russia’s TechnoNICOL show how virtual reality and AI are becoming powerful tools to drive industrial competitiveness and sustainable development.

Machine Vision Enhancing Labor Safety

A large-scale modernization project is underway at Techno Plant in Serpukhov, part of the TechnoNICOL group. The upgrade targets the plant’s warehouse infrastructure and integrates virtual reality (VR) technologies to simulate logistics workflows using a digital twin of the facility. This approach allows managers to test various product shipment scenarios without investing in physical implementations, ultimately reducing costs and operational risks.

As a result, warehouse productivity is projected to increase by 60%, throughput capacity by 25%, and logistics operations speed by 35%. Operational costs could fall by 15%, and the likelihood of errors may be cut by 75%. Time spent by transport vehicles on-site is expected to shrink to just 60 minutes.

A similar project is underway at another Techno Plant in Chudovo, Novgorod Region, and is slated for completion by the end of 2025. Here, the company expects a 20% improvement in warehouse productivity and logistics efficiency.

Machine vision will also be integrated with production control systems to improve occupational safety. If a worker enters a hazardous zone, an AI-powered neural network will automatically halt equipment and prevent it from restarting until the zone is clear. This safety system is already in use at seven of TechnoNICOL’s stone wool plants across Russia.

A couple of years ago, during the presentation of our book ‘Through the Thorns to Digital,’ I said, ‘In 5–6 years, TechnoNICOL will be seen as an IT company that manufactures building materials.’ That vision is quickly becoming reality. In terms of digitalization and business process automation, we’re reaching the same level as the most tech-savvy sectors—like finance and banking. We are integrating digital technologies across manufacturing, logistics, and customer service

Sergey Kolesnikov

founder and co-owner of TechnoNICOL Group

Transitioning to a Full-Scale Digital Ecosystem

The company is not stopping there. At the Chudovo facility, a Manufacturing Execution System (MES) will be implemented to collect and analyze real-time data from production lines on a unified platform. MES systems are already operational at eight of TechnoNICOL’s stone wool facilities in Russia.

Looking ahead, the company plans to use artificial intelligence in collaboration with the MIREA Russian Technological University to analyze historical data from the MES system and enhance decision-making.

Embracing Industry 4.0

All these efforts reflect TechnoNICOL’s broader strategy to align with the principles of Industry 4.0. For Russia’s IT sector, this demonstrates that domestic industrial players are ready for large-scale digitalization and the integration of cutting-edge technologies in day-to-day operations.

It sends a clear signal to the market: Russian enterprises are not only adopting advanced tools but are also leading in the development of proprietary solutions that can compete globally.

Domestic and Global Outlook

The implementation of advanced IT technologies in regions where TechnoNICOL operates strengthens local tech infrastructure and promotes workforce development. The company is committed to training its personnel to operate digital systems, which lays the foundation for a new generation of highly skilled logistics professionals. This could, in turn, attract further investments and interest from other high-tech enterprises.

Digital transformation has also helped the company improve environmental performance, boost energy efficiency, and enhance product quality. TechnoNICOL’s offerings are becoming increasingly competitive, both domestically and internationally. The company’s products are exported worldwide—from Asia to Latin America.