Can affordable and high-quality abrasive tools be combined? Can Ukrainian manufacturers create a product that competes and sets new industry standards? Zaporizhzhia Abrasive Plant is ready to answer these questions—the launch of the new SMART cutting wheel line is set to change the market. This journey has been a true challenge, from an ambitious idea to an actual product entering serial production. We spoke with Ignat Bashmakov, Head of the Abrasive Tool Technology Center, to learn how SMART was developed, what makes it unique, and what opportunities it opens.

– Ignat, what was your primary task when you assumed your position in December last year?

– The first and foremost goal was to standardise and stabilise the quality of our entire range of abrasive tools. Another key objective was to develop and implement three quality levels of cutting and grinding wheels based on a bakelite bond produced at site 29. These include the economy, standard, and premium product lines. This is currently my main area of focus.

– Were these product lines developed from scratch?

– You could say so, as the existing technology has not undergone any fundamental changes since production began.

– What progress has been made in this direction so far?

– The Economy project has been developed and launched. Its main goal is to lower retail prices. The company is already producing cutting wheels in this segment. One of our tender products, Rapid, has been manufactured using economy technology and is now available in stock.

Regarding the mid-range line, we have successfully stabilised quality and fixed the cutting coefficient of these wheels at 1.0 or higher. We also see a trend toward improving this coefficient.

Currently, within the standard line, we are launching the SMART project.

– When will the production of these wheels begin?

– We have already started. Sales officially began in early March.

– Is SMART the only project you are focusing on right now?

– We have a few other products in development, but yes, SMART is our main focus, as we have high expectations for it. In the future, the mid-range line may consist solely of the SMART series.

– What inspired the idea of creating SMART cutting wheels?

– I saw untapped potential in the grinding materials we produce. The abrasive grains made by ZAK perform exceptionally well and undergo additional, more rigorous quality control. We need to maximise their effectiveness, and we can do so. This realisation was the foundation for developing the SMART standard line.

– Why the name SMART? What does it represent?

– To me, it signifies a wise investment in our tools. The mission of SMART wheels is to deliver reliable, high-performance results. The money spent on this tool fully pays off. That’s why SMART is an innovative and cost-effective investment.

– What key innovations have been implemented in the new SMART line?

– We have fundamentally revised our approach to selecting bonds and optimised the thermal processing regimes. We introduced critical changes to enhance durability and efficiency.

– What about the production technology?

– The technology remains standard—we use the cold pressing method, where raw wheels are formed at room temperature. The production is carried out using Italian equipment.

– How do SMART wheels differ from other cutting tools?

– Compared to our economy wheels, SMART offers twice the performance. In simple terms, if an economy wheel makes 20 cuts, a SMART wheel makes 40.

– What industries and applications are SMART wheels best suited for?

– SMART is a versatile tool for household and industrial use. On the consumer side, SMART is perfect for everyday users. It pairs well with portable electric tools, known as “angle grinders” or “Bulgaria.” This type of tool is found in nearly every professional and home workshop. SMART wheels allow users to perform various tasks efficiently, from metal cutting to surface grinding.

e industrial side, SMART is a valuable asset for manufacturing companies. It offers high cutting efficiency, an increased number of cuts, and optimal cost-per-cut performance. This results in significant economic benefits, enabling businesses to achieve high-quality results with lower costs.

– What cutting performance trends have been observed in SMART wheel testing?

– We see a positive trend in improving SMART’s performance metrics. The leading indicator, cutting efficiency, is steadily increasing, confirming the tool’s growing effectiveness.

According to our test results:

– For 1.0-1.2 mm wheels, the cutting coefficient increased from 0.65 to 1.1;

– For 1.6 mm wheels, it rose from 0.8 to 1.4;

– For 2 mm wheels, it improved from 0.8 to 1.4;

– For 2.5-3 mm wheels, it went from around 1 to 1.8.

These results demonstrate an average performance increase of about 40%. Our tests confirm that SMART is a significant leap in productivity, providing greater efficiency while maintaining optimal tool longevity.

– Have SMART wheels been distributed for consumer testing?

– We are eager to hear honest feedback from customers. That’s why we are launching the “SMART in Action” campaign, where anyone can request free sample wheels in exchange for leaving a review. Applications can be submitted via our new website: www.smart.zak.ua.

– How does the SMART line fit into the company’s overall development strategy?

Our company prioritises high–quality products at a reasonable price. We want to—and now can—produce a superior, reliable product, which in this case is represented by the SMART line. This line has the most potential. In the future, we will also introduce a premium series. Still, for now, our focus is on making SMART a stable and widely available product that is also more affordable than our competitors in the domestic market.

– Is there a plan to expand the SMART line further?

– We are considering expanding SMART to include non-reinforced cutting wheels. These would replace the now nearly obsolete vulcanite-bonded cutting wheels. Non-reinforced cutting wheels are primarily used in industrial settings for cutting metal workpieces, especially profile elements made from austenitic stainless steel.

Such wheels have unique properties—they do not cause burns at the cut site, meaning the metal does not melt or produce burrs, reducing or eliminating the need for additional mechanical processing. They can also be used with cooling lubricants, such as water-fed cutting systems.

Additionally, the SMART line may introduce dual-layer grinding wheels. We already have the necessary equipment for this—an MDM 350-L press from Maternini. These wheels combine two functions: rough grinding to remove a significant amount of metal and finishing grinding to create a smoother and more polished surface.

– In your opinion, what is the main competitive advantage of the SMART line?

– Price, availability, and quality. Additionally, the fact that it is made in Ukraine, by Ukrainians, using domestically produced abrasive grains.

– Where do you see SMART in the Ukrainian and global markets?

– Number one in Ukraine and a strong competitor internationally.

– What advice would you give users to maximise the effectiveness of the abrasive tool?

Read and follow the instructions, wear protective eye and hand gear, and always operate an angle grinder with a safety guard. The rest SMART will handle—because it’s that good!